C7000 C-Series User Manual Rev 3 July 2006

Safety Notices

Trademark Cadex, BatteryShop, QuickLearn, QuickTest, QuickSort, FlexArm are registered trademarks of Cadex Electronics Inc. All other trademarks mentioned herein are the property of their respective owners.

Copyright Copyright © 2006 by Cadex Electronics Inc. All rights reserved. No part of this publication or the firmware controlling Cadex product(s) may be reproduced, transmitted, transcribed, stored in a retrieval system, or translated into any language or computer language in any form or by any means without the express written permission of Cadex Electronics Inc.

Revision Rights Cadex Electronics Inc. reserves the right to revise this publication and make changes in the contents thereof without obligation to notify any person of such changes. Please e mail [email protected] for suggestions or corrections.

Disclaimer While every effort is made to ensure that the information contained in this manual is accurate and up-to-date, Cadex Electronics Inc. does not warrant or guarantee the accuracy of the contents of this manual. Further, Cadex makes no warranties, either expressed or implied, as to the merchantability or fitness for a particular purpose of the Cadex C7000-C Series Battery Analyzers (C7200-C, C7400-C and C7400ER-C) equipment and/or its documentation. In no event will Cadex or its officers or employees be responsible for any consequential, incidental, or indirect damages (including damages for loss or business profits, business interruption, and the like) arising out of the use or inability to use the Cadex C7000-C Series Battery Analyzers (C7200-C, C7400-C and C7400ER-C) Battery Analyzer equipment and/or its documentation.

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Safety Notices

Safety Notices Use of Equipment The Cadex C7000-C Series Battery Analyzers (C7200-C, C7400-C and C7400ER-C) are designed with adequate safeguards to protect the user from shock and other hazards when used as specified within this document. However, if the equipment is used in a manner not specified by this documentation, the protection provided by this equipment may be impaired. Please read this document and equipment labeling before using the equipment.

Modification of Equipment CE, FCC, CSA and other approvals apply only to Cadex C7000-C Series Battery Analyzers (C7200-C, C7400-C and C7400ER-C) in the factory-authorized configuration. Changes or modification to the equipment not expressly approved by Cadex will void the approvals and void the user’s authority to operate the equipment.

Disposal of Waste Electrical and Electronic Equipment (WEEE) in the European Union This symbol on the product and package indicates that this product must not be disposed of with unsorted municipal waste. Instead, it is your responsibility to dispose of WEEE by handing it over to a designated collection point for the disposal. The separate collection and recycling of waste equipment will help conserve natural resources and ensure that it is disposed of in a manner that protects human health and the environment. For more information about where you can drop off your waste equipment for disposal, please contact your local municipal office, waste disposal service or wherever you purchased the product.

Cadex Electronics Inc. C7000-C Series Battery Analyzers

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Safety Notices

ROHS Compliance The C7000-C Series of Battery Analyzer complies with the European Union’s Directive 2002/95/EC, Restrictions of Hazardous Substances (RoHS)

Radio Interference This equipment generates, uses and radiates radio frequency energy. If the equipment is not installed and used in accordance with the instructions in this manual, it may cause interference with radio communications. The equipment has been tested and found to comply with the limits for a Class “A” digital device pursuant to Subpart B of Part 15 of the FCC Rules, which are designed to provide reasonable protection against such interference when operated in a commercial environment. Operation of this equipment in a residential area may cause interference, in which case the user is required to take whatever measures needed to correct the interference, at their own expense. EN55011/EN55022 Warning: This is a Class A product according to EN55011/EN55022. In a domestic environment, this product may cause radio interference, in which case the user, at their own expense, may be required to take adequate corrective measures. The equipment is designed with adequate safeguards to protect the user from shock and other hazards when used as specified within this document. If the equipment is used in a manner not specified by this documentation, the protection provided by the equipment may be impaired. Please read the documentation and equipment labeling before using the equipment. The analyzer may be affected by interference from other devices. If the unit is running abnormally, please ensure that the analyzer is moved away from any source of radio interference.

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Safety Notices

Explosion Hazard Batteries can burst if treated improperly. Follow these precautions at all times.

ü Clean battery contacts befor e servicing. To clean battery contacts, use a lint-free cotton swab dipped in 100% isopropyl alcohol.

ü Press the battery firmly into the adapter to ensure a good connection. ü Ensure that the selected C-Code is correct for the chemistry, voltage, and rating of the battery being serviced.

ü Observe battery temperature. Service batteries between 5°C (41°F) and 50°C

(122°F). Stop service if battery becomes very hot. The temperatures cited here are the battery temperatures, not ambient the ambient temperatures. Fast charging outside this temperature range may damage or reduce the life of the battery. Allow cold batteries to warm up and hot batteries to cool before charging.

û Do not attempt to charge non-rechargeable and primary batteries such as alkaline, carbon-zinc, or non-rechargeable lithium batteries.

û Do not short the positive and negative battery terminals together at any time. û Do not connect leads from one station to another, or to the case. An electrical short to any point outside the station bypasses the current regulation loop and may blow a fuse or cause permanent component damage.

û Do not exceed the battery manufacturer’s recommended charge current and voltage limits for batteries.

û Do not remove the adapter from the analyzer while the battery is running.

Cadex Electronics Inc. C7000-C Series Battery Analyzers

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Safety Notices

Charging and Discharging Lithium-ion (Li-ion) Batteries Lithium-ion (Li-ion) batteries are safe when used as directed. Battery safety cannot be assured when a battery pack is built with individual cells of an unknown nature with a serial and parallel connection. Not all Li-ion cells are suited for multi-cell packs. Only cells that meet tight voltage and capacity tolerances can be used for serial and parallel connection. Mismatched packs are subject to overcharge resulting in venting with flame and fire. Check with the cell manufacturer to see if the cells are suitable for multi-cell packs. In the past, single Li-ion cells were only available to authorized battery manufacturers. Today, imports are becoming readily available and often fall into the hands of the inexperienced. While most brand name cells are equipped with an internal cell disconnect that permanently opens the current path on high pressure, some brands do not provide this safeguard. Many brands don’t’ use a separator that shuts down the battery when high temperatures are reached. The internal safety features are omitted for cost reasons. Please follow the following guidelines when charging and discharging lithium-ion cell(s) and packs. Failing to follow these rules could result in venting with flame, explosion, fire and personal injury.

û Never connect cells in parallel and/or series that are not designed for that purpose. A cell mismatch may overcharge and vent with flames.

û Never charge or discharge the battery without connecting a working protection circuit. Each cell must be monitored individually and the current disconnected if an anomaly occurs.

û Never leave the battery unattended while under charge or discharge. ü Always attach a temperature sensor when charging and discharging the battery. The temperature sensor must disconnect the current on excess temperature.

ü Only connect cells that are matched and have the identical state-of-charge. ü Pay special attention when using an unknown brand. Not all brands contain intrinsic safety features that protect the cell when stressed.

ü During experiments, place the test battery into a well-ventilated fireproof container. v

Safety Notices

Shock Hazard The Cadex Battery Analyzer contains high-voltage circuits, and can pose a shock hazard when the upper cover is removed. Do not attempt to perform any service procedures on the analyzer other than replacement of the external fuse (see Chapter 11, Services and Upgrades , page 100).

ü To reduce the risk of electrical shock hazard, service batteries only when they are removed and disconnected from their end-use equipment.

ü Use the analyzer only as specified in the documentation. Other uses may impair the protection provided by the unit.

ü Use only a grounded AC outlet to power the analyzer. ü Before attempting any internal service, remove all batteries from the battery stations, turn the analyzer off and disconnect the power cord from the wall socket. Wait a few minutes before opening the cover.

ü Replace fuses only with fuses of the same type and rating (see Replacing the Primary (Input) Fuse, page 100).

Cadex Electronics Inc. C7000-C Series Battery Analyzers

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Warranty & Service

Warranty & Service Cadex Electronics Inc. warrants the Cadex Ba ttery Analyzer against defective materials and workmanship for a period of two (2) years from the original purchase date. The warranty does not cover: • • • • • •

Damage caused by abusive operation, negligence, accident, or improper installation. Damage caused by an attempted repair not authorized by Cadex. Cosmetic damage caused by normal wear and tear. Damage from external causes such as leakage spills, power fluctuations, power failure or inadequate shipping. Product received without the appropriate model number, serial number, or safety markings. Products used for rental purposes.

Warranty Service Before sending the unit for service, contact Cadex Technical Support. If the product requires warranty service, the representative will provide a Return Authorization form or number and the location of the nearest service center. • • •

Ship the product to the service center with freight, insurance, and customs duties prepaid. The Return Authorization form must be included to obtain warranty service. Ensure that the unit(s) is properly packed before shipping, preferably in the original Cadex boxes. Damage caused in transit due to improperly packed items is not covered under warranty. Products returned from warranty service are shipped with freight prepaid by Cadex.

Non-Warranty Repairs Before sending the unit in for service, contact Cadex Technical Support at 1 800 5655228. If the analyzer is not covered by warranty, the representative will provide the contact information for the nearest service center. Contact the service center directly to vii

Warranty & Service

arrange to send the product in for service. A Return Authorization form or number will be provided only if the product is returning to the Cadex Head Office. • •

Ship the product to the service center with freight, insurance and customs duties prepaid. Ensure that the unit(s) is properly packaged before shipping.

Note

Cadex Electronics Inc. and Cadex authorized service centers require a Purchase Order or written authorization to proceed with repair.

Cadex Electronics Inc. C7000-C Series Battery Analyzers

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Table of Contents

Table of Contents

Chapter 1

Overview ...1

Product Features... 1 Connecting to Cadex BatteryShop™ ... 2

Chapter 2

Getting Started ...1

Contents of the Box... 1 Using this Manual... 1 Conventions... 3 Direction Keys... 3 Symbols ... 3 Abbreviations and Acronyms... 4 Commonly Used Terms... 5

Chapter 3

Operating Principles ...7

Components... 7 Front LCD Display Interface ...10 Lights (LEDs)...12 Menu Structure ...13 Battery Adapters...14

Chapter 4

Basic Battery Service...17

Chapter 5

Battery Service Programs...21

Basic Programs...21 Auto...22 Charge...23 Prime...23 QuickSort...24 ix

Table of Contents

Advanced Programs...25 SelfDCH (Self-Discharge Test)...26 Life-Cycle...27 DCHOnly (Discharge Only)...28 ExtPrime (Extended Prime)...29 OhmTest...30 RunTime...31 Boost...33 Learn...34 Q-Learn (Quick Learn)...36 QuickTest™...38 Custom 1, 2, 3, and 4...39 Battery Service Times...40

Chapter 6

C- Codes (Configuration Codes)...41

Basic C-Code Parameters...42 Program...42 Target Capacity...43 Chemistry...43 Battery Voltage (Volts) ...43 Battery Rating (mAh)...44 C-Code Setup Name...44 Scaled C -Code...44 C-Code Matrix...45 Locked C-Code...45 Extended C-Code Parameters...45 Charge Rate...45 Discharge Rate ...45 Trickle-Charge Rate (NiCd and NiMH only) ...46 Recondition Discharge Rate (NiCd and NiMH only)...47 Temperature Sensing ...47 Negative Slope (NiCd and NiMH only)...47 End of Discharge...48 End of Recondition (NiCd and NiMH only)...49 Charge Method (NiCd and NiMH only)...49 Maximum Standby Voltage (SLA and Li-ion only)...49 Cadex Electronics Inc. C7000-C Series Battery Analyzers

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Table of Contents

Maximum Charge Voltage (SLA and Li-ion only)...50 End of Charge (SLA and Li- ion only)...50 Default Extended C-Code Settings...51 Default Extended C-Code for NiCd Batteries...51 Default Extended C-Code for NiMH Batteries...51 Default Extended C-Code for SLA Batteries...52 Default Extended C-Code for Li-ion Batteries...52 Extended C-Code Settings for Special Cases ...53 Intrinsically Safe Batteries...53 Hawker SLA Batteries...53 Gell SLA Batteries...53 Managing C-Codes...54 Select a C-Code ...54 Display a C-Code...54 Change Target Capacity or Program ...54 Create or Edit a C-Code...55 Add or Edit the C-Code Setup Name...56 Reset Extended C-Code to the Default settings...57 Delete a C -Code...57 Copy a C -Code (including QuickTest matrix)...57 Copy all C -Codes (and matrices) from One Adapter to Another...58

Chapter 7

System Setup And Options...59

Date and Time...59 Company Name...59 Sound Options...60 Voltage Display ...61 Battery Service Counter...62 Connecting to BatteryShop or a Printer...63 Connecting to BatteryShop...63 Connecting Other Devices to the Serial Port...64 Security...66 Security Level Functions...66 Program Parameters...68 xi

Table of Contents

Starting Battery Service ...68 Performing an Automatic OhmTest...69 Optimizing Charge Time or Capacity...70 Termination Condition on dT/dt...71 Saving Program and Target Capacity Settings...71 Resuming Service After Power Failure...72 Short Key Functions...74

Chapter 8

Reports and Labels...75

Automatically Print Reports or Labels (Auto-Print)...77 Automatic Report or Label printing...77 Manually Print Reports and Labels ...78

Chapter 9

Events and Data Logs...80

Logging Events...80 Setting up the Event Log ...80 Using the Event Log...81 Logging Data ...82 Sample text strings...85 Setting up the Data Log...86 Using the Data Log...88

Chapter 10 Custom Programs...91 Cycle 1 and Cycle 2...92 Test...93 IF Statements...93 THEN and ELSE Statements...94 Phase Done...95 Creating and Editing Custom Programs...96 Sample Custom Program ...97

Chapter 11 Services and Upgrades... 100 Replacing the Primary (Input) Fuse... 100 Upgrading the Firmware ... 101 Cadex Electronics Inc. C7000-C Series Battery Analyzers

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Table of Contents

Resetting the System...101 Cleaning the Analyzer...102

Chapter 12 System Calibration ...103 Calibrating Voltage ...103 Servicing the Voltage Calibration Adapters...103 Calibrating Adapters...104 Adapter Calibration Values...105 Acceptable Calibration Values for New Adapters...105

Chapter 13 Solving Problems and Getting Help ...106 Troubleshooting...106 Manual Updates and Other References...110 Technical Support...110

Appendix A Messages and Warnings ...112 Non-Coded Messages...113 By Code...114 By Detailed Message...118

Appendix B Charge Algorithms ...135 NiCd and NIMH batteries...135 SLA and Li-ion batteries...137

Appendix C Specifications...139 Hardware...139

Appendix D Parts and Accessories...141

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Chapter 1

Overview

The Cadex C7000-C Series of Battery Analyzers includes the C7200-C, C7400-C and C7400ER-C.

Product Features •

Services rechargeable nickel-cadmium (NiCd), nickel-metal hydride (NiMH), sealed lead-acid (SLA), lithium-ion (Li-ion) batteries and lithium-polymer (Li- Poly). In this manual “Li-ion” refers to both lithium-ion and lithium-polymer batteries.

•

Programmable with a total of 17 programs including: o Four basic programs: Auto; Charge; Prime and QSort. o Ten advanced programs o Four user-programmable programs.

•

Battery Adapters allow convenient interface to all battery types. Over 1000 custom Battery Adapters are available and specialty adapters can be ordered.

•

Adapters can be programmed with 10 C-Codes. C-Codes contain the chemistry, voltage and rating. Custom adapters are provided with C-Codes of the most common batteries.

•

A menu-driven interface with messages in plain English and status lights.

•

Prints battery service reports and battery service labels.

•

Analyzers can be connected to a PC and operated with BatteryShop™ software.

•

BatteryShop™ software allows automated operation and networking of multiple analyzers.

Connecting to Cadex BatteryShop™ BatteryShop™ is a powerful Windows-based battery management software tool that allows automation of the Cadex battery analyzer functions to increase productivity. •

Provides control and monitoring of large -scale battery services by connecting up to 120 Cadex analyzers to service up to 480 batteries simultaneously.

•

Provides easy access to a database of information for over 1000 battery models, including C-Code settings. Even a novice user can perform a variety of tests and programs.

To find out how Cadex BatteryShop™ can enhance battery maintenance, contact Cadex Electronics Inc (see Connecting to BatteryShop™, page 63).

Cadex Electronics Inc. C7000-C Series Battery Analyzers

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Chapter 2

Getting Started

Contents of the Box •

The Cadex Battery Analyzer package includes these items:

•

One Cadex Battery Analyzer

•

One IEC320 Power Cord (North American Version)

•

One User’s Manual

Using this Manual The Cadex C7000-C Series Battery Analyzer User’s Manual contains the concepts, procedures and other information necessary to operate the Cadex battery analyzer equipped with firmware version 1.00. Chapter 1 - Overview provides basic information about product features and connecting the Cadex analyzer to a computer. Chapter 2 - Getting Started goes through the items that are included with the analyzer and how the manual works. It also explains common symbols, abbreviations, acronyms and commonly used terms. Chapter 3 - Operating Principles provides information about the Cadex analyzer, components, display screen, interface and how to use Battery Adapters with the analyzer. Chapter 4 - Basic Battery Service provides the basic procedures for servicing a battery. Chapter 5 – Battery Service Programs provides detailed information about all the battery service programs.

Chapter 6 -C-Codes (Configuration Codes) provides detailed information on selecting and managing battery parameters (C-Codes). Chapter 7 - System Setup and Options describes the analyzer’s menu system and provides information about modifying the operation of the analyzer to suit particular needs. Refer to this chapter when connecting devices to the analyzer (i.e. printers or a PC with BatteryShop™ software). Chapter 8 - Reports and Labels provides information about printing battery service reports and labels. Chapter 9 - Events and Data Logs describes methods of obtaining and graphing detailed voltage/current/temperature/impedance analysis. Chapter 10 - Custom Programs describes how to create user -defined programs for specialized or advanced applications. Chapter 11 - Services and Upgrades provides information on servicing the Cadex analyzer, including upgrading the firmware. Chapter 12 - System Calibration provides instructions for calibrating the analyzer. Chapter 13 - Solving Problems and Getting Help provides solutions for common problems that may occur when operating the analyzer. Appendix A - Messages and Warnings provides detailed information on fault codes and messages that appear on the display. Appendix B - Charge Algorithms describes the charge and discharge algorithms.

Cadex Electronics Inc. C7000-C Series Battery Analyzers

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Conventions Typeface

Meaning

SMALL CAPS

Menu options to select Default settings Names of keys on the battery analyzer

BOLD SMALL CAPS

Italics Bold & Italic

Emphasized words References to other sections in this manual

Direction Keys Direction keys are represented in this manual as follows: UP = 5 DOWN = 6 LEFT = 3 RIGHT = 4 Symbols Caution Information that, if ignored, can result in damage to the Battery Analyzer, Battery Adapters or the battery. Potential shock hazard. Potential explosion hazard.

3

Abbreviations and Acronyms Abbreviation

Name or Term

16k adapters AWG

These adapters have the extra memory to handle matrices for QuickTest™. These adapters are marked “16K” on the rear label. American wire gauge (a U.S. wire size standard)

LCD

Liquid Crystal Display (also called display)

LED

Light Emitting Diode (also called light)

Li Li-ion

Lithium-ion and Lithium -polymer battery chemistry Lithium-ion battery chemistry

mA

Lithium-polymer battery chemistry. This chemistry is treated in the same way as Li-ion. Milliampere

mAh

Milliampere hour

mOhm

Milliohm

NiCd

Nickel- cadmium battery chemistry

NiMH

Nickel- metal-hydride battery chemistry

OEM

Original equipment manufacturer

PC

IBM compatible personal computer

RF

Radio frequency

P/N

Part number

SoC

State of Charge

SoH

State of Health

SLA

Sealed Lead Acid battery chemistry

USB

Universal Serial Bus

Li-polymer

Cadex Electronics Inc. C7000-C Series Battery Analyzers

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