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CADEX C4000 SERIES
SATTERY ANALYZER
USER'S MANUAL
CADEX ELECTRONICS INC.
111- 7400 MacPherson Ave.
Burnaby, B.C. Canada V5J 5B6
Tel (604) 451-7900
Fax (604) 451-7991
Toll Free 1-800-565-5228
WARRANTY
DISCLAIMER
REVISIONS
TRADEMARK
COPYRIGHT
CADEX ELECTRONICS INC. warrants the Cadex C4000
Battery Analyzer against defective materials and workmanship
for ONE YEAR from the purchase date. Service is available by
returning the unit to the manufacturer. The manufacturer will
assume one half of the shi in cost.
The information contained herein is accurate to the best of our
knowledge and belief. Since the conditions of handling and use
are beyond our control, we make no guarantee on results if
equipment is improperly handled or misused.
CADEX ELECTRONICS INC.
reserves the right to revise this
publication and make changes in the contents hereof without
obligation to notify any person of such changes.
CADEX
is a registered trademark of CADEX ELECTRONICS
INC.
Copyright (c) 1993 by
CADEX ELECTRONICS INC.
All rights
are reserved. No part of this publication or the firmware
controlling the 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, electronic, mechanical, magnetic, optical,
chemical, manual or otherwise without the written permission of
CADEX ELECTRONICS INC. 111- 7400 MacPherson Ave.
Burnaby, B.C., Canada V5A 3G1.
Document MUC49503
Firmware Versions V3.00 &V3.00P
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DO'S AND DONT'S
Do: • Connect the C4000 Battery Analyzer to the correct line voltage.
The operating voltage is indicated on the instrument label on bottom of
the unit.
• Recharge NiCd batteries between SoC and 3S 0C (410F and 96
oF). Fast-charging outside this temperature range may cause damage
to the battery.
Note Allow cold battery to warm up before charging;
Allow hot battery to cool before charging.
• Use the correct battery for which the adapter is configured to.
Failure to do so may cause damage to the battery. Battery parameters
can be verified by pressing the appropriate Display Key when the
Station is empty.
•
•
Don't:
• Clean battery contacts before servicing •
• Do not short 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 will cause a fuse to blow. A shorted battery will
cause no harm.
• Do not transmit in close proximity. The C4000 is equipped with high
frequency switch-mode power supplies. The advanced circuits may be
sensitive to RF interference.
• Rule of Thumb: The following distances should be observed when
transmitting:
0.5 Watt of transmit power=0.3m (1')
1 Watt of transmit power=0.6m (2')
2 Watts of transmit power=1.2m (4')
4 Watts of transmit power=204m(8')
• Do-not restrict the airflow of the analyzer. Leave the fan opening
clear. Fan operation is automatic.
• Do not expose LCD to direct sunlight.
WARRANTY
DO'S AND DON'TS
Table of Contents
I
II
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CHAPTER 1 - INTRODUCTION
1-1
1. Overview of Cadex C4000
1-2
2. Getting Started
1-3
CHAPTER 2 - BASIC OPERATION
2-1
1. Power Up
2-2
2. Analyzing Batteries
2-3
3. Evaluation of Battery Results
2-6
CHAPTER 3 - PROGRAMS
&
TARGET CAPACITY
3-1
1. Application Table
3-2
2. Prime
3-3
3. Charge
3-5
4. Auto
3-6
5. Custom
3-8
6. Standby
3-8
7. Target Selector
3-9
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8. Calculation of Target Capacity
3-10
CHAPTER 4 - STATUS INDICATORS
4-1
1. LED Indicators
4-2
2. Audible Tone Signals
4-3
3. Status Indicator Tables
4-4
4. Display (LCD)
4-6
5. Display Messages
4-8
CHAPTER 5 - FAULT CODES
5-1
1. Application Tables
5-2
2. Correctable Faults
5-4
3. Voltage Faults
5-6
4. Timing Faults
5-9
5. Temperature Criteria
5-10
6. Electrical Limitations
5-11
7. Corrected Faults
5-12
CHAPTER 6 - BATTERY ADAPTERS
6-1
1. Battery Adapter Styles
6-2
2. Installation
6-4
3. Battery Adapter Errors
6-5
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Table of Contents
•
CHAPTER 7 - PROGRAMMING BATTERY ADAPTERS
7-1
1. C-Code Definition
7-2
2. C-Code Structure
7-3
3. Quick View of Battery Parameters
7-4
4. Menu Tree
7-4
5. Menu Functions
7-6
CHAPTER 8 - UTILITIES
8-1
1. Reset to Factory Default
8-2
2. Copy Settings
8-3
3. Set Password
8-3
4. Station Target Capacity
8-5
5. Company Name
8-5
6. Calibrate Station
8-6
CHAPTER 9 - CUSTOM PROGRAMS
9-1
1. Setting up Custom Program
9-2
2. Typical Applications
9-5
3. Code Definition
9-8
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4. Program Variations
9-11
CHAPTER 10 - OPTIONS
10-1
1. Data Retention
10-2
2. DatelTime
10-3
3. Printer Interface
10-4
4. Print Formats
10-5
5. Computer Interface
10-7
6. Event Log
10-8
CHAPTER 11 - C-CODE TABLES
11-1
1. Battery Type
11-7
2. Number of Cells
11-8
3. Battery Rating
11-9
4. C-Rate
11-11
5. Trickle Charge
11-13
6. Recondition Discharge
11-14
7. Capacity Offset
11-15
8. Temperature Sensor
11-17
9. Negative Slope
11-17
10. End of Discharge
11-18
11. End of Recondition (NiCd, NiMH)
11-19
12. charge method
11-19
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13. Float Voltage (SLA)
11-20
14. Voltage Limit (SLA)
11-21
15. Topping Charge Plateau (SLA)
11-22
CHAPTER 12 - DIAGNOSTICS
1. RAM/Clock/LCD Check
2. Start-up Messages
CHAPTER 13 - SERVICE
1. Static Precautions
2. Replacing Fuses
3. Replacing Back-up Battery
4. Replacing the EPROM
5. Installing OPTION-P
6. Motherboard Layout
CHAPTER 14 - SPECIFICATIONS
APPENDIX
GLOSSARY
INDEX
Table of Contents
12-1
12-2
12-3
13-1
13-2
13-2
13-3
13-5
13-6
13-8
14-1
A-1
G-1
1-1
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CHAPTER 1
CHAPTER 1
INTRODUCTION
1-1
INTRODUCTION
Introduction
•
1. Overview
of Cadex C4000
-ON-OFF S .
witch on the b
ack panel
Liquid Crystal Display (LCD)
Station with
out Battery Adapters
Program Selector Switch
Run
Read~
Fail'Y~
LED Indicators (0
ne group
per Station)
1-2
Menu Key
Display Key
Target Selector S .
witch
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Introduction
2. Getting Started
Plug in and turn on Plug and on-off switch are located on the back of the
C4000.
Select the program The Program Selector Switch is on the front of the
analyzer.
Select: • PRIME for new or stored batteries prior to use
• CHARGE for fast-charging only (no analysis)
• AUTO to service batteries with unknown conditions.
Set Target Selector Target Selector switch is on the right hand side of the
front panel.
Select: • 80% for most requirements
• 90% or 100% for more demanding applications
• 60% or 70% for less critical applications.
•
Battery Adapter
Insert the Battery
When battery servicing
is complete
Display
Configured Battery Adapters are pre-programmed for
specific battery types. To reprogram, refer to CHAPTER
7 - PROGRAMMING BATIERY ADAPTERS .
When contact is made, a "Beep" is heard and the
yellow RUN LED comes on.
The Green READY LED is on if the battery has
successfully completed the program.
The red FAIL LED comes on if the battery has failed to
meet the specified requirement.
Global The status of each battery is shown on the top line of
the LCD display. The lower section of the LCD shows
the relative voltage of each battery in a line-graph form.
Detailed Detailed information about the battery can be seen by
pressing the corresponding Display Key.
•
After completion of the
program
Record the test results. The battery may be removed or
left in the analyzer until needed. When the battery is
removed, the test results are canceled .
1-3
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CHAPTER 2
BASIC OPERATION
CHAPTER 2
BASIC OPERATION
2-1
Basic Operation
1. Power Up
Start-up messages
Global Display
Battery Adapters
Before connecting the C4000, check for the correct line
voltage. The line voltage label is located on the bottom
of the unit. The on-oft switch is on the back panel.
When the power is turned on, the display (LCD)
message briefly reads:
:,gM9!:"(ll~'.::.B.~::.eEElmgrff:!~nISi:.:::.:
:):;i }:;:),:::::::
:MeBstQN#::alQOfR:::::n::QIAGNQSTIGS}PA$$}~;tjj: :::',::::: .
The display then shows the Target Capacity setting
briefly, then switches to the Global Display. If the
Battery Adapters are installed in Stations 1, 2 & 3, but
not 4, the display shows:
The analyzer is now ready to service batteries in
Stations 1, 2&3.
Note It is advised to install a Battery Adapter in all
vacant stations. This prevents damage by static
electricity.
The batteries interface with the C4000 through Battery
Adapters. You can install, replace and reprogram the
adapters while other batteries are being serviced. For
more details on the various types of Battery Adapters,
refer to CHAPTER 6 - BATTERY ADAPTERS.
2-2
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Basic Operation
2. Analyzing Batteries
Set Program
Before servicing a battery, select the desired program
(refer to CHAPTER 3 - PROGRAMS & TARGET
CAPACITY).
Set Target Capacity
Select the Target Capacity. If you are not certain what
setting to use, select 80%. For more detail. refer to
CHAPTER 3- PROGRAMS & TARGET CAPACITY.
Verify correct battery
setting
Check that the Battery Adapter is set to the correct
battery parameters. With the display indicating EMPTY,
press the appropriate Display Key. The display now
indicates the setting of the Battery Adapter in question.
STATIQII 4
ZOfE 2
VQ.TAGE
Battery rating
STATION 3
STATION 2
Battery voltage
NiCd
(STD.);
AUTO-SCALED
12 CELLS
(15.00V); 4000 mAh
Z0fE1
EN) OF
DISCHARGE
SHORT
#2
1
2
3
4
EN) OF
Number of cells
C4000 Battery Parameter Display For A NiCd Battery
Station number
STAros
VQ.TACE
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Figure 2.1
Viewing different
display frames
Since not all information can be shown on one display
frame, the battery parameters are contained in several
frames. The basic information is shown in the first
frame. followed by more detailed definitions in the
subsequent frames.
To step through the frames, press the appropriate
Display Key several times. For more details on the
display, refer to CHAPTER 4 - STATUS INDICATORS.
•
Reverse polarity and
short protection
The C4000 is electronically protected against reverse
connection and short circuits. No harm is done to the
equipment if the battery has a short or is accidentally
connected in reverse polarity .
2-3
Basic Operation
"Dead" batteries
Connect battery
Program Sequence
PRIME and AUTO
If the battery to be serviced has no voltage reading, an
initial brief charge by a designated charger is required.
The C4000 will not start the program if battery voltage is
not detected.
After selecting the program and target capacity, you are
now ready to connect the battery. Battery connection is
acknowledged with a beep tone. While the battery is
being serviced, the yellow RUN LED is on.
The program starts with discharge, followed by charge.
If the battery has no capacity (no energy), the program
starts with charge.
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CHARGE On the CHARGE program, the battery commences with
charge. No discharge is applied.
Method of battery
analysis
Definition of battery
capacity
It is not possible to obtain an immediate capacity
reading by inserting a battery. The capacity is derived
by discharging the battery at a calibrated current to the
end-of-discharge threshold voltage. The elapsed time
is measured and displayed as the derived battery
capacity.
When the batt-ery starts discharging, the Global Display
reads "CAP: 0%". The flashing capacity figure indicates
that the number is counting upwards. When the battery
voltage has dropped to the end-of-discharge threshold,
the discharge terminates. The readings stop flashing
and the true capacity is then known.
Several capacity readings may be shown. If more than
five discharge-charge cycles have been applied, the
2nd, 3rd, 4th and 5th readings indicate the latest four
capacities. The first reading (Residual Capacity)
remains visible at all times.
The capacity reading is the percentage of the
manufacturer's battery rating. The rating is measured in
mAh (milliampere per hour). For more information, refer
to CHAPTER 11, "3. Battery Rating".
2-4
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Interrupt
Changing control
settings
Full Load
Basic Operation
Example
A fully-charged battery rated at 1000mAh
must be able to provide a discharge current of 1000mA
for one hour. If the battery can provide this current for
that time, the derived capacity is 100%. If the battery
can only provide the current for 30 minutes, the capacity
is 50%.
When a battery is disconnected while in service, a beep
tone sounds. If the battery is reconnected within five
seconds, service resumes without interruption. If not re-
connected, the Station resets to EMPTY in five seconds
and the battery data is lost.
Pressing the Display Key during the five-second
interrupt resets the Station immediately.
Changing the Program Selector while a battery is
serviced does not affect the program in progress. To
restart with a different program, remove the battery and
press the appropriate Display Key to reset the station.
Select the new setting and re-insert the battery .
Changing the Target Selector during service is possible.
Since the Target Capacity setting is read at the end of
each discharge, the effect of changing the setting will
depend on the battery's position in the program
sequence at the time of change.
Batteries requiring charge or discharge power in excess
of the unit's capacity are put on a waiting queue. The
display message for batteries on hold reads WAITING.
When the charge or discharge power becomes
available, a battery that is waiting resumes service.
Note Energy from discharging batteries is used to
charge the other batteries .
2-5
Basic Operation
3. Evaluation of Battery Results
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Global Display The status of each battery in service is shown on the
first line of the display. The average cell voltages are
displayed in bar-graph form on the second line.
Detailed Display Pressing the Display Key allows you to get more detail
on the battery services. Several capacity figures are
shown on multi-cycle programs. Average cell voltage
and battery Fault Codes (if present) are also displayed.
For more information, refer to CHAPTER 5 - FAULT
CODES.
Evaluation by LEDs
PRIME and AUTO
CHARGE
Evaluation by display
Each Station is equipped with RUN, READY and FAIL
LEOs. During service, the RUN LED is on. When the
program is completed and the battery has met or
exceeded the Target Capacity, the READY LED lights
up. If the Target Capacity has not been reached, the
FAIL LED comes on. A flashing FAIL indicates incorrect
battery voltage due to defective cells.
Since no capacity reading is taken on the CHARGE
program, the READY LED blinks when the battery is
fully charged. For a summary of LED signals, refer to
CHAPTER 4-STATUS INDICATORS.
In addition to the RUN, READY and FAIL LEOs, the
C4000 is equipped with an aO-character display.
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2-6
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CHAPTER 3
PROGRAMS&TARGET CAPACITY
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CHAPTER 3
PROGRAMS & TARGET CAPACITY
3-1
Programs
&
Target Capacity
Introduction
Selection
Indicators
The CADEX C4000 features user-selectable programs
with decision-making capabilities that evaluate the bat-
tery and apply an appropriate service to improve or
restore a battery. This section explains the different
applications, and recommends the best choice of
program and target capacity settings to be used.
The programs are selected through the Program Selec-
tor Switches on the front panel of the C4000. You can
set each Station to a different program.
Important Select the correct program before connecting the
battery. Changing the setting after the battery is
connected will have no effect.
While the program is running, the RUN LED for that
Station is on. The program is completed when the RUN
LED turns off and either the READY or FAIL LED comes
on (refer to CHAPTER 4-STATUS INDICATORS).
•
1. Application Table
Table 3.1 summarizes the typical applications of
program setting.
PRIME
CHARGE
AUTO
WHEN TO USE IT
Prepare new batteries for
Fast-charge only.
Restore batteries affected
field use.
by "memory".
Condition batteries that
Top-up charge of
Identify marginally
have been in storage.
partially discharged
performing batteries.
batteries.
Verify battery condition
Weekly or monthly routine
to support a warranty
battery maintenance.
claim.
TIME (in hours)
NiCd
l
5 to 10
1.5
2.5 to 10
NiMH2
10 to 20
3
5 to 18
SLA3
40 to 80
10
20 to 40
Table 3.1
(Time at Default C-Rate of 1C.
zTime at Default C-Rate of 0.5C.
3Time at Default C-Rate of 0.3C charge and 0.1 discharge.
3-2
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Programs & Target Capacity
2. Prime
•
When to use it
Program time
How it works
• Prepare new batteries for field use.
• Condition batteries that have been in storage.
• Verify battery condition to support warranty
• claim.
PRIME is used to condition new batteries prior to use. A
new (or stored) battery may require several charge/
discharge cycles until peak performance is reached.
The time required may vary depending on the battery
type. At a C-Rate of 1C, the program time is:
NiCd 5 to 10 hours
NiMH 10 to 20 hours
SLA 40 hours or longer.
For more information on C-Rates. refer to
CHAPTER 11 - C-CODE TABLES .
The battery first discharges to the end-of-discharge
threshold voltage and recharges. A second discharge-
charge cycle is applied and its resulting capacity is
compared with the first reading.
5
% improvement
Very low-capacity
battery
If the improvement is 5 % or higher, a further charge-
discharge is applied. This cycle is repeated until the
improvement is less than 5 %. At this percent, it is
assumed that the battery has reached the peak
performance. The program concludes with a final
charge.
A battery that cannot obtain a capacity of 5% is cycled
four times. This feature allows additional priming cycles
on a new battery that cannot accept a full charge at
first.
•
Empty battery A fully-discharged battery will proceed with charge
immediately.
Trickle charge After the service is completed, trickle charge is applied.
If one or more cells within the battery are bad then the
battery fails. No trickle charge is applied.
3-3
Programs & Target Capacity
Indicators
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Lights •
•
READY if the battery meets or exceeds the Target
Capacity.
FAIL if the battery cannot meet the Target Capacity .
Display
When the program is successfully completed, the Global
Display shows the Final Capacity reading. By pressing
the appropriate Display Key, the display shows
additional information. If the battery failed, a Fail Code is
shown (refer to CHAPTER 5 - FAULT CODES).
The Global Display shows a maximum of five capacity
readings on PRIME. The first reading is the Residual
Capacity, the middle readings are the Transitional
Capacities and the last is the Final Capacity.
• Residual Capacity is the charge that is left before
• Transitional Capacities are the middle readings.
• Final Capacity represents the final reading.
3-4
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Programs
&
Target Capacity
3. Charge
•
When to use it
Program Time
How
it
works
• Top-up partially charged batteries.
• Serves as a fast-charger.
The time required may vary depending on the battery
type. At a C-Rate of 1C, the charge time is:
NiCd 90 minutes typically
NiMH 3 hours typically
SLA 10 hours typically.
For more information on C-Rates, refer to CHAPTER 11
- C-CODE TABLES.
CHARGE fully charges a battery. After full charge is
reached, trickle charge is applied to maintain full charge
capacity. Full charge is detected by the Negative Slope
method. Poorly matched cells that do not produce an
adequate slope are timed out by the Plateau Timer. The
combination of these two methods provides an accurate
and safe means to terminate the fast-charge. No
temperature sensing is required if the battery is serviced
within the recommended temperature range.
•
Partially or fully charged The analyzer recognizes a partially or fully charged
batteries battery. On these batteries, the charge time is
shortened accordingly. A shorter charge time also
applies to batteries that have a low capacity.
Reverse Load Charge Reverse Load Charge is used to promote the
Method recombination of gases generated during the fast-
charge of the NiCd and NiMH batteries. The Reverse
Load Charge intersperses discharge currents between
the charge pulses. The results are a cooler and more
effective charge than conventional chargers. In addition,
the "memory" phenomenon is reduced as the battery is
stimulated while charging. Refer to "4. Auto" for
definition of memory.
Note Reverse Load Charge is used for all charge and
trickle charge functions .
3-5
Programs & Target Capacity
•
Indicators
LEDs
Blinking READY if the battery is fully charged (blinking
indicates that no capacity evaluation was taken). FAIL if
the voltage is too low.
Display
When the program is successfully completed, the
Global Display shows "DONE". If the battery failed, a
Fail Code is shown (refer to CHAPTER 5 - FAULT
-CODES).
4. Auto
When to use it
Exercises batteries to maintain peak performance.
Reconditions those NiCd batteries that are unable to
reach the Target Capacity.
Identifies and "weeds out" marginally performing bat-
teries.
Applies battery maintenance for battery fleet.
AUTO is the recommended program for routine
•
maintenance of NiCd batteries. Batteries that meet the
Target Capacity are exercised to retain the optimal
performance. Batteries that are unable to reach the
target are reconditioned. This program is effective in
restoring batteries with "memory".
Memory
Memory is a crystalline build-up that forms when the
battery is repeatedly recharged without sufficient
discharge. This phenomenon occurs on NiCd batteries
only and causes progressive capacity degradation.
Program Time
The time required may vary depending on the battery
type. At a C-Rate of 1C, the program time is:
NiCd
2.5 to 10 hours
NiMH
5 to 18 hours
SLA
20 to 40 hours.
For more information on C-Rates, refer to CHAPTER 11
- C-CODE TABLES.
•
3-6
•
How it works
If Residual Capacity
meets target
Programs
&
Target Capacity
The battery is first discharged to one volt per cell during
which the Residual Capacity is measured. If the
capacity meets or exceeds the target, a final charge is
applied. Typical program time is 2 to 3 hours
If Residual Capacity is If the Residual Capacity is below target, the battery is
below target fully recharged and a second discharge is applied to
measure the full-charge capacity.
If second discharge If the second discharge meets the Target Capacity, the
meets target program concludes with a final charge. The READY
LED comes on.
NiCd, NiMH If the Final Capacity meets the target, the READY LED
comes on. If below target, the FAIL LED comes on.
•
If second discharge
capacity is below target
Indicators
If the second discharge capacity is below target,
Recondition is applied. The battery is fully recharged
and discharged once more to measure the Final
Capacity. A concluding charge follows.
SLA For SLA batteries, AUTO consists of 1 or 2 discharge/
charge cycles. Recondition is omitted.
For more information on the NiCd battery, refer to a
separate publication referred to as "Characteristics of
Rechargeable Batteries".
•
Recondition
Recondition is a controlled deep discharge that
removes the crystalline build-up, or "memory", on the
cell plates .
3-7
Programs
&
Target Capacity
5. Custom
The Custom Program is used if a special function or a
sequence of functions is required, such as:
• Discharge only for purpose of shipping or storage
• Long-term reliability test by cycling the battery until
the capacity drops below the set Target Capacity.
The information on this program is extensive. Refer to
CHAPTER 9 - CUSTOM PROGRAMS for details.
6. Standby
Standby automatically runs 30 days after the battery
has completed AUTO, PRIME or CHARGE.
•
Why is it needed
If a NiCd battery is left on trickle charge for prolonged
periods, deterioration due to "memory" occurs (refer to
"4. Auto" for definition of memory).
On the other hand, if a fully-charged battery is placed
on the shelf, it is subject to significant self-discharge.
•
Self-discharge Approximately 10% of the battery's charge is lost in the
initial 24 hours. The self-discharge is reduced to 10%
per month thereafter. At higher storage temperatures,
the self-discharge rate is higher. Likewise, older bat-
teries have a higher self-discharge than a newer one.
What does it do
How
it
works
• Maintains batteries that must be kept charged for
unscheduled use.
• Makes fully-charged batteries available for
equipment rental.
• Verifies long-term battery performance.
Standby applies a discharge-charge cycle after the
battery has been on trickle charge for 30 days. The
setting of the Program Selector has no effect on the
Standby operation. The capacity readings are displayed
as per the PRIME program.
3-8
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•
Programs & Target Capacity
7. Target Selector Setting
The Target Capacity is set through the Target Selector
Switch. The setting is global and applies to all Stations.
Individual Target Capacity settings are possible through
the menu-driven interface. Refer to CHAPTER 8 -
UTILITIES, "4. Station Target Capacity".
Select 80% for most
applications
The Target Selector lets you set the minimum
acceptable level you must obtain from a battery. If
uncertain what setting to use, select 80%.
Note The Target Capacity setting does not affect the
charge level; the batteries are always fully charged
regardless of the setting.
The suggested Target Capacity settings are as follows:
•
•
60%, 70% The low-end Target Capacity settings are used for
applications where the battery power demand is not
critical or is of brief duration. These settings pass the
largest number of batteries when serviced.
80% This is the most common Target Capacity setting. It
satisfies the need for adequate energy reserve as well
as economical use of the batterY fleet.
90%, 100% The high-end Target Capacity settings are used for
critical applications that require maximum energy
reserve and high reliability. These settings pass the
least number of batteries when serviced .
3-9
Programs
&
Target Capacity
8. Calculation of Target Capacity
To establish a workable target setting for your require-
ment, the following evaluation is recommended:
• Use a battery with a known working-capacity reading
• Fully charge the battery and use it in a normal field
situation
• Measure the remaining capacity after the routine
shift.
• Select PRIME or AUTO and insert the battery. The
first discharge reveals the Residual Capacity. The
second discharge is the Full Capacity.
•
• With the Residual and Full Capacities known, the
consumed energy can be calculated by deducting
the Residual Capacity from the Total Capacity.
Example of Target Working Capacity of battery when fully charged
Capacity calculation Residual Capacity after a routine shift
Consumed Capacity
100%
20%
80%
•
Recommended Target
Capacity setting
If the Residual Capacity is less than 20%, the Target
Capacity should be increased by 10%. Likewise, if the
Residual Capacity is 30% and higher, the Target
Capacity may be reduced by 10%.
3-10
•
•
•
•
CHAPTER 4
STATUS INDICATORS
CHAPTER 4
STATUS INDICATORS
4-1
Program in progress
Program completed
Test results negative.
Status Indicators
Introduction
1. LED Indicators
The light-emitting diode (LED) provides the user with a
quick overview of the battery test results. The battery
status is indicated for each Station by the LEOs as
follows:
RUN (yellow)
READY (green)
FAIL (red)
Detailed battery test results are shown on the 80-
character display.
•
RUN
steady Battery service in progress.
blinking"
Below temperature range for charge; will proceed
automatically when temperature rises to acceptable
level.
READY
steady
Battery ready; capacity not available or capacity
compared to target setting
blinking
Battery ready; CHARGE mode only.
•
FAIL
steady
Program completed; Target Capacity not met.
blinking
Battery voltage fault; cannot be corrected.
POWER
steady
Analyzer operational; normal condition.
blinking
Analyzer is on hold because its internal temperature is
above operating range; resumes when normal.
•
Temperature trigger point: 70°C (158°F) .
•
Minimum hold time: 1 minute .
READY
blinking"
Battery hot; program terminated (CHARGE program
and FAIL
only).
MENU
steady
Menu mode. Batteries in service are not disrupted by
the menu but resume service as usual.
" with temperature sensor option only
4-2
•
•
Status Indicators
2. Audible Tone Signals
The C4000 Analyzer produces a variety of audible
signals to mark events such as buttons pressed or
programs ending. The signals and the events are listed
below.
Single beep tone:
• Battery connected (long beep)
• Display Key pressed (short beep)
• Menu Key pressed (short beep).
PRIME/AUTO: Target Capacity met or exceeded.
Triple beep:
(High pitch)
Ready
CHARGE:
Full charge done.
Continuous tone
•
Triple beep:
(Low pitch)
Wailing sound
Ready
PRIME/AUTO: Target Capacity not met.
Shorted battery, not serviceable. Remove battery or
press Display Key to stop tone .
Wrong polarity. Remove battery and reverse
connection.
•
Fading tone (gong)
Low tone
New battery parameters stored in Battery Adapter.
New battery parameters not accepted, or invalid
parameters .
4-3
Status Indicators
3. Status Indicator Tables
Table 4.1 summarizes the LED and sounder schedules.
•
CONDITION
LEOs
SOUNDER MODE COMMENTS
NO BATIERY
Open terminal
RUN
off
silent
reset
Station resets
READY
off
when battery
FAIL
off
removed.
BATTERY
Battery in
RUN
single beep active
Beep tone when
INSERTED
service
READY
off
service
battery inserted.
FAIL
off
BATTERY READY
Normal battery
RUN
off
triple beep trickle
Target capacity
(CHARGE)
voltage
READY ___
charge
not used in
FAIL
off
CHARGE mode.
BATTERY READY
Battery capacity
RUN
off
triple beep trickle High-pitch triple
(PRIME or AUTO)
meets target
READY
charge
beep if READY;
capacity
FAIL
off
low pitch if FAIL.
Battery fails to
RUN
off
silent
trickle If program was
meet target
READY
off
charge
PRIME, try
capacity
FAIL
AUTO.
REVERSE
Leads are
RUN
off
wailing no charge
Check leads.
POLARITY/SHORT
reversed or
READY
off
Charge battery in
battery has low
FAIL
••••••••••
manufacturer's
voltage
specified charger.
Do not leave
battery
unattended.
LOW VOLTAGE
Battery has
RUN
off
silent no charge
Partial short. low
shorted cell(s)
READY
off
voltage or
FAIL
••••••••••
depressed V.
Discard battery.
SOFT BATTERY
Battery voltage
RUN
off
silent no charge
Charge
rises too high
READY
off
terminated,
FAIL
•••••
••
discard battery.
INTERMITTENT
Unable to clamp
RUN
off
silent
no charge Check condition.
battery voltage
READY
off
FAIL
•
•
•
Table 4.1
4-4
•
CONDITION
LEOs
SOUNDER
MODE
COMMENTS
COLD BATTERY
Temperature
RUN
---
silent
trickle
Trickle charges
below +10°C
READY
off
charge
until room temp.
(+50°F)
FAIL
off
is reached, then
fast charge.
HOT BATTERY
Battery reaches
RUN
off
silent
trickle
Battery is
TERMINATED
+45°C (+113°F)
READY' ___
charge
considered fully
FAIL
• •
charged .
•
•
Temperature Sensor
(optional)
Table 4.2
Thermal Protection
Status Indicators
The sensor inhibits fast charging outside the operational
temperature range. Battery sensing is not required if the
batteries are serviced within the specified temperature
range.
The temperature sensor measures the cell temperature
of the battery. The sensor may be part of the battery
assembly or installed externally.
The C4000 is thermally protected by a fan and an
internal thermal cutoff.
System Fault
Fan The cooling fan engages at 45°C (113°F) and turns off
at 35°C (95°F).
Heat Rail If the internal heat rail exceed lO°C (158°F), the service
is suspended and resumes when the temperature has
dropped (refer to Table 4.3).
The C4000 performs a number of diagnostic tests when
turned on.
If a system fault occurs during operation, the LEDs may
flash at random and the unit will not respond as usual.
Turn the power off and on again. If the condition
persists, do not attempt to service any batteries. Turn
the unit off and call for service .
•
1CHARGE mode only.
4-5
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