Cadex C7000, C7000ER User Manual

C7000 & C7000ER

Battery Analyzer

User’s Manual

This page is blank

C7000 & C7000ER Battery Analyzer

User’s Manual

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 C7000 and C7000ER Battery

Analyzer 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 of business profits, business
interruption, and the like) arising out of the use or inability to use the C7000 and C7000ER

Battery Analyzer equipment and/or its documentation.

Year 2000 Compliance

All functions and performance of the Cadex C7000 and C7000ER Battery Analyzers are
independent of the date stored in the analyzer. Therefore, all functions and the performance of
the C7000 and C7000ER Battery Analyzers are not affected by dates during and after the year

2000.

Cadex Electronics Inc.

22000 Fraserwood Way
Richmond, British Columbia
Canada V6W 1J6
T el: [phone] Fax: [phone]
Web: www.cadex.com Email: [e-mail]

Copyright

Copyright © 2000 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.

Cadex Electronics Inc. reserves the right to revise this publication and make changes in its
contents without obligation to notify any person of such changes.

Trademark

CADEX is a registered trademark of Cadex Electronics Inc. All other trademarks mentioned
herein are the property of their respective owners.

89-207-1001 Rev 8

March, 2000 Printed in Canada

i

1 Overview.............................................................................. 1

Product Features ............................................................................................ 1

What’s New in the C7000 V3.5 firmware ........................................................ 2

Firmware Upgrade: Resetting the System ...................................................... 3

Connecting to BatteryShop™ ......................................................................... 3

Peripherals......................................................................................................4

2 Getting Started.................................................................... 5

Contents of Box .............................................................................................. 5

About this Manual ........................................................................................... 5

Conventions.................................................................................................... 5

Symbols .......................................................................................................... 6

Abbreviations and Acronyms .......................................................................... 6

Commonly Used Terms................................................................................... 7

3 Operating Principles ........................................................... 8

Components ................................................................................................... 8

Option Boards................................................................................................. 9

Components ............................................................................................... 9

Battery Adapters ........................................................................................... 10

Special Handling Tip for Smar t Cable Adapters ....................................... 11

User Interface ............................................................................................... 12

Display ...................................................................................................... 12

Menu......................................................................................................... 14

Commands ............................................................................................... 15

Function Keys ...........................................................................................15

Lights (LEDs) ............................................................................................ 16

4 Basic Battery Service ....................................................... 17

Servicing Batteries with Bar Code ................................................................ 20

5 Battery Service Programs ................................................ 21

Basic Programs ............................................................................................ 21

Specialty Programs...................................................................................... 22

Target Capacity ............................................................................................. 23

Selecting a Program or Setting Target Capacity ........................................... 24

Editing Program Settings .............................................................................. 25

Duration of Service ....................................................................................... 26

ii C7000 & 7000ER Battery Analyzer V3.5

Contents

6 Battery Configuration/C-Codes....................................... 27

Basic C-Code................................................................................................27

Extended C-Code ......................................................................................... 28

Viewing C-Codes .......................................................................................... 30

Managing C-Codes ....................................................................................... 30

Selecting Correct Voltage .........................................................................31

Intrinsically Safe Settings ......................................................................... 31

Default Settings for Extended C-Codes.................................................... 32

7 Custom Programs............................................................. 33

Cycle 1 and Cycle 2...................................................................................... 34

Test ............................................................................................................... 35

Tr ue and False Statements ........................................................................... 37

Phase Done .................................................................................................. 38

Example ........................................................................................................ 38

Creating or Modifying a Custom Program..................................................... 40

8 System Security................................................................ 41

Password Requirement................................................................................. 41

Setting Security............................................................................................. 42

Changing Password and Removing Security................................................ 42

9 System Setup .................................................................... 43

Setting Up System Information ..................................................................... 44

Calibration Procedures ................................................................................. 44

Calibrating Voltage.................................................................................... 44

Calibrating Station .................................................................................... 45

Output Devices .............................................................................................46

Serial Port Settings ...................................................................................46

Serial and Parallel Por t Device Settings ................................................... 47

10 Print Utilities...................................................................... 48

Printing Report or Label ................................................................................49

11 Event Log .......................................................................... 50

Log Events.................................................................................................... 51

Managing Event Log..................................................................................... 51

iii

12 Messages and Warnings .................................................. 52

By Detail ....................................................................................................... 53

By Code ........................................................................................................ 63

13 Services and Upgrades .................................................... 66

Replacing the Primary (Input) Fuse .............................................................. 67

Standard Model (C7000-1, C7000-2, C7000-9)........................................ 67

Extended Range Model (C7000ER) ......................................................... 68

Replacing the Station Fuses......................................................................... 69

Standard Model (C7000-1, C7000-2, C7000-9)........................................ 69

Extended Range Model (C7000ER) ......................................................... 70

Replacing Backup Battery (with OP-70 or OP-72 only) ................................ 71

IEC320 Power Cord ......................................................................................72

14 Specifications ................................................................... 73

Hardware ...................................................................................................... 73

Firmware .......................................................................................................74

15 Getting Help/Problem Solving ......................................... 75

Troubleshooting............................................................................................. 75

Manual Updates and Other References ....................................................... 78

Technical Suppor t ......................................................................................... 78

16 Safety Notice and Warranty ............................................. 80

Radio Interference ........................................................................................ 80

Explosion Hazard.......................................................................................... 81

Shock Hazard ...............................................................................................82

Warranty & Services ..................................................................................... 83

Obtaining Warranty Service ...................................................................... 83

Non-warranty Repairs............................................................................... 83

Index........................................................................................ 84

iv C7000 & 7000ER Battery Analyzer V3.5

The Cadex C7000 and C7000ER Battery Analyzers are sophisticated
programmable battery analyzers capable of servicing batteries with different
electrical properties and mechanical dimensions.

Product Features

• Service Nickel Cadmium (NiCd), Nickel-Metal Hydride (NiMH), Sealed Lead
Acid (SLA) and Lithium Ion (Li-Ion). The C7000 and C7000ER are also
capable of supporting Smart Batteries based on the ‘single wire’ and SMBus
system.

• Operate each station simultaneously and independently of each other.

• Support over 600 interchangeable battery adapters for easy interface with

most commercially available battery models.

• The battery adapter contains the battery configuration code, also know as

C-Code

serving the battery . Each adapter contains 10 C-Codes to accommodate
different batteries in the same product family.

, which automatically sets the analyzer to the correct parameters for

1

Overview

• Offer a variety of programs for battery services: 3 Basic Programs (Auto,
Charge, Prime), 6 Specialty Programs and 4 user-programmable Custom

Programs.

• Easy to use menu-driven interface, plain English messages and status lights.

• Produce Service Reports and Battery Labels.

• Support fleet management. Support bar code entry , print Bar Code Labels

and Battery Labels, and produce a range of reports.

• Can be networked for automated battery maintenance with BatteryShop™.

1

1

What’s New in the C7000 V3.5 firmware

At Cadex, it is our goal to continue to listen to feedback and suggestions from
customers, and improve our products. Below is a list of product enhancements:

Version New Features/Changes

3.5 Runtime program

Support for BatteryShop 3.0
Definable Resistance Threshold in OhmTest
Recognition of 16Kb Battery Adapters
Improved NiMH charge algorithm
Reorganized programs, separated Basi c and Specialty Programs
4 additional Custom Programs
Improved user interface

3.4 Sup po rt fo r B a tte ryS hop
General updates

3.3 Improved OhmTest
Incorporation of OhmTest into the Auto, Pri me and Charge programs
Automatic identification of battery parameters through Battery Adapters

3.2 OhmTe st to test battery internal resistance in 5 seconds
Support for label printer
Temperature sensor to improve safety
Display of battery model numbers
Improved NiMH charge algorithm
Improved bar code

2 C7000 & 7000ER Battery Analyzer V3.5

Firmware Upgrade: Resetting the System

If you are upgrading the analyzer firmware to V3.5 from an older version, you
need to reset the system to the factory defaults to erase the old system
parameters.

Some of the parameters that are reset include:

• OhmTest, Runtime, Self-Discharge, Life-Cycling and Custom Programs

• Battery Startup settings

• Parallel Port Device to Printer

• Serial Port Device to LabelMaker

• Voltage Display to Volts/Cell

• Number of batteries serviced (Service Counter) to 0

! Press and release the Alt key , then press 0.
Note that this function also serves as a general system reboot.

Overview 1

Connecting to BatteryShop™

BatteryShop™ is a powerful Windows-based battery management tool that
allows automation of the C7000 and C7000ER functions to increase productivity .

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

• Contains a database of over 2000 battery models that provides easy
access to C-Code settings and other information. Even a novice user can
perform a variety of tests and programs.

Refer to
the analyzer for BatteryShop.

To find out how BatteryShop can enhance your battery maintenance system,
contact Cadex.

Serial and Parallel Device Settings

or BatteryShop Help on preparing

3

Peripherals

The C7000 and C7000ER support the following peripherals to maximize performance:

• Epson compatible dot-matrix printer to print reports.

• Label Printer to print labels. The DYMO LabelWriter SE300 is recommended.

For more information on label printers, contact Cadex or DYMO-CoStar.

• Bar Code Scanner to scan bar-coded labels. The bar code scanner is included
with the purchase of the OP-72 option board.

4 C7000 & 7000ER Battery Analyzer V3.5

Contents of Box

The Cadex C7000/C7000ER Battery Analyzer package includes:

• 1 C7000/C7000ER Battery Analyzer

• 1 IEC320 Power Cord (C7000-1 only)

• 1 User’s Manual

About this Manual

The C7000 & C7000ER Battery Analyzer User’s Manual contains the concept,
procedures, and information that is necessary to operate the analyzer.

Conventions

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2

Getting Started

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5

Symbols

Symbol Meaning

Information that, if ignored, can result i n damage to
the C70 00/C7000ER Battery Analyzer, Ba ttery
Ad a p te r s o r the b a tte r y.

Shock Hazard.

Explosion Hazard.

Abbreviations and Acronyms

Abbreviation Name or Term

AWG American Wire Gauge. A U.S. wire size standard.

BMS Ba tte r y Mainte nanc e S ys te m.

LCD Liquid Crystal Display. Referred to as Display.
LED Li ght Emitting Diode. Referred to as Light.

Li-Ion Lithi um-Ion battery chemistry.

NiCd Nickel Cadmium battery chemistry.

NiMH Nickel-Metal Hydride battery chemistry.

OEM Ori ginal Equipment Manufacturer.

RF Rad i o F re q uency.

P/N Part Number.

SLA S ealed Lead Aci d battery chemistry.

6 C7000 & 7000ER Battery Analyzer V3.5

Commonly Used Terms

Term Explanation

Ampere Hour (Ah) Battery capacity or rating. A battery that provides a

current of 1 ampere for 1 hour i s rated at 1Ah.

Getting Started 2

Configuration Code

(C-Code)

C-Rate Unit by which charge and discharge times are scaled.

Intrinsic a lly Sa fe (I/S) Ba tte ry wi th bui lt- i n sa fe ty pro te ctio n ci r cui try. The s e

Recondition A deep discharge below 1.0V/Cell with a controlled

Residual Capacity C harge capacity remaining in the battery when inserted in

Smart Battery Battery equipped with specialized circuitry that can

Target Capacity The battery cap acity benchmark for pass/fail set by the

Battery parameters stored in B attery A dapters to servi ce
a b atte r y. Re fe r to Battery C on figuration/C-Codes.

For example, a battery rated at 1000mAh provides
1000mA for 1 hour if discharged at 1C. A discharge of
1C draws a current equal to the rated capacity. The same
battery discharged at 0.5C would provi de 500mA for two
hours.

batteries are primarily used in explosive environments.

current. Recondition helps to revert large crystals as a
result of memory to small desi rable sizes, often restoring
the battery to its full capaci ty. Applies to NiCd and NiMH
only.

an analyzer.

communicate with an analyzer and provide battery
information.

user.

7

Operating Principles

Components

Component Function

Battery Stations Take Battery Adapter.

Prog Key Access servi ce programs and Target Capacity.
Print Key Print labels and reports.

CCode Key A c c es s b atte ry pa ra me te rs.

Esc

ENTER Key Save settings and start servi ci ng.

Ventilation Grill

Battery Stations

Prog Key

Print Key
CCode Key

Esc Key

Fn Key

Station
Keys

LCD

LED

Indicators

Numeric
Keypad

Menu Key

Alt Key

ENTER Key

Key Exit menus or cancel changes.

Fn Key Shortcuts to common functions when pressed with a second

key.

Alt Key Reset to factory defaults when pressed with the 0 ke y a fte r

a firmware upgrade or as a general system reboot.

Menu Key Acc ess menu.

Numeric Keypad Enter numeric parameter settings.

LED Indicators Provide current status of batterie s in service. Activated

LCD Vi ew status for each station and detailed servi ce

Station Keys V iew C-Codes, details of a service, or as cursor keys in

8 C7000 & 7000ER Battery Analyzer V3.5

when a service starts.

information.

editing mode.

Option Boards

All models of the C7000 and the C7000ER come with a RS-232 Serial Port that
connects to a label printer or to BatteryShop. There are 2 option boards, OP-70 and
OP-72, that can be purchased for additional support. (The C7000ER is already
equipped with the OP-70 option board.) The option board sticker is at the back of
the analyzer. The option board configuration is also displayed during start-up.

3

Power Input
(ER model on side panel)

Input Fuse Drawer

Fan Outlet RS-232 Serial PortOn/Off Switch

Note that the option board is blank unless purchased.

5-pin DIN Bar Code Wand
RS-485 Ports (Not Used)

Parallel Printer Port

Components

• Parallel Printer Port: connects to a parallel printer. Refer to
on how to set up the parallel port device settings.

• Battery Backup RAM: retains test data on power interruption, resumes
service when power is restored, and retains dates and time.

• Bar Code Wand: reads bar-coded labels.

OP-70 OP-72

System Setup

Option Board

Parallel Port

Battery Backup RAM

Bar Code Wand Not Activated

Y ou can upgrade your standard analyzer to OP-70 or OP-72. Contact Cadex for
upgrade information.

"

"

"

"

"

9

Battery Adapters

Adapters are designed to fit specific battery types and shapes. The snap lock latch
allows easy insertion and removal.

There are 3 types of battery adapters:

Adapter Type D escription

Custom Adapters Accommodate any specifi c battery shape.

There are over 600 Custom Adapters available.

Dual-station

Custom Adapters

Smart Cable Adapters

(Universal Adapters)

Designed to handle dual packs that contain 2
separate battery systems.

Used when a Custom Adapter for a battery is
not available. Alligator clips attach to positive
and negative terminals.

Custom Adapter

Smart Cable Adapter
(Universal Adapter)

Dual-station
Custom Adapter

10 C7000 & 7000ER Battery Analyzer V3.5

Operating Principles 3

Each adapter contains up to 10 battery parameters (C-Codes) for optimal battery
services. Once the adapter is inserted, the battery station receiving the adapter
automatically chooses the last selected C-Code as the active C-Code.

Note that Smart Cable Adapters need to be programmed, and the user must enter
the correct C-Code settings for the battery to be serviced. Refer to

C-Codes

For Li-Ion batteries of greater than 7.2V (2 cells), a custom designed
adapter is strongly recommended.

Cadex continuously designs adapters for new battery models and also designs
custom adapters for a nominal fee. Please contact Cadex for a current adapter
catalog or download a copy from our Web site, www.cadex.com.

Special Handling Tip for Smart Cable Adapters

! Insert a battery only when the Smart Cable Adapter is inserted into the

for more information.

station. Likewise, do not remove the adapter before the battery is removed.

11

User Interface

Display

••

• Global Display: provides status information of stations and batteries in service

••

at a glance.

Adapter inserted Adapter not inserted

EMPTY EMPTY NO ADAPT NO ADAPT

EMPTY EMPTY NO ADAPT NO ADAPT

EMPTY EMPTY NO ADAPT NO ADAPT EMPTY EMPTY NO ADAPT NO ADAPT
Auto Charge

Auto Charge

Auto Charge Auto Charge

CHARGE EMPTY NO ADAPT NO ADAPT

CHARGE EMPTY NO ADAPT NO ADAPT

CHARGE EMPTY NO ADAPT NO ADAPT CHARGE EMPTY NO ADAPT NO ADAPT

1.35V Charge

1.35V Charge

1.35V Charge 1.35V Charge

••

• Detailed Display: provides detailed information about the battery service or

••

station
in Station 1, the following is displayed when the S1 key is pressed:

Program

Process

Voltage/Current

when the appropriate station key is pressed

. For example, during a service

Station

Process

S1 CHARGING

S1 CHARGING

S1 CHARGINGS1 CHARGING

1.35V/Cell 1006mA 233m

1.35V/Cell 1006mA 233m

1.35V/Cell 1006mA 233m 1.35V/Cell 1006mA 233m

Average Cell Voltage Resistance

Charge/Discharge Current

Pressing the station key again will give additional details such as warning codes,
cycles and program phases.

12 C7000 & 7000ER Battery Analyzer V3.5

32

32

ΩΩΩΩ

32 32

oooo

C 1:05

C 1:05

C 1:05C 1:05

Temperature

Program Duration (hh:mm)

Operating Principles 3

••

• Menu Display: provides access to various functions of the analyzer when

••

the Menu key is pressed.

Time

MAIN MENU 17:52:55

MAIN MENU 17:52:55

MAIN MENU 17:52:55 MAIN MENU 17:52:55
System Security

System Security

System SecuritySystem Security

! Use the

!!

!(S1) and

!!

""

"(S2) keys to scroll through the menu and press

""

ENTER when the desired function is displayed. For example, you will see
the following if System Security is selected:

SYSTEM SECURITY 17:53:10

SYSTEM SECURITY 17:53:10

SYSTEM SECURITY 17:53:10 SYSTEM SECURITY 17:53:10
Set Security

Set Security

Set SecuritySet Security

System Security
feature

Menu

See

for the overview of the functions.

13

Menu

The menu-driven interface allows access to the various functions of the analyzer. Refer
to the individual functions for details and instructions.

Menu

SYSTEM

SECURITY

S2S1

SYSTEM

SETUP

S2S1

PRINT

UTILITIES

S2S1

EVENT LOG

ENTER

ENTER

ENTER

ENTER

S1, S2
ENTER
Esc

to exit.

Set Security
Change Password
Remove Security

Date/Time
Battery Startup
Program Settings
Company Name
Calibration
Output Devices
Sound Control
Voltage Display

Battery Service Report
Battery Label
Bar-Code Label
System Setup Report
Auto-Print

View Event Log
Print Event Log
Clear Event Log
Events to Log

to scroll,

to select,

PROGRAM

SETTINGS

PROGRAM

SETTINGS

CALIBRATION

OUTPUT

DEVICES

ENTER

ENTER

ENTER

ENTER

Auto
Charge
Prime
SPECIALTY PROG.

OhmTest
Runtime
Self-Discharge
Life-Cycling
Discharge Only
Extended Prime
Custom 1
Custom 2
Custom 3
Custom 4
BASIC PROGRAMS

Voltage Calibration
Station Calibration

Serial Port Device
Serial Port Settings
Parallel Port Device

14 C7000 & 7000ER Battery Analyzer V3.5

BatteryShop

Commands

Operation Principles 3

To Press

Se le ct a value

S c r ol l t hr ough m enu

!!

! (S1) or

!!

##

#

(S3) or

##

""

" (S2), then ENTER

""

$$

$

(S4)

$$

levels o r fie ld s

""

Print a report or label*

Station key, Print,

!!

" or

! (to select format), then

""

!!

ENTER

Discard changes or

Esc

go back in menu

*Y ou can also print a report or label using the menu. Refer to

.

Label

Function Keys

Press To

Fn-5

View number of batteries serviced

Fn-7 Vi ew firmware version
Fn-8

Calibrate adapter/station*

Printing Report or

*Y ou can also calibrate adapter/station using the menu. Refer to

Station

.

Calibrating

15

Lights (LEDs)

Light Status Explanation

RUN (Yellow) on Service completed.

READY (Green) on Service in progress.

flashing Cold b a ttery. Servic e re s umes when batte ry

warms up (Cod e 1 2).

FAIL (Red) on Battery failed.

flashing Hot battery. Service resumes when battery cools

down (Code 13).

All flashing

randomly

System failed. Turn off the analyzer and turn it
back on. Contact Cadex if the condition
persists.

16 C7000 & 7000ER Battery Analyzer V3.5

Basic Battery Service

This section covers the basic general procedures on how to service a battery.

1. T urn the power on and insert the Battery Adapter into a station.

! Slide the lower front part of the adapter into the station towards the display.

Press the back end down to close the snap lock with a click.

For example, if you insert the adapter in Station 1, the following is displayed:

Adapter inserted No Adapter inserted

EMPTY NO ADAPT NO ADAPT NO ADAPT

EMPTY NO ADAPT NO ADAPT NO ADAPT

EMPTY NO ADAPT NO ADAPT NO ADAPT EMPTY NO ADAPT NO ADAPT NO ADAPT
Auto

Auto

Auto Auto

Program

2. Insert the battery into the adapter. The following message appears on the
display when the battery is detected:

S1 Press ENTER and verify settings,

S1 Press ENTER and verify settings,

S1 Press ENTER and verify settings,S1 Press ENTER and verify settings,
then ENTER again to START

then ENTER again to START

then ENTER again to START then ENTER again to START

4

Warning: Make sure that the battery contacts are clean before inserting
the battery. Otherwise melting can occur. To clean the battery contacts,
use a lint-free cotton swab dipped in 100% Isopropyl Alcohol.

3. View the battery configurations (C-Codes) by pressing the ENTER key.

Nominal Voltage

Battery Chemistry

****

S1

S1

C4

C4 NiMH 6.00V, 500mAh, Auto

S1S1

Station, C-Code

Refer to

NiMH 6.00V, 500mAh, Auto

C4C4

NiMH 6.00V, 500mAh, Auto NiMH 6.00V, 500mAh, Auto
Press [CCode] to Edit

Press [CCode] to Edit

Press [CCode] to Edit Press [CCode] to Edit

Battery Configuration/C-Codes

Capacity

• If the active C-Code (indicated by the “

for details on C-Codes.

!!

!”) is correct, proceed to step 7

!!

Program Setting

to start service.

17

4. Select the correct C-Code.

""

! Use the

adapter, then press ENTER when the correct C-Code is displayed.

"

(S2) and

""

!!

!

(S1) keys to scroll through the available C-Codes in the

!!

! Press ENTER again to confirm the selection. The selected C-Code now

!!

becomes active, indicated by the “

If a Smart Cable Adapter is first used, create a custom C-Code:

!”.

!!

! Press CCode.
! Use the

Advance or go back using the

""

" (S2) and

""

! Press ENTER and select Yes. Now you can proceed to step

Refer to

Warning: Always use the correct C-Code, especially the correct chemistry.
Failure to do so may cause damage to the battery, fire or explosion.

5. Select program. (Refer to
and their uses.)

Battery Configuration/C-Codes

!!

! (S1) keys to select or the keypad to enter the settings.

!!

$$

$ (S4) and

$$

Battery Service Programs

##

# (S3) keys.

##

7 to start service.

to add or edit C-Codes.

for the various programs

! Press the PROG key.
! Use the

press ENTER when the desired program is displayed.

""

" (S2) and

""

!!

! (S1) keys to scroll through the available programs, then

!!

! Press ENTER to confirm the selection. To cancel, press Esc.

6. Verify the settings again after pressing ENTER.

18 C7000 & 7000ER Battery Analyzer V3.5

7. Start service by pressing ENTER.
The analyzer will now proceed through the instructions in the selected

program. The display and lights show the status of the process:

Status

DISCHARGE NO ADAPT NO ADAPT NO ADAPT

DISCHARGE NO ADAPT NO ADAPT NO ADAPT

DISCHARGE NO ADAPT NO ADAPT NO ADAPTDISCHARGE NO ADAPT NO ADAPT NO ADAPT

-592mA

-592mA

-592mA -592mA

Current / Voltage (mV)

! T o view details, press the station key .

S1 DISCHARGING CAP:0%

S1 DISCHARGING CAP:0%

S1 DISCHARGING CAP:0%S1 DISCHARGING CAP:0%

1.28V/Cell -592mA N/Am

1.28V/Cell -592mA N/Am

1.28V/Cell -592mA N/Am 1.28V/Cell -592mA N/Am

N/A

N/A

ΩΩΩΩ

N/A N/A

8. Service is complete.

READY NO ADAPT NO ADAPT NO ADAPT

READY NO ADAPT NO ADAPT NO ADAPT

READY NO ADAPT NO ADAPT NO ADAPT READY NO ADAPT NO ADAPT NO ADAPT
620mA

620mA

620mA 620mA

oooo

C 0:02

C 0:02

C 0:02C 0:02

Basic Battery Ser vice 4

! T o view details, press the station key

.

! T o remove the adapter , press the latch-bar behind the label and lift the

adapter upwards.

19

Servicing Batteries with Bar Code

This applies when the analyzer is equipped with the OP-72 option board which supports
a bar code reader.

1. Print Bar Code Labels: one with Battery ID, one with C-Code. (Refer to

Utilities

2. Place the labels onto the battery.

3. With the Battery Adapter inserted, select the station by pressing the station key .

4. Scan the Battery ID.

5. Scan the C-Code.

6. When the READY (green) light flashes, insert the battery and press ENTER to
start service.

Note that the active C-Code displayed is
adapter reserved for bar code entries.

for detailed procedures.)

C11

, a read-only position in the

Print

20 C7000 & 7000ER Battery Analyzer V3.5

The Cadex analyzer can be programmed with any combination of service functions
to suit special battery needs. The 10 pre-programmed service programs combine
discharge, charge, recondition, and resistance test to achieve results as required.

Basic Programs

The basic programs include Auto, Charge and Prime. Each program performs
functions for different purposes:

Function Use

5

Battery Service Programs

Auto Exer cis e s b a t te rie s to m a i nta in

optimum performance. If the Target
Capacity cannot be reached,
recondition is applied.

Charge Applies fast charge. No capacity

readings are taken and no di scharge
is applied.

Prime Repeatedly cycles battery until

maximum capacity is reached. If
capacity i mprovement is more than 5%
over previous reading, an additio nal
cycle is applied.

*

If the voltage drops below the level required by the processor within the
Smart Battery, information can be lost. In some cases, this can cause the
battery to become non-operative.

Restore batteries affected by "memory".
Routi ne b a tte ry ma inte nanc e .
Identify marginally performing batteries.
S e rvice bat t e r ie s in unk nown c ondit ion.
Veri f y ba tte r y co nd i tio n fo r wa rra nty
claim.

Fast charge.
Topping up of partially discharged or
partially used batteries.

Prepare new batteries for field use.
Condition batteries that have been in
storage. Warning: Do not store Smart

Batteries in discharged state.*

21

Specialty Programs

Specialty programs include OhmTest, Runtime, Self-Discharge, Life-Cycling,
Discharge Only, Extended Prime, and 4 programmable Custom Programs.

Function Use

OhmTest Tests internal resistance against the

user definable Resistance Threshold.
Passes or Fails the battery.

Runtime Measures length of time a battery can

provide a given current and remain
above its End of Voltage. Runti me
Cycles are editable.

Self-

Discharge

Life-

Cycling

Discharge

Only

Reads fully charged battery capacity,
recharges and reads the capacity
again after a user definable wait
period. If the second reading is lower
by 30% or more, the battery is failed.

C o ntinuo us ly c yc le s b atter y unti l
capacity drops below Target Capacity.
Displays initial and final capacity,
OhmTest result and self discharge
readings (if self discharge is included).

Discharges a battery to its End of
Discharge voltage.

Check if the battery is in good condi tion.
De t e rmine if the ba tte ry re q ui r e s to b e
further analyzed.

Tests runtime of batteries for wireless
communicatio ns equipment.

Identify high self discharge on batteries
that otherwise may have good ca pacity
readings.

Veri f y ba tte r y li fe c ycle .
Esti ma te p erfo rmance ti me .

Determine residual capacity of battery.
Prepare batteries for storage. Warning:

Do not store Smart Batteries in
discharged state (See * on p.21)

Determine battery performance under
load.

Extended

Prime

Custom

1, 2, 3, 4

22 C7000 & 7000ER Battery Analyzer V3.5

Applies a 16 hour trickle charge,
followed by cycling to obtain peak
capaci ty.

Fully programmable by the user. See
Custom Programs.

Recommended for new batteries or
batteries i n extended storage.

Accommodate special needs.

Target Capacity

Target Capacity is the percentage of the battery capacity compared to the nominal
capacity. It serves as the threshold for reconditioning a battery in the Auto program.

The Target Capacity can be set between 50% and 150%. Following are the
recommended values:

90% Maintains batteries for critical applications which require maximum

energy reserve and high reliability . Fewer batteries will pass.

80% Recommended (default) setting which provides a balance between

adequate energy reserve and long service life.

70% Recommended for less stringent applications where battery power

demand is not critical or is of brief duration. More batteries will pass.

Battery Ser vice Programs 5

Target Capacity is a pass/fail mark and does not affect the final charge level.

example, a battery with a 90% capacity will pass if the Target Capacity is 80% but
fail if the Target Capacity is 100%. The batteries are always fully charged.

For

23

Selecting a Program or Setting Target Capacity

The following procedures describe how to select a program and/or set the Target

before

Capacity
Capacity when a battery is inserted for service, follow the procedures in

Service

.

1. Press the station key , then use the

you want to select the program and/or set the Target Capacity.

2. Press Prog.

3. Select the desired program, depending on which program list you are in:

••

• If you are in the Basic Program list

••

a battery is inserted. To select a program and/or set the Target

""

!!

" and

! keys to find the C-Code for which

""

!!

Basic Battery

PROGRAM

SETTINGS

••

• If you are in the Specialty Program list

••

PROGRAM

SETTINGS

ENTER

ENTER

Auto
Charge
Prime
SPECIALTY PROG.

OhmTest
Runtime
Self-Discharge
Life-Cycling
Discharge Only
Extended Prime
Custom 1
Custom 2
Custom 3
Custom 4
BASIC PROGRAMS

4. Set the Target Capacity using the keypad or

5. Press ENTER to confirm.

""

" and

""

!!

! keys.

!!

24 C7000 & 7000ER Battery Analyzer V3.5

Editing Program Settings

Only the following program settings can be edited:

••

• Threshold of internal resistance in OhmTest

••

••

• Wait period in Self-Discharge

••

••

• Inclusion of Self-Discharge test in Life-Cycling

••

••

• Cycle time and load current in Runtime

••

••

• Custom Programs (refer to

••

Custom Programs

Battery Ser vice Programs 5

)

1. Select Program Settings on the menu. Refer to

2. Select the program to edit.

3. Press Prog, then edit the program settings.

""

!Use the

Advance or go back using the

!!

" and

! keys to select or the keypad to enter the new settings.

""

!!

$$

##

$ and

# keys.

$$

##

4. Select Yes to accept changes.

Menu

.

25

Duration of Service

The following table displays the approximate service times at default Charge/Discharge
rates.

NiCd and NiMH SLA Li-Ion

Auto

Charge 1. 5 ho ur s 10 ho u rs 4 hour s

Prime

OhmTest

Runtime

Discharge

Cycling

Discharge

Only

Extended

Prime

Custom

1, 2, 3, 4

* Duration depends on settings.

2.5-10 hours 20-40 hours 6-20 hours

5-10 hours 40-80 hours 12-25 hours
5 seconds 5 seconds 5 seconds

*

30 hou rs 60 hou rs 50 hou rs

Self

Life

1500 Cycles (NiCd)

500 Cycles

1. 5 hour s 2 0 ho u rs 4 hour s

21-26 hours 56-96 hours 28-41 hours

---

200-500 Cycles 1000 Cycles

(NiMH)

---

26 C7000 & 7000ER Battery Analyzer V3.5

Battery Configuration/C-Codes

Configuration Codes, or C-Codes, are battery parameters to service a battery .
Battery Adapters are pre-programmed with the available C-Codes for that battery
type. The adapters store C-Codes once entered and can be moved between
stations.

A maximum of 10 C-Codes can be stored, allowing you to conveniently service all
battery types. The unused positions (Null Codes) remain empty and can be
programmed. You can view, select, create, copy and edit a C-Code. Refer to

Managing C-Codes

When a Smart Cable Adapter is first used, the “NULL” status appears on the
display . You will need to create a custom C-Code before servicing. Refer to

Managing C-Codes

A C-Code is divided into 2 parts:

••

• Basic C-Code that includes chemistry, voltage, and capacity.

••

••

• Extended C-Code that consists of Charge/Discharge C-rates, Trickle Charge

••

rate, recondition settings, and other parameters specific to the battery .

ExtendedC-Code parameters are preset to default settings and normally do
not need to be changed.

. Note that

on how to create a C-Code.

the C-Code in active service cannot be edited

.

6

Basic C-Code

Parameter Des cription

Chemistry Often labeled on the battery, refers to the battery type.

Battery Voltage Terminal voltage of the battery. Voltage range depends on

Battery Rating

(Capacity)

*The battery types of SLA are Gell (for most batteries) and Hawker (for cylindrical
SLA batteries manufactured by Hawker).

Includes Nickel Cadmium (NiC d), Nickel Metal Hydride
(NiMH), Sealed Lead Acid* (SLA), and Lithium Ion (Li-Ion).

the model and chemistry. Refer to Specification:

Firmware

Capacity (mAh) specified by the manufacturer. Ranges
from 100mAh to 24,975mA h in increments of 25mAh.

.

27

Extended C-Code

Parameter Des cription

Charge Rate A 1000mAh capacity with a charge current of 500mA

Discharge Rate A 1000mAh capacity with a discharge current of

will have a C harge C-rate of 0.50C. A lower Charge
C-rate reduces the charge current and i ncreases
service time. The maximum charge current is
2000mA (2A).

500mA will have a D is charge C-rate of 0.50C. A
lower Di scharge C-rate reduces the discharge
current and i ncreases service ti me.The maximum
discharge current is 2000mA (2A).

Trickle Charge Rate

(NiCd and NiMH only)

Recondition

Discharge Rate

(NiCd and NiMH only)

Capacity Offset Adjusts the capacity readings when di scharging a

Temperature Sensing The temperature range i n which a station will service

Neg a tive Slo p e

(NiCd and NiMH only)

Amount of trickle applied to maintain the charge on a
battery after service. From 1% to 10% in increments
of 1%.

A slow and gradual discharge after the battery
reaches the End of Discharge voltage. During this
process, the crystalline build-up (memory) on the cell
plates di ssolves and the battery often restores i tself.
From 2% to 20% i n increments of 2%.

battery at a higher or lower C-rate than specified by
the ma nufac turer.
Mainly used for SLA batteries. From -50% to +49%
in increments of 1%.

the battery. Effective only for batteri es or adapters
equipped with temperature sensor.

A measure of the voltage drop when the battery
reaches full-charge. The charge cycle is terminated
when the voltage drop reaches the set value. From
16 to 64mV/C ell.

28 C7000 & 7000ER Battery Analyzer V3.5

Battery Configuration/C-Codes 6

Parameter Des cription

End of D i scharge The threshold point at which the discharge cycle is

terminated. Chemistry dependent.
Available settings: 0.76-1.12V /Cell (NiCd, NiMH);

1.36-1.95V/Cell (SLA); 2.30-3.20V/Cell (Li-Ion).

End of Recondition

(NiCd and NiMH only)

Charge Method

(NiCd and NiMH only)

Max. Standby Voltage

(SLA and Li-Ion only)

Max. Charge Voltage
(SLA and Li-Ion only)

End of C harge

(SLA and Li-Ion only)

The threshold poi nt at which the reconditioning cycle i s
complete.
Available settings: Disabled or 0.40-0.80V/Cell.

Allows setting of Reverse Load. The Reverse Load
method intersperses discharge pulses between charge
pulses to keep batteries cool and promotes the
recombination of gases.
Available settings: DC Charge, No Rev Load, Rev
Load 5-12%.

Maintains the battery at full charge state after service
is complete.
Available settings: 2.15-2.45V /Cell (SLA); 3.90-

4.35V/Cell (Li-Ion).

The threshold poi nt at which the analyzer stops
charging the battery. At this point, the current charge
drops whi le maintaining the Max. Charge Voltage.
Available settings: 2.20-2.65V /Cell (SLA); 3.90-

4.35V/Cell (Li-Ion).

Detects full charge state. When the End of Charge
condition is reached (Charge rate difference is less

than the specified value), the battery is considered fully
charged and the analyzer completes the charge cycle
on the battery. From 0.01 to 0.10C.

29

Viewing C-Codes

! Press the station key , then use the

$$

$

and the

$$

and

Managing C-Codes

! Press the station key to display the basic C-Code, then:

""

!!

" and

! keys scroll through the basic C-Codes

""

!!

##

#

keys to view the extended C-Code parameters.

##

To Procedures

Select a C-Code

Edit a C-Code

Delete a C-Code

Create a C-Code

Res e t Extend e d

C-Code to default*

Copy a C-Code

Copy all C-Codes

to another adapter

""

Scroll to the C-Code with the
and select Yes. The “

!!

!” appears beside the C-Code number on

!!

!!

" and

! keys, then press ENTER

""

!!

the display .

""

Scroll to the C-Code with the

""

Use the

!!

" and

! keys or the keypad to change the settings.

""

!!

Advance or go back using the

!!

" and

! keys, then press CCode.

""

!!

$$

##

$ and

# keys. Then press ENTER

$$

##

and select Yes.

""

Scroll to the C-Code with the

!!

" and

! keys, then press Fn-0 and

""

!!

select Yes.

""

Scroll to an empty C-Code with the

""

CCode. Use the

!!

" and

! keys to select or the keypad to enter

""

!!

the settings. Advance or go back using the

!!

" and

! keys, then press

""

!!

$$

$ and

$$

##

# keys. Then

##

press ENTER and select Yes. Select Yes again to select the new
C-Code.

""

Scroll to the C-Code with the

!!

" and

! keys, then press Fn-1 and

""

!!

select Yes.

""

Scroll to the C-Code with the the

!!

" and

! keys, then press Fn-3.

""

!!

Press the station key of the adapter to copy to, scroll to the C­Code (usually an empty one) and press ENTER, then select Yes
again.

Press Fn-6. Then press the station key of the adapter to copy to
and select Yes.

Add, edit or erase

a b atte r y setup

*Refer to

30 C7000 & 7000ER Battery Analyzer V3.5

Default Settings for Extended C-Codes

name

""

Scroll to the C-Code with the

""

the

!!

" and

! keys or the keypad to enter, edit or erase the battery

""

!!

!!

" and

! keys, then press Fn-7. Use

""

!!

setup name. Advance or go back using the
select Yes.

.

$$

$ and

$$

##

# keys. Then

##

Battery Configuration/C-Codes 6

Selecting Correct Voltage

The voltage is based on a nominal cell voltage of 1.2V/Cell for NiCd and NiMH,
2V/Cell for SLA and 3.6V/Cell for Li-Ion.

On some NiCd and NiMH batteries, manufacturers may rate their batteries based
on 1.25V/Cell rather than 1.2V/Cell. In this case, as an example, the batteries may
state 7.5V or 12.5V . To obtain the correct voltage, multiply this voltage by 0.96 to
get the correct value to use. Test results are not affected by this change since these
voltages are definitions only .

Some manufacturers may state the number of cells of their batteries. To get the
correct voltage, multiply the number of cells by the chemistry type. For example, the
voltage of a 6 cell NiCd would be 6 x 1.2V = 7.2V. Use 7.2V on the analyzer.

Intrinsically Safe Settings

! Before servicing intrinsically safe (I/S) batteries, select the following settings:

• Charge method: DC Charge

• End of Discharge: 0.96V/Cell

• Charge Rate: 0.10C

• Discharge Rate: 0.10C

The Charge rate and Discharge rate can be set to higher values to speed up
servicing if no fault code appears.

31

Default Settings for Extended C-Codes

Pa ra me te r De fa u lt S e ttin g s

Charge

1.00C

1.00C

0.30C

1.00C

(NiCd )
(NiMH)
(SLA )
(Li-Ion)

Discharge 1.00C (Ni C d)

1.00C (NiMH)

0.10C (SLA - Gell), 0.40C (SL A - Ha wker)

1.00C (Li-Ion)

Trickle Charge Rate 5% (NiC d)

2% (NiMH)

Recondition

12% (NiC d , NiMH)

Discharge Rate

Ca p a city Offs e t

0%

Temperature Sensi ng Disabled (adapters without temperature sensor)

o

C (NiCd, NiMH, SLA)

0-45

o

C (Li-Ion)

5-45

Negative slope 32mV/Cell (NiCd)

16mV/Cell (Ni MH)

End of Discharge 1.00V/Cell (NiC d , NiMH)

1.75V/Cell (SL A - Gell),

1.62V/Cell (SL A - Ha wk e r)

3.00V/Cell (Li-Ion)

End of Recondition 0.40V/Cell (Ni C d , NiMH)

Charge Method Rev Load 9%

Max. Standby Voltage

Max. Charge Voltage 2.40V/Cell (SLA - Gell), 2.60V/Cell (S LA - Ha wk e r)

End of C harge 0.05C (SLA , Li-Ion)

32 C7000 & 7000ER Battery Analyzer V3.5

2.25V/Cell

4.05V/Cell

(SLA - Gell),
(Li-Ion)

4.20V/Cell (Li -Ion)

2.35V/Cell

(S L A - Ha wk e r)

Custom Programs

Warning: Creating a Custom Program requires a good understanding of
rechargeable batteries and the analyzer.
the battery manufacturer’s specifications or recommendations can damage a
battery.

If you regularly modify Custom Programs, we strongly recommend BatteryShop.
The graphical user interface of BatteryShop allows easy programming. Refer to
BatteryShop Help for detailed instructions.

Custom Programs run virtually any sequence of service cycles. They are stored in
the analyzer and can be assigned to any C-Codes in the adapters.

A Custom Program consists of 6 phases: Phase 1-5 and Phase Done.

• Each of the first 5 phases consists of 2 cycles (Cycle 1 and Cycle 2), Test
and the True and False statements.

Previous Phase

Applying routines that conflict with

7

Cycle 1 Cycle 2 Test True / False

Next Phase

• Phase Done consists of one cycle.

The analyzer will go through the first phase, then follow the paths taken by the
decision making True and False statements in each phase. The following lists
describe the values allowed for the cycles, the True and False statements and the

Done phase.

33

Cycle 1 and Cycle 2

Discharge Ti me

(Discharge for 000:00:00

(Charge for 000:00:00)

Recondition Time

(Recondition for 000:00:00)

Trickle Charge Time

(Trickle Chg for 000:00:00)

(Rest for 000:00:00)

Option Description

Skip Cycle Skip the cycle and go to the next cycle or the

statement.

Test

Discharge the battery for the specified time
period (in hhh:mm:ss format)* at the specified

@100% )

Charge Time

Res t Time

OhmTest Perform the OhmTest on the b a tte r y.

setting.
A setting of 50% will give a discharge current
that is 50% of the Di scharge rate. The
Discharge rate is set in the Extended C-Code.

Charge the battery for the specified time period
(in hhh:mm:ss format)*. The Charge rate is set
in the Extended C-Code.

Recondition (Deep discharge) the battery for
the spec ified time per iod ( in hhh: m m : s s
format)*.
The Recondit ioning Dischar ge ra t e is set in the
Extended C-Code. This cycle will be ski pp ed
for SLA or Li-Ion as these chemistries cannot
be reconditioned. This cycl e can onl y be

applied after a discharge cycle.

Trickle charge the battery for the specified time
period (in hhh:mm:ss format).
The Trickle Charge rate is set in the Extended
C-Code and only applies to NiCd/NiMH.

Apply no current for the specifi ed time period
(in hhh:mm:ss format).

The tim e m ust be spe ci fied or the cycl e wil l be

skipped.

In this case , the resistance threshold is not
definable.

*If the default time period of 000:00:00 is used, the analyzer will service the battery
according to End of Charge, End of Discharge or End of Recondition set in the
Extended C-Code.

34 C7000 & 7000ER Battery Analyzer V3.

Test

Custom Programs 7

Test provides the condition for selecting the True or False statement.

Option Description

Skip Test Go to the True statement. The False statement is

ignored.

IF Target Capa city Met If the capacity during the last discharge cycle

meets the Target Capacity, go to the True
statement. Otherwise the False statement i s
selected.

IF Target Capa city Not Met If the capacity during the last discharge is below

the Target Capacity, go to the True statement.
Otherwise the False statement is selected.

IF < 5% Ca pacity Increase If the improvement in capacity during the last two

discharge cycles is less than 5% (for example,
the last one is 88% and the one before is 85%;
or 80% and 90%), go to the True statement.
Otherwise (for example, 90% and 80%) the False
statement is selected.

IF > 5% Ca pacity Increase If the improvement in capacity during the last two

discharge cycles is more than 5% (for example,
the last one is 90% and the one before is 80%),
go to the True statement. Otherwise (for
example, 88% and 85%, or 80% and 90%) the
False statement is selected.

35

(Test contin ued)

IF To tal Capacity < 5% If the capacity during the last di scharge cycle is

IF To tal Capacity > 5%

IF User Defined Timeout If the time period set in Cycle 1 or Cyc le 2 has

IF Loop Count < Max

IF Loop Count > Max If the number of cycle (the loop count) is more

Option Description

less than 5%, go to the True statement.
Otherwise the False statement is selected.

If the capacity during the last discharge cycle i s
gre a te r than 5 %, g o to the
Otherwise the False statement is selected.

expi red before the battery is fully charged,
discharged or reconditioned, go to the True
statement. Otherwise the False statement i s
selected.
For Trickle Charge and Rest, the program will
proceed to the True statement only.

If the number of cycle (the loop count) is less
than the value s et i n ’THEN REPEAT 0 times’ of

True

the
in the

statement or ’ELSE REPEAT 0 ti me s’

False

statement. Otherwise the
selected.

than the value s et i n ’THEN REPEAT 0 times’ of
the True statement or ’ELSE REPEAT 0 time s’
in the False statement, go to the True
statement. Otherwise the False statement i s
selected.

True

statement, go to the

False

statement.

True

statement is

36 C7000 & 7000ER Battery Analyzer V3.5

True and False Statements

Option Description

THEN Goto Next Phase Go to the next phase.

Custom Programs 7

THEN Goto Phase 1
THEN Goto Phase 2
THEN Goto Phase 3
THEN Goto Phase 4 Go to P hase 4.
THEN Goto Phase 5

THEN Goto Done Go to Phase D one.

THEN RE PEAT 0 times Repeat acti ons in the current phase by the number

THEN RE ST for 000:00:00

THEN FAIL Fai l the battery. The battery is electrically

Phase 1

Go to

Phase 2

Go to

Phase 3

Go to

Phase 5

Go to

of ti mes specified. Avai lable settings: 1-8 and

Forever

for 2 5 5 time s . Re fe r to ’IF Loop Count < Max’ and
the ’IF Loop C ount > Max’ in

Apply no current for the specifi ed time period (in
hhh:mm:ss fo r ma t) . The Re s ting xx:xx messa ge
(code 19) is displayed.
After resting, the program goes to the next phase.

disconnected and the Fail 16 code will be
displayed with the FAIL light on.

Forever

. If

.
.
.

.

is selected, the cycle repeats

Test

.

37

Phase Done

Ready - No Charge Complete the program. The REA DY li ght will be

Ready - Trickle Charge Trickle charge the battery accordi ng to the

Example

NiCd or NiMH batteries that do not meet the Target Capacity should always be
reconditioned. If the battery does not meet the Target Capacity after reconditioning, the
program will fail the battery . This is a shortened version of the Auto program because
this program does not determine the initial capacity of the battery when it came from the
field.

Option Description

on and no trickle charge is applied.

Trickle Charge rate in the Extended C-Code.
Includes the Standby maintenance cycle whi ch
periodically performs discharge/charge every 30
days (180 days for SLA).

Trickle Charge Trickle charge the battery according to the

Trickle Charge Rate in the Extended C-Code.

Phase Action

Phase 1 Discharge for 10 m inutes to avoid charging a fully charged battery.

Then fully charge the b a tte ry.

Phase 2 Discharge to find the battery capacity. If the capaci ty meets the

Target Capacity, complete the program (Phase Done). If the Target

Capaci ty is not met, apply the recondition cycle (Phase 3).

Phase 3 Recondition and charge the battery.
Phase 4 Discharge to find capacity after the recondition cycle. If the

capacity meets the Target Capacity, charge the battery (Phase 5).
If the Ta rg e t Ca p a c ity i s no t me t, fa i l the ba tte ry.

Phase 5 Fully charge the battery.

Phase Done Complete the program with a trickle charge to maintain capacity.

38 C7000 & 7000ER Battery Analyzer V3.5

The following flowchart demonstrates the routines of the program:

Custom Programs 7

Phase 1

Phase 2

Phase 3

Phase 4

Cycle 1
Cycle 2
Test
True / False

Cycle 1
Cycle 2
Test
True / False

Cycle 1
Cycle 2
Test
True / False

Cycle 1
Cycle 2
Test
True / False

Discharge

Skip

TC Met

True
(Goto Done)

Discharge

Charge

Skip

True
(Goto Phase 2)

True
(Goto Phase 4)

Discharge

Skip

TC Met

True
(Goto Phase 5)

(10 mins)

False
(Goto Phase 3)

Recond.

Charge

Skip

False
(Fail)

Phase 5

Cycle 1
Cycle 2
Test
True / False

Phase Done

Done

Ready
Trickle Charge

Done

Charge

Skip
Skip

Ready
Trickle Charge

Done

Fail

39

Creating or Modifying a Custom Program

1. Select Program Settings on the menu. Refer to

Menu

.

2. Select the program. For example, Custom 1.

3. Press Prog. If applicable, enter the program name, then press ENTER. Y ou
can enter up to 9 characters/numbers. Otherwise press Esc to skip.

4. Enter the program settings.

""

!!

" and

! Use the

the settings. Move between the fields using the

! keys to scroll through the phases and cycles or select

""

!!

$$

##

$ and

# keys.

$$

##

5. Press ENTER when all the settings are entered, then select Yes to accept
changes.

40 C7000 & 7000ER Battery Analyzer V3.5

System Security

The C7000 and C7000ER offer three security levels for protection against
tampering: Level 0 (Off) is the default, Level 1 (Low) and Level 2 (High).
Depending on the security level, you will be asked to enter the password for some
features.

8

A password must have at least 3 digits.

by setting the security level.

Password Requirement

Level 0 (Off) L evel 1 (Low) Level 2 (High)

C-Code Not required Edit C-Code Edit C-Code

Security

System Setup

Prin t U t ilities

Not req ui re d Se t Se c uri ty

Not required Time/Date

Not req ui re d Auto-P ri nt B a tte ry Se rvi ce Rep o rt

You can control the access to the features

Se t De fa ult C-Co d e

Set Security
Change Password
Remo ve S e curi ty

Program Settings
Output Devi c e s

Change Password

Remo ve S e curi ty

Time/Date
Battery Startup
Program Settings
Company Name
Calibration
Output Devi c e s
S o und Co ntr o l
Voltage Di splay

Battery La bel
Bar-Code Label
System Setup Report
Auto-Print

Event Log

Not required Clear Event Log

Events to Log

Clear Event Log
Events to Log

41

Setting Security

1. Select Set Security on the menu.

2. Enter the desired security level (0, 1, or 2) or select the security level using the

""

!!

" and

! keys. Then select Yes to accept changes.

""

!!

Changing Password and Removing Security

! Select Change Password or Remove Security on the menu.

• To change the password (for Level 1 and Level 2), enter the old
password. Then enter and re-enter the new password.

• To remove security, select Yes. Then enter the password.

42 C7000 & 7000ER Battery Analyzer V3.5

System Setup

Feature Description

Time/Date Se t up the time and d a te i nfo rm a ti on pr i nte d o n B a tte r y

Labels, Battery Service Reports and Event Log.
Analyzers with an option board have battery backup RAM
that retai ns dates and times on power interruption or when
the analyzer is turned off.

Default: current date and time.

Battery Startup Specify i f the analyzer will ask for the Battery ID and/or

C-Code when a battery i s i nserted. Specifying the Battery
ID and C-Code prevents the use of wrong settings.

Default: No for Battery ID and Yes for Ba tte r y C- Co d e .

Pro g ra m Se ttin g s Edi t program settings. Refer to Editing P r o gra m

Settings.

Company Name Set up the company name for printing on Battery Labels

and Battery Service Reports. You can enter up 20
characters/numbers.

Default: CADEX ELEC TRONICS.

Calibration

(Shortcut: Fn-8)

Output Device Connect the analyzer to a printer, label printer or

Sound Control Turn on or off the audible signals for Key Press events

Voltage D isplay Set voltage display mode to Volts/C e ll or Volts.

Correct variations of component tolerances due to aging.
Calibrating the voltage once a year mai ntains
performance specifications, especially for Li-Ion batteries.
Station Ca libration compensates for voltage loss from
cables and electrical contacts.

BatteryShop.

and Alert events.
Default: Yes for both Key Press events and Alert events.

Default: Volts/Cell.

9

43

Setting Up System Information

1. Select the feature on the menu.

2. Enter the required information or select the settings.

""

!!

" and

! Use the

! keys to scroll through and select the option, numbers or

""

!!

characters in both upper and lower cases.

$$

##

$ and

! Use the

# keys to move the insertion point.

$$

##

3. Select Yes to accept changes.

Calibration Procedures

CALIBRATION

ENTER

Voltage Calibration
Station Calibration

Calibrating Voltage

Y ou need a calibration kit (P/N 92-770-0210). This kit can be purchased from Cadex or
through your Cadex Representative. The C7000 calibration kit consists of 4 calibration
adapters (P/N 07-130-0000) and an instruction sheet (P/N 89-204-1017).

Servicing the Voltage Calibration Adapters : Return the V oltage Calibration Adapters
to the factory every 3 years for authorized calibration. Call Cadex for a Return
Authorization number.

44 C7000 & 7000ER Battery Analyzer V3.5

1. Make sure that no Battery Adapter is inserted.

2. Select Voltage Calibration on the menu.

3. Firmly insert the 4 Voltage Calibration Adapters into each station.

4. Wait for the prompt, then remove the calibration adapters.

5. Press Menu to return to the Global Display.

6. Press Fn-7. The “#” sign should appear in the upper right corner of the
startup screen, indicating successful completion of voltage calibration.

Calibrating Station

Failing to calibrate Battery Adapters could cause inaccurate capacity readings,
especially on low voltage batteries or single cells.

Recalibrate adapters when they

are moved from one station to another.

System Setup 9

1. Make sure that there is no battery inserted into the adapter.

2. Select Station Calibration on the menu. You can also press Fn-8.

3. For each station, select the station and short the battery leads

adapter

together using a short length of heavy gauge wire (AWG 10).

on the

Warning: Never short the contacts on the battery.

4. Once the display indicates that a good connection has been established,
press ENTER to start calibrating.

5. Wait for a few seconds and remove the wire when prompted.

45

Output Devices

OUTPUT

DEVICES

ENTER

Serial Port Device
Serial Port Settings
Parallel Port Device

BatteryShop

Serial Port Settings

Before connecting any device to the serial port, match the serial port settings with those
of the device being connected.

Consult the device’s manual for the proper settings.

Option Available Settings Default

Baud Rate 1200, 2400, 4800, 9600 9600

Hands ha k e NONE , C TS/RTS , X ON/XOFF CTS/RTS

Data Bits 7, 8 8

Stop Bits 1, 2

1

Parity NONE, ODD , EVEN NONE

Serial Cable Pin Configurations

DB-9 to DB-25

DB-9 DB-25

RD 2 -- 2 TD

TD 3 -- 3 RD
CTS 8 -- 4 RTS
RTS 7 -- 5 CTS

SG 5 -- 7 SG

46 C7000 & 7000ER Battery Analyzer V3.5

Note: If connecting to a serial printer, it may also be
necessary to jumper pins 6 (DSR), 8 (DCD), and 20
(DTR) together on the printer’s DB-25 connector. Other
jumpers may also be required. Check your printer
manual for specific information.

System Setup 9

DB-9 to DB-9

DB-9 DB-9

RD 2 -- 3 TD

TD 3 -- 2 RD
CTS 8 -- 7 RTS

RTS 7 -- 8 CTS

SG 5 -- 5 SG

Note: If connecting to a serial printer, it may also be
necessary to jumper pins 6 (DSR), 1 (DCD), and 4 (DTR)
together on the printer’s DB-9 connector. Other jumpers
may be also required. Check your printer manual for
specific information.

Serial and Parallel Port Device Settings

The serial port is a DB9 connector which is standard on all models and is located at
the back of the analyzer.

Option Description

Disabled No output i s provided to the serial port.

Printer Print reports and labels on a serial printer.

LabelMaker (Default Setting) Print Bar-Code Labels and Battery Labels on

a DYMO LabelWriter SE300 Printer.

Computer Transfer service data to the computer.

BatteryShop C o nnect to B a tte ryS hop .

The parallel port is a DB25 connector available only to analyzers with the OP-70 or
OP-72 option boards.

Option Description

Disabled No output i s provided to the parallel port.

Printer (Default Setting) Print reports and labels on a parallel printer.

LabelMaker Print Bar-C ode Labels and Battery Labels on a DYMO

LabelWri ter SE300 Printer.

47

Print Utilities

Battery Service Reports and Battery Labels must be printed

with the exception of Auto-Print

. Once the battery is removed, the station resets to

before

removing the battery

prepare for the next battery , and the battery information is lost.

Report/Label Description

Battery Service Re port

Lists Battery ID , type, number of cells, rating, and
cell voltage. Also describes the C-Code , cycles
performed, Charge/Di scharge rates, any ap plicable
fault codes and final capacities.

Battery Label

Co ntai ns co mpa ny name, date , tes t res ult with any
fault codes, and the Battery ID number (if available).
To be attached to the batteries after service.

Bar-Code Label Contains Battery ID or C-code.

System Setup Report Li sts time, date, company name, serial port and

printer port settings, event logging setup, adapter
setup and Custom Program information.

Auto-Print The sys tem automatically prints a Battery Service

Report or Battery L abel when a battery is removed
from the a na lyzer a fte r servi c e . De fa ult s e tting is

Neither

.

Service Date

Battery ID

48 C7000 & 7000ER Battery Analyzer V3.5

Bar-Code Label with C-Code

Bar-Code Label with Battery ID

Battery Labels with capacity and
resistance readings

BATTERY SERVICE REPORT

Company: CADEX ELECTRONICS
Date: 01/19/2000
Time: 16:47:11

BATTERY STATUS

Battery: STATION 2
Battery ID: 1234567890

Current Cy cle: PROCESS COMPLETE
Cycle Capacities: 30% 82% 98%
Battery Resistance: 122m
Cell Voltage: 3.91V/cell
Charge Cycles: 3
Discharge Cycles: 3
Recondition Cycles: 0
Elapsed Time: 0 Days 6 Hours 40 Minutes

BATTERY PARAMETERS

Battery C-Code: 40-02-016:0505-505-3407
Program: Auto
Target Capacity: 80%

Battery Type: 42 - Lithium Ion
Number of Cells: 2 (7.2V)
Battery Rating: 400mAh

Charge Rate: 0.50C ( 200mA) Max. Charge Voltage: 4.10V/Cell
Discharge Rate: 0.50C ( 200mA) End Discharge: 4.10V/Cell
End of Charge: 0.10C ( 40mA) Max. Standby Voltage: 4.05V/Cell
Capacity Offset: 0% Temperature Sensing: 5

FAULT CODES

FINAL STATUS

Ready

Ω

o

C - 45oC

10

Battery Service Report

Please visit the Cadex Web site for a print sample of the System Setup Report.

Printing Report or Label

! Select the report or label on the menu.

• For Battery Service Report and Battery Label, press the station key of
the corresponding station, then select Yes to start printing.

• For Bar-Code Label, specify the label type and press the station key of
the corresponding station. Then select Yes to start printing.

• For auto print, select the option, then Yes to confirm.

49

Event Log

The Event Log stores the last 50 selected event data for later viewing or printing. This
allows tracking of general battery service trends, identification of potential problems, and
tracing battery or system events.

View Event Log Vi ew the last 50 events in the event log.
Prin t E ve n t Lo g Print the event log.

Clear Event Log Clear all events in the event log.

Ev en ts to Lo g Speci fy events to record or ignore.

DATE TIME STN CODE DESCRIPTION
01/18/2000 14:07 0 200 POWER ON
01/18/2000 14:07 0-1 201 ADAPTER INSERTED
01/18/2000 14:07 0-2 201 ADAPTER INSERTED
01/18/2000 18:57 0-1 115 TARGET CAPACITY NOT MET
01/18/2000 19:00 0-1 26 BATTERY REMOVED
01/19/2000 10:25 0-2 18 PROCESS SUSPENDED
01/19/2000 10:25 0-2 188 SUSPENDED PROCESS ABORTED
01/19/2000 10:25 0-2 17 BATTERY REMOVED

Feature Description

Event Log

50 C7000 & 7000ER Battery Analyzer V3.5

Log Events

Log Event D escription

Errors Problems that stop the service.

Warnings Problems that do not stop the service, but may affect the

battery performance.

System Events Events recorded by the system.

Battery Events Battery completion events in the battery’s service cycle.
Battery Cycles Detailed events in the battery’s service cycle.

Ec ho to P r i nte r W hethe r to s e nd the e ve nts to the p r i nte r.

Managing Event Log

! Select the feature on the menu.

• To view the event log, use the
reach the end of the log, you can go back to the first event by pressing

""

" key twice. Press Esc to exit.

the

""

""

!!

" and

! keys to scroll through. When you

""

!!

11

• To clear the event log, select Yes to confirm. T o cancel, press Esc.

• To specify events to log, select Yes to activate or No to de-activate. Use

$$

the
accept changes.

##

$ and

# keys to toggle between the events. Then select Yes to

$$

##

51

Messages and Warnings

This section describes all the messages and warnings that can appear on the display .
Global message is the first message that appears, usually with the Code. For example,

! To view the Detail message, press the Station key.

Global Message

Code #

FAIL 120 EMPTY NO ADAPT NO ADAPT

FAIL 120 EMPTY NO ADAPT NO ADAPT

FAIL 120 EMPTY NO ADAPT NO ADAPT FAIL 120 EMPTY NO ADAPT NO ADAPT

0mA Charge

0mA Charge

0mA Charge 0mA Charge

When you get a message or warning, you can look into the possible reason(s) and
solution(s) by detail or code number.

52 C7000 & 7000ER Battery Analyzer V3.5

By Detail

Detail Global Possible Reason(s) / Solution(s)

12

>2000 m

Adapter data invalid FAIL 209 Invalid value i n selected C -Code. Modify the C-Code or

A

Adapter inserted ADAP T IN Adapter is detected on a station. Global message should

Adapter not set up FAIL 208 Adapter is not programmed with a C-Co de or the C-Code

Adapter removed ADAPT OUT Adapter is removed from a station. If message persists,

Bad adapter FA IL 210 Adapter is not recognized by the analyzer. Remove and

B

Bad fuse or driver FAIL 160 The analyzer is not able to supply current to the battery

Ω

-

Resista nc e of ba tte r y i s to o high. Dis c har g e b a ttery be fo re
performing the

delete and re-enter the C-Code.
The C-Co d e is not c omp a tible wi th the fi r mwa re ; the

adapter could have been configured with a newer firmware.
Delete and re-enter the C-Code, reset the E xtended
C-Code to default values or upgrade the analyzer with the
latest firmware.

be displayed. If not, remove and re-insert adapter.
If the message persists, re-enter the C -Code.

is invalid. Re-enter a C-Code.

press

Esc

re-insert the adapter. Clean the gold contacts on the
underside of the adapter.

Reset the Extended C-Code to default values or delete and
re-enter a C-Code.

throug h its c urrent drivers. Very low values o f current (about
0mAh) may be displayed on the analyzer before this code
appears and processing stops. Check and replace the
station fuse. If fuses are ok, then the current drivers could
have failed on the analyzer. Before calling Cadex for
service, check the following items for other causes of
faults:

Ensure that battery and adapter contacts are clean.

OhmTest

.

.

Verify that mAh rating of the battery matches the C-Code
mAh s et ting.

The battery may not be able to accept the current load.
Lower or raise the Charge rate in the Extended C-Code .

The batte r y may b e intri ns i c ally safe . Us e I/S settings .
Refe r t o Intrin sically Sa fe S e ttings.

Try a d iffer e nt batter y i n the s a me stati o n.

53

Detail Global Po ssible Reason (s) / Solution(s)

Batshop mode wait BATSHOP Battery is detected on an analyzer connected to

BatteryShop. Global message should be di splayed. If not,
check the C-Code in BatteryShop and ensure that all the
settings are correct for the battery.

Battery inserted INSERTED Battery is detected on an ada pter.
Battery over temp OVERHEAT Battery is overheated during charge. Station will go to

Resting 00:00 (code 19) until the battery cools.
If using a non OE M battery, the battery thermistor may be

incorrect for the adapter. Turn off temperature sensing in
the C -Cod e. N ote: For safety purposes, this step is not

poss ible if t h e C-Co de ch e mistry is L i-Io n . Conta ct
Cadex to upgrade the adapter for your particular
battery.

Battery removed REMOVED

(Code 17)

Battery removed REMOVED

(Code 26)

Battery shorted FAIL 122 Battery is not accepting charge in the initial charge cycle

Battery too cold C OLD WAIT Ba ttery temperature is below set value when inserted. The

Ba tte ry too hot HOT WAIT B a tte ry temp e ra ture is too hot when i nse rte d . C o ol the

Battery is removed when the program completed. This
message appears instantaneously when the battery is
removed.

A 5 second delay after the battery is removed when the
program completed.

(the voltage remains low). C heck that the battery voltage is
above 0.30V/Cell. The C harge rate may have to be
lowered. If all else fails, discard the battery.

batte r y will auto ma ti c a lly star t pr oc e ss i ng when
temperature reaches mi nimum value set i n the C -Code.
Warm the battery to room temperature.

Fo r no n OE M b atter y, turn off tempe r a ture s e ns i ng in the
C-Code. (see code 14, Battery over temp.)

battery or use the analyzer in a coo ler room.
For non OEM battery, turn off temperature sensing. (see

cod e 1 4, B a tte ry over te m p.)

54 C7000 & 7000ER Battery Analyzer V3.5

Messages and Warnings 12

Detail Globa l Possible Reason(s) / Solution(s)

Calibrate CALIBRATE Calibration in process. Process will complete in 10

C

Calibration fault FAIL 170 Current cannot pass through shorted termi nal during

Cap. improved to
target

C-Code locked C-CODE

Cell mismatch WARNING For NiCd b atteries only. The cells reach full charge at

READY Target Capacity is achieved or exceeded after an initia l

LOCKED

seconds.

calibration. Repeat calibration procedures. An AWG 10
(2.5mm) wire is recommended to short contacts/leads.

warning (code 115, Target capacity not met).

C-Code is locked and cannot be edited. Use an unlocked
C-Code or delete and re-enter the C-Code.

different times so the negative slope is not well-defined.

The program proceeds to the next cycle as normal. Wai t
until processing is complete since the
programs will attempt to correct this warning. If corrected,
code 192 (Cell mismatch corrected) will appear.

The negative slope i n Extended C-Cod e may have to be
increased to 32mV/Cell or more.

Battery may be old and operating time is reduced. Either
monitor battery use or discard the battery.

If the battery is new, use the

Prime

Auto

program.

and

Prime

Cell mismatch
corrected

Charge complete hot WARNING Battery is fully charged but the temperature is at or above

Charge current low FAIL 164 Current driver cannot provi de the requested charge current.

Charge current
complete

READY Cell mismatch (code 112) is corrected through several

Charge/Discharge cycles. Use the battery as normal.

the maximum set value in the C-Code. See code 154,
Chrg c o mp le te te mp ris e , f o r d e ta ils .

For non OEM battery, turn off temperature sensing in the
C-Code.

See code 160, Bad fuses or driver.

END
CYCLE

Charge cycle completed. Program i s goi ng into the next
step.

55

Detail Globa l Po ssible Reason(s) / Solution(s)

Charge timeout FAIL 144 C harge time has exceeded the expected value for the

batte r y. Check that the m Ah rating o f the b a ttery matc hes
the C -Cod e mA h s e tting. The Charg e ra te in the E xtend e d
C-Code may have to be raised.

Charge wai t CHG WAIT Station is on hold until sufficient power is available. This is

normal if large batteries are being serviced. Se rvice will
automatically resume when sufficient power is available to
the station.

Charging CHARGE Battery is being charged normally.
Chrg c o mp le te te mp

rise

Current rise WARNING For SLA only. Battery current suddenly increased as the

Cycle resumed RESUMED Power resumed or the battery is re-inserted into the

Discharge current low FAIL 162 The analyzer is not able to discharge the battery. Very low

D

Discharge cycle
complete

WARNING Battery is being charged normally but temperature is rising

rapidly towards its end of charge state. Wai t until
processing is complete. An appropriate WAIT code may
appear until the battery has cooled before the next process
begins. The Charge rate in the Extended C -Code may
have to be lowered. Observe battery performance. The
battery may be old.

For non OEM battery, turn off temperature sensing.

End of Charge condition was achieved. If the battery is a
Hawke r c ell, use the Ha wk e r C - C ode se ttings ( re fer to
Defa ult Se ttings for E xten ded C-Co des) . Allow the
station to complete service.

adapter.

values of current (< 50mA) are disp layed on the analyzer
before this code appears. See code 1 60, Bad fuses or
driver.

END
CYCLE

Discharge cycle completed. Program is going into the next
step.

56 C7000 & 7000ER Battery Analyzer V3.5

Messages and Warnings 12

Detail Global Possible Reason(s) / Solution(s)

Discharge timeout FAIL 142 Battery capacity has exceeded 250% of the rated capaci ty.

Chec k that the mAh rating of the b a tte r y ma tc hes the
C-Code mAh setting. The Discharge rate in the Extended
C-Code may have to be raised.

Discharge wait DCHG WAIT Station is on hold until sufficient power is available. Wait

until other stations have completed battery service.

Discharging
Hot at low voltage FAIL 156 Battery temperature went to its maximum setting in the

H

Ins er t the b at ter y INSE RT Insert ba tte ry i nto the s ta ti o n.

I

Intermi ttent battery FA IL 129 Battery connection opened 5 times in 1 minute. Check and

Low voltage negative

L

slope

DISCHARGE

FAIL 126 The battery is losing charge faster than it is bei ng supplied

Battery is bei ng discharged normally.

ini ti a l c harg e cycle . C o o l the ba tte ry to the s e rvi c e
temperature. Rai se the temperature sensing in the
C-Code.

The internal cells may have shorted or the battery is old.
Either monitor battery use or discard.

Fo r no n OE M b atter y, turn off tempe r a ture s e ns i ng .

clean the battery contacts. Check that correct contacts are
used. Check that the battery is properly inserted. The
Charge rate in Extended C-Code may have to be reduced.

Protection circuitry opened at End of Discharge voltage.
Raise End of Discharge voltage.

Fo r intri nsic a lly sa fe b a tte r y, use I/S se ttings . Re fe r to
In tr in s ically S af e S e tti ngs .

into the battery in the initial charge cycle. For NiCd and
NiMH batteries only. The Charge rate in the C -Code may
have to be reduced.

If battery is a high capacity NiCd, reduce the Charge rate
to 0.5C. Otherwise reduce to 0.6C.

If all fails, di scard the battery.

57

Detail Global Possible Reason(s) / Solution(s)

Low voltage temp.
rise

Low voltage timeout 1 FAIL 123 The battery stopped accepting charge 1 C -minute into the

Low voltage timeout 2 FAIL 124 The battery stopped accepting charge 10 C -minutes into

Low voltage timeout 3 FAIL 127 C harge terminated. Correct voltage could not be obtained

N/A m -

N

No adapter NO A D AP T No Battery A dapter is i nserted or the inserted adapter i s

No batter y EMP TY No b a tte ry i s inser te d or the inse rted batte r y i s not

No slope timeout

zone 1

Null C-Cod e i n
adapter

FAIL 152 Battery temperature i s risi ng rapidly at low voltage (usually

at the initial stage of charge). Charging is terminated. The
Charge rate in the Extended C-Code may have to be
reduced.

The battery may be old or have shorted cells. Discard the

battery.
For non OEM battery, turn off temperature sensing.

charge cycle. See code 122, Battery shorted.

the charge cycle. See code 122, Battery shorted.

in allotted time due to high battery capacity for set charge
current, incorrect voltage setting or shorted cells. Check
C-Code settings and battery rating. Replace battery if low

voltage remains.

OhmTest

reading is avai lable.

not de te c te d. C hec k c o ntac ts . C lean wi th a lint-fre e c o tto n
swab dipped in 100% Isopropyl Alcohol.

detected. C heck contacts. Turn on battery switch if
applicable. Check for correct battery for the adapter and
adapter contacts. Clean all contacts.

FAIL 125 The battery is losing charge faster that it is be ing supplied

in the initial charge cycle. For SLA and Li-Ion batteries
only. The C harge rate i n the C-Code may have to be
increased. If all fai ls, discard the battery.

FAIL 211 An empty C-C ode i s selected. Select a programmed

C-Code or program the selected empty C-Code.

has not been performed yet so no resistance

58 C7000 & 7000ER Battery Analyzer V3.5

Messages and Warnings 12

Detail Global Possible Reason(s) / Solution(s)

Over voltage FAIL 120 Ba ttery voltage is too hi gh on insertion. Discharge the

O

PIC communications

P

error

Plateau timeout WARNING B attery was fully charged before full-charge conditions

Power on POWER ON Power is detected inside the analyzer.
Process completed FINIS HED Battery service completed.
Process suspended INTERRUPT Battery is removed during service. Re-insert battery within

Program fault
detected

Ready READ Y Battery is ready. Faults or warnings (if any) were corrected.

R

Recondi tion timeout WARNING Recondition time has exceeded the expected value for the

Re co nditioning RECO ND Batt er y is curre nt ly being r ec ond iti oned .

PIC ERROR An internal communication error has occurred inside the

WARNING The C ustom Program has produced an error and the

battery in its original equipment. Check the electrolyte. If all
fai ls , dis ca rd the b a tte ry.

analyzer. Turn off and turn on the analyzer or press
reset the system.

were met. For SLA and Li-Ion batteries only. The End of
Charge setting in the C-Code may have to be increased.
Battery may be old and operating time will be less than
manufacturer’s specifications.

5 seconds to resume service.

statement is not processed. The program is terminated.
Check the Custom Program statements.

Remove battery and use as normal.

battery. Program proceeds to the next cycle. The
Recondi tion Discharge in the Extended C-Code may have
to be raised.

The battery may be intrinsically safe, preventing deep
di s c har g e . Us e I/S s e ttings fo r the b a t te ry. Refer to
In tr in s ically S af e S e tti ngs .

Cells are mismatched, or if battery is new, use the
program.

Alt-0

Next

Prime

to

59

Detail Global Po ssible Reason(s) / Solution(s)

Resistance test OHMTEST

(Code 27)

Resistance test OHMTEST

(Code 28)

Resistance thrs.
Exceeded

Resting XX:XX RESTING

Resting XX:XX RESTING

Set t ing up

S

calibration
Shorted or

reversed

SM-Bus adapter
inserted

Sma r t b a tte r y
inserted

Soft battery FAIL 128 B attery voltage is rising quickly during charging, even after

FAIL 135 The battery resistance has exceeded the set resistance

(Code 19)

(Code 21)

CAL WAIT Station is preparing for a calibration process.

SHORT/REV Battery voltage is too low on insertion. Battery may be

SM ADP IN SMBus Adapter is detected on a station.

SM BAT IN Smart battery is detected on a SMBus Adapter.

A manually selected or programmed resistance test for the
battery is i n progress. Program completes in 5 seconds.

An automatic resistance test under the
program is in progress. The program should complete in 5
seconds.

threshold i n
Station is in rest period as specified i n the Custom

Program.
Station is in an automatic rest period specified in the

Charge

automatic if temperature sensing for the adapter is not
enabled.

connected backwards in the adapter. Ensure battery leads
are connected properly.

Battery may be fully di scharged. Recharge battery in its
original charger before placing it in the analyzer.

Ba tte ry may have shor te d c e lls. D is ca r d the b a tte ry.

cod e 11 8 ( S o ft battery ste p d o wn). Pro c e s s ing has
terminated.

Battery may be overcharged. Discharge the battery for 10
minutes, then charge again.

Battery may be a high capacity type battery. Reduce the
Charge rate.

Ba tte ry is new. Use the
batte r y for use .

Check that correct contacts are used.

OhmTest

program for NiMH batteries. The procedure i s

. Program has terminated.

program to prepare the

Prime

Life Cycling

60 C7000 & 7000ER Battery Analyzer V3.5

Messages and Warnings 12

Detail Global Possible Reason(s) / Solution(s)

So ft b atte ry ste p
down

Start battery process START Battery service has started.
Station cali brating CALIBRATE Station is in calibration. Process takes about 10 seconds.
Station off line OFFLINE Station is not readi ng the adapter. Remove the adapter

Suspended P rocess
Aborted

Target capacity not

T

met

Temperature hold ­Cooling

WARNING Battery voltage rising too quickly while charging. Analyzer

is cutti ng the C harg e ra te i n half and wi ll a tte mp t to
complete service at lower current rate. Wait until
processing is complete. If voltage rises agai n, code 118
(Soft battery) will appear and the program terminated.
Charge rate in the Extended C-Code may have to be
reduced. If the battery is new or in storage, use the
program.

and restart the analyzer. Delete the C-Code that was
selected for the battery. Make sure all your analyzers have
the same firmware version number. P ress
system.

INTERRUPT B a ttery is re moved during se rvice for mo re than 5 seco nds.

Program terminated.
Fo r no n OE M b atter y, turn off tempe r a ture s e ns i ng .

WARNING Final capacity of the battery is below the Target Capacity.

The analyzer will attempt to improve the capacity by
reconditioning the battery. Wait until processing is
complete. The
correct this warning. If corrected, code 195 (Cap. improved
to tar ge t) will a p p ea r. Chec k that the mA h ra ti ng of the
battery matches the C-Code mAh setting. Battery may be
old and operating time will be less than manufacturer’s
specification.

SYS-TEMP This i s normal. All cycles are bri efly suspended due to high

temperature inside the analyzer. Service will resume in a
few mi nutes or after the board has cooled. This may occur
a num b er of t im e s p er ho ur. If i t r e o c cur s c o nt inuall y, mo ve
the analyzer to a cooler room.

Auto

and

programs will attempt to

Prime

Alt-0

Prime

to re s e t t he

61

Detail Global Possible Reaso n(s) / Solution (s)

Thermistor failure FAIL 150 Battery or adapter thermistor is open or shorted. Clean the

conta cts o n the ba tte ry. Wa rm the b a tter y to roo m
temperature.

The battery thermistor may be damaged. Use another good
battery to check and disc ard battery i f damaged. If the
battery is still good and code 150 (Thermistor failure)
appears, contact Cadex Service.

Trickle charge TRKL CHRG The reconditioning process completed and the battery is

being recharged.
The program has specified a trickle charge.

Trickle charge

overheat

User programmed

U

timeout

FAIL 159 The temperature on the battery has ri sen over its maximum

setting. The trickle charge stops. The Trickle Charge rate
or the Max. Standby voltage in the Extended C -Code may
have to be reduced. Check that the mAh rating of the
battery matches the C-Code mAh setting. Lower the room
temperature.

For non OEM battery, turn off temperature sensing.

END CYCLE The ti m e prog ra mmed i n the C ustom P r ogram c o mp lete d .

The program is moving into the next step.

62 C7000 & 7000ER Battery Analyzer V3.5

By Code

The codes are listed in ascending numeric order and cross-referenced to both the
Detail and Global display . Refer back to

Code Detail Global

By Detail

000 STATION OFF LINE OF F L INE

001 NO ADAPTER NO ADAPT
002 CHARGING CHARGE
003 TRICKLE CHARGE TRKL CHRG
004 RECONDITIONING RECOND
005 READY READY
0 06 DISCH ARG E WAIT D CHG W AIT
007 DISCHARGING DISCHARGE
008 INSERT THE BATTERY INSERT
00 9 CHARGE WA IT CHG WA IT
01 0 NO B ATTE RY EMP TY

011 START BATTERY PROCESSING START
012 BATTERY TOO COLD COLD WA IT
01 3 BATTE RY TOO HOT HOT WAIT
01 4 BATTE RY OVER TE MP OVE RHE AT
015 PROCESS COMPLETED FINIS HED
01 6 PRO GRA M FA ULT D E TEC TE D WARNING
01 7 BATTE RY REM OV ED REMO V E D
018 PROCESS SUSPENDED INTERRUPT
019 RESTING XX:XX RESTING
020 BATTERY INSERTED INSERTED

021 RESTING XX:XX RESTING
02 2 SETTING UP CA L IBRATION C AL WAIT
023 STATION CALIBRATING CALIBRATE
02 6 BATTE RY REM OV ED REMO V E D
027 RESIS TANCE TEST OHMTEST
028 RESIS TANCE TEST OHMTEST
029 CALIBRATE CALIBRATE
030 CHARGE CYCLE COMPLETE END CYCLE

for possible reason(s)/solution(s).

Messages and Warnings 12

63

Code Detail Global

031 DISCHARGE CYCLE COMPLETE END CYCLE

032 CYCLE RESUMED RESUMED
033 USER PROGRAMMED TIMEOUT END CYCLE
034 BATSHOP MODE WAIT BATSHOP
035 SM-BUS ADAPTER INSERTED SM ADP IN
036 SMART BATTERY INSERTED SM BAT IN

112 CE L L M ISMATC H WARNING
113 PL ATE A U TIME OUT WARNING
115 TARGE T C APA CITY NOT MET WA RNING
118 SOFT BATTERY STEP DOWN WARNING

120 OVER VOLTAGE FAIL 120

121 SHORTED OR REVERSED SHORT/REV

122 BATTERY SHORTED FAIL 122
123 LOW VOLTAGE TIMEOUT 1 FAIL 123
124 LOW VOLTAGE TIMEOUT 2 FAIL 124
125 NO SLOPE TIMEOUT ZONE 1 FAIL 125
126 LOW VOLTAGE NEGATIVE SLOPE FAIL 126
127 LOW VOLTAGE TIMEOUT 3 FAIL 127
128 SOFT BATTERY FAIL 128
129 INTERMITTENT BATTERY FAIL 129
13 0 CURRE NT RISE WARNING
135 RESISTANCE THRS. EXCEEDED FAIL 135
142 DISCHARGE TIMEOUT FAIL 142
144 CHARGE TIMEOUT FAIL 144
146 REC OND ITION TIMEOUT WARNING
15 0 THE RMISTO R FA ILURE FAIL 150
152 LOW VOLTAGE TEMP. RISE FAIL 152
15 4 CHRG COM P L E TE TEMP. RISE WARNING
156 HOT AT LOW VOLTAGE FAIL 156
15 8 CHA RG E COMP LE TE HOT WARNING
159 TRICKLE CHARGE OVERHEAT FAIL 159
160 BAD FUSE OR DRIVER FAIL 160

64 C7000 & 7000ER Battery Analyzer V3.5

Code Detail Global

16 2 DISCHA RGE CURRE NT L OW FA IL 1 6 2
16 4 CHARGE CURRE NT LOW FA IL 16 4
170 CALIBRATION FAULT FAIL 170
188 SUSPENDED PROCESS ABORTED INTERRUPT
192 CELL MISMATCH CORREC TED READY
195 CAP. IMPROVED TO TARGET READY

200 P OWER ON P OW E R ON

201 ADAPTER INSERTED ADAPT IN

202 ADAPTER REMOVED ADAPT OUT
207 TEMPERATURE HOLD - COOLING SYS-TEMP
208 ADAPTER NOT SETUP FAIL 208
209 ADAPTER DATA INVALID FAIL 209
210 BAD ADAPTER FAIL 210

211 NULL C-CODE IN ADAPTER FAIL 211

21 2 PIC COMM UNICATIONS E RRO R P IC E RRO R

Messages and Warnings 12

65

Services and Upgrades

Caution

• Unauthorized disassembly and/or repair of the analyzer by other than an
authorized Cadex Service Center will void the warranty .

• Observe anti-static precautions before and during service. The circuitry used
in the analyzer is sensitive to electrostatic discharge and may be damaged if
not handled properly . Static charge is generated through the contact of non­conductive materials such as plastic bags, synthetic clothing and carpeted
floors.

• It is recommended that a grounded wrist and/or foot band be used when
dismantling the analyzer. If a wrist or foot band is not available, firmly grasp
the metal edge of the RS-232 Serial Port before touching any components.
Repeat often during service.

Warning

• Before performing any service, remove all Battery Adapters, turn off the
analyzer, and disconnect the power cord.

• For C7000ER, a high voltage is present on the power supply circuit board
and the capacitors for at least 30 minutes after the power switch is turned off.
To ensure satisfactory discharge of energy, allow the analyzer to sit for at
least 30 minutes before removing the chassis cover.

66 C7000 & 7000ER Battery Analyzer V3.5

Replacing the Primary (Input) Fuse

If the analyzer does not power up but the input line is checked and power cord is
firmly inserted, the primary (input) fuse may need to be replaced.

Model Primary Fuse Size Replacement Cad ex P/N

C7000-1 T1.6 Amp 250V 5 x 20 mm Schurter 034.3119 52-546-0160
C7000-2 T1.6 Amp 250V 5 x 20 mm Schurter 034.3119 52-546-0160
C7000-9 T0.8 Amp 250V 5 x 20 mm Bussman GDC800mA 52-546-0080

C7000ER T3.5 Amp 250V 5 x 20 mm Littlefuse 216 31.5 52-546-0315

Standard Model (C7000-1, C7000-2, C7000-9)

1. Remove all batteries and adapters, turn off the analyzer and unplug the power
cord.

2. Locate the fuse drawer below the power cord socket.

13

Fuse Drawer

3. Open the fuse drawer by pulling the release tab outward with a fingernail or
small screwdriver.

4. If the primary (input) fuse needs to be replaced, remove the fuse from the fuse
drawer and replace the fuse.

5. Push the release tab back to the fuse drawer until it clicks shut.

6. Insert the power cord and turn on the analyzer.

67

Extended Range Model (C7000ER)

1. Remove all batteries and adapters, turn off the analyzer and unplug the power
cord.

2. Locate the fuse holder under the rear metal cover extension.

Fuse Holder

3. Use a small screwdriver to turn the fuse holder clockwise until it is released. Then
pull the holder.

4. If the primary (input) fuse needs to be replaced, remove the fuse from the holder
and replace the fuse.

5. Insert the fuse drawer taking care that the side springs are inserted into the socket.
Turn counterclockwise to close the holder .

6. Insert power cord and turn on the analyzer.

68 C7000 & 7000ER Battery Analyzer V3.5

Replacing the Station Fuses

Each station is protected by its own fuse. An open station fuse is identified by the
absence of charge or discharge current with a battery in service, and/or a message
shown on the display , such as code 160 (Bad fuse or driver).

Model Station Fuse Size Rep lacement C adex P /N

All F2.5 Amp 250V 5 x 20 mm Li ttlefuse 217 02.5 52-526-0250

Standard Model (C7000-1, C7000-2, C7000-9)

1. Remove all batteries and adapters, turn off the analyzer and unplug power
cord.

2. Unscrew the 3 screws located on the rear. The cover will still be attached to
the analyzer by a grounding strap. Put the cover to one side.

Services and Upgrades 13

Ground Strap

Rear Cover Screws

Top Cover

3. Remove the open fuse from the holder, taking care

electrical components

. The station fuses are located in the left rear corner of

the analyzer on the motherboard:

Station 1 Fuse

Station 2 Fuse
Station 3 Fuse
Station 4 Fuse

Option Board Label

Option Port

not to touch any of the

69

4. If necessary , check the removed fuse with an ohmmeter to confirm diagnosis
and/or replace the station fuse.

5. Replace the upper cover of the C7000, (make sure the front edge of the top
cover is properly inserted into the notches in the plastic cups), and re-install the
screws to secure cover.

Extended Range Model (C7000ER)

1. Remove all batteries and adapters, turn off the analyzer and unplug power cord.

Wait 30 minutes to allow the voltage to discharge.

2. Unscrew the 2 screws located on the rear to remove the top cover. Disconnect the
wire on the power supply circuit board that is attached to the power assembly filter.

3. Remove the open fuse from the holder, taking care

electrical components

. The station fuses are located in the left rear corner of the

not to touch any of the

analyzer on the motherboard (refer to the diagram for standard model).

4. If necessary , check the removed fuse with an ohmmeter to confirm diagnosis
and/or replace the station fuse.

5. Reconnect the wire on the power supply board and re-install the screws to secure
cover.

70 C7000 & 7000ER Battery Analyzer V3.5

Services and Upgrades 13

Replacing Backup Battery (with OP-70 or OP-72 only)

An analyzer equipped with the OP-70 or OP-72 option board contains a backup
battery to retain date/time, print formats and other information when the power is off
or interrupted. With the analyzer off, the battery lasts for 2 to 3 years; with the
analyzer on, the backup battery can last for 10 years.

Replace the battery if the date/time setting is no longer retained after the analyzer is
turned off.

Model Backup B attery Siz e R eplacement Cadex P /N

All 3V, 200mAh 200 x 3.2mm Panasonic BR2032

or Standard CR2032

45-206-0001

Warning: Make sure the polarity is correct when replacing the backup
battery. Discard the used battery according to the battery manufacturer’s
instructions. Failure to do so may cause explosion.

1. Remove all batteries and adapters, turn the analyzer off and unplug power
cord.

2. Unscrew the 3 screws located on the rear of the C7000 (2 screws on the
C7000ER) to remove the top cover.

• The cover will still be attached to the C7000 by a grounding strap. Put the

cover to one side.

3. Locate the backup battery on the option board mounted vertically in the rear
corner of the analyzer.

4. Gently lift the retainer arm which holds the backup battery and slide the battery
out. Take care

electronic components

something similar. The ribbon cable or the option board may have to be
removed in order to access the backup battery .

not to short-circuit the backup battery or touch any of the other

inside the analyzer. Do

not

use a metal screwdriver or

71

5. Install a new backup battery and make sure that the battery is inserted properly . If
the ribbon cable was removed, replace the cable.

6. Replace the upper cover (make sure the front edge of the top cover is properly
inserted into the notches in the plastic cups) for the C7000, and re-install the
screws to secure the cover.

IEC320 Power Cord

The C7000 and C7000ER analyzers use a standard IEC320 power connector, allowing
you to obtain suitable power cords for connection to any standard line voltage source. If
you need a special power cord for your particular wall socket, obtain an approved cord
fitted with an IEC320 socket at one end, and the appropriate local fitting at the other
end.

If you obtain a universal IEC320 power cord with a socket but no plug, you should
connect the appropriate plug as follows:

IEC320 Socket
(connects to Battery Analyzer)

• Brown = Line (AC Hot)

• Blue = Neutral (AC Neutral)

• Green or Green/Y ellow = Ground (Earth)

Warning: Make sure this is conducted by a licensed electrician.

72 C7000 & 7000ER Battery Analyzer V3.5

Brown

Blue

Green or
Green/Ye llow

Line (AC Hot)
Neutral

Ground (Earth)

Hardware

14

Specifications

C7000-1

Standard

Part Number

Line Voltage

Frequency

Main (Input) Load

Output Load

Total* max 80W max 80W max 80W max 160W

Current/Stati on max 2A max 2A max 2A max 2A

Operating Te mp. 0

Dimensions

Width 280mm (11.0") 280mm (11.0") 280 mm (11.0") 280mm (11.0")

Depth 374mm (14.7") 374mm (14.7") 374mm (14.7") 412mm (16.7")

Height 88mm

Weight

Accuracy

Voltage +
Current +

Throughput

Connectors

Interface

Keypad Numeric pa d with 8 function keys, 4 station selection/cursor keys

Warranty

Approvals

Options

* Continuous, intelligent overload protection.

07-771-0000 07-772-0000 07-779-0000 07-778-0000

115VAC +

60Hz 50-60Hz 50-60Hz 47-63Hz
max 180W max 180W max 180W 225W (Power

o

C to 40oC (32oF to 104oF)

6.3kg (13.9lb); with option board: 6.4kg (14.1lb) 5.7kg (12.6lb)

1% at max rated voltage

2.5% at 1A

4 batteri es every 4 - 8 hours (up to 160 batteries per month) based on 2 batches

per day.
3-pin AC plug IE C 320 P ower Cord (only available on C7000-1)

Serial DB-9 RS-232 (standard on all models)
Parallel D B-25 (OP70 and OP-72 only)
DIN Jack (5-pin) for Ba r Co de Wand (OP-72 only)

LCD 80 Character wi th multiple display formats (Global, Detailed, Menu)

LED 3 Status lig hts (RUN, READY, FAIL) for each station

Limited (2) years parts and labor

Tested and approved by ITS to comply with CSA/UL/CE standards

Battery Backup RAM (OP-70 and OP-72)
Bar Code Reader (OP -72)

Windows-based BatteryShop

10% 100VAC +10% 220-240VAC +5% 90-250VAC

(3.6") 88mm (3.6") 88mm (3.6") 95mm (3.75")

C7000-2

Standard

C7000-9

Standard

TM

C7000-ER

Ext end ed Rang e

Factor Corrected)

73

Firmware

Supported Chemistries NiCd NiMH SLA Li-Ion

Frequency (Standby)

Firmware Version Version 3.5

Supported Settings A ll Types All Types Ge ll, Hawk e r All Types

Voltage

C7000-1, 2 & 9 1.2V-14.4V 1.2V-14.4V 2.0V-16.0V 3.6V-14.4V

C7000-ER 1.2V-28.8V 1.2V-28.8V 2.0V-30.0V 3.6V-28.8V

Battery Rating/

Capacity

100mAh-

24,975mAh

100mAh­24,975mAh

100mAh­24,975mAh

100mAh­24,975mAh

Charge Method Reverse Load Constant voltage with current limit

Display Format

Capacity Percentage of nominal rating

Voltag e Vo lts /Cell or Vo lts

Temperature

Resistance m

Auto Se rv ic e

Security

Outputs

o

C

Ω

30 Days 30 Days 180 Days 30 Days

3 Le vel P a ss wo rd E nable d S e curi ty (Off, Lo w, High)
Battery Labels, Bar Code Labels, Battery Service Reports, System

Setup Reports

Printer Support Epson compatible dot-matrix (9-pi n), DYMO LabelMaker SE 300 P rinter

74 C7000 & 7000ER Battery Analyzer V3.5

Troubleshooting

The common problems and solutions listed below will answer most of your questions.
The detailed alphabetical list of display messages in
help to sort out problems not listed here.

If personalized help becomes necessary , contact the Technical Support department.

Problem Possible Reason (s) / Solution(s)

Getting Help/Problem Solving

Messages and Warnings

can

15

1. The C 7000 does not power
up.

2. The fan turns off and on, even
when no battery is bei ng
analyzed.

3. Password is not accepted
even though no password is
stored in the analyzer.

4. Dates are changing or
negative dates are
appearing.

5. Bar Code Wand reads
intermittently.

Check that the power input on the rear label is
correct.

Make sure that the power cord is firmly
inserted in the back connector.

Check the input fuses.

Thi s i s no r ma l .

Replace the backup battery.

Replace the backup battery.

Use correct bar-code format: C-Code - ’2 of 5’;
ID - ’3 of 9’ or bar 128 format.

The label is damaged or dirty.

A fast swipe reads better than a slow swipe.

Try a different angle and speed.

Artificial li ghts, fluorescent lights and direct
sunlig ht c a n a ffe c t the w a nd.

75

Problem Possible Reason(s) / Solution(s)

6. Printing Problems. Check the serial port setup of the serial printer.
Check that the seria l or parallel port i s enabled

for c o r re c t p rint d e vi c e .

Set the other port to Disabled.

The Lab elMaker op ti o n in the Serial Port
Device or Parallel Port Device of System
Setup is wrongly selected. Select Printer
instead.

Check if the seria l cable is correctly configured
(refer to Serial Port Settings for serial cable
pin conf ig u rat i ons) .

7. Battery servi ce does not
start.

Ensure that the adapter is firmly inserted into

the analyzer.

Check that the battery i s correctly and firmly
inserted into the adapter. Make sure that the
contacts on the battery are meeting the
contacts on the adapter.

Turn on the battery switch if applicable.

Press ENTER a fter selecting the C -Code and

the service program.

Check that the selected C-Code is correct for

the batte ry.

8. Connection between battery
and the analyzer is
intermittent.

The ba tte r y ma y be intri ns i c ally sa fe . C ha nge

the charge method in the Extended C-Code to
DC Charge; lower the C harge rate and
Discharge rate; reduce the End of Discharge to

0.92V/Cell.

76 C7000 & 7000ER Battery Analyzer V3.5

Getting Help/Problem Solving 15

Problem Po ssible Reason(s) / Solution(s)

9. Program did not resume
after a power fai lure.

10. Si ngle cell gives inconsistent
results.

11. Capacity readings between
st a t io ns ar e inco nsis te nt .

12. Resistance readings are
co ns is t e ntly hig h.

Check if an option board (OP -70 or OP-72) is
installed. The option board sticker is at the
back of the analyzer. The option board
configuration is also displayed during start-up.

The analyzer was saving the battery information
when the power failed. Battery information is

saved once a minute. If the power fails during

the information save, the program will not

continue when power resumes.
Replace the backup battery.

Calibrate the stati on.
Set the charge method in the Extended

C-Code to DC Charge d ue to lo w te r minal

voltage.

Single cells are dischargi ng and/or charging

too quickly. Lower the Discharge rate and

Charge rate to about 0.2C.
Verify that the C-Codes are the same between

stations.
Calibrate the stati ons.

Calibrate the stati on.

The battery or adapter contacts may be

damaged.

The ba tte r y i s fa ulty.

13. Battery passes on analyzer
but fai l s i n the fi e ld .

Use the

OhmTest

. If the res i s ta nce i s hig h, the

battery may not be ab le to hold charge.
Use the Self Discharge program to check the

differenc e of the last two readings. If it is more

than 30 %, the b a tte ry fai l s.

77

Manual Updates and Other References

We maintain an Internet Web site as an additional resource and reference for those
who work with batteries. Detailed technical and practical information about all aspects
of battery maintenance is available at www.cadex.com:

• Articles and T echnical Papers

• Frequently Asked Questions about Batteries

• Battery Adapter Catalog

• Updates of User’s Manuals

Technical Support

If you have a technical problem that cannot be solved with this manual or the Cadex
Web site, you can contact our Technical Support department by phone, fax, email, or
mail. Please provide the following information:

• Serial Number of the analyzer.

• Firmware Version. You can find the version number by pressing Fn-7.

• Display message and/or code.

• LED lights that are on or flashing.

• What happened and what you were doing when the problem occurred.

For questions related to batteries or adapters:

• Battery Model Number.

• Adapter Number.

• C-Code being used.

• Display message and/or code.

78 C7000 & 7000ER Battery Analyzer V3.5

Getting Help/Problem Solving 15

Y ou can reach Cadex Technical Support by phone at 8:00 am - 4:30pm Pacific
Time (GMT -08:00), Monday through Friday.

• Technical Support Phone: [phone]

• Toll Free: + 1 800 565-5228 (US and Canada only)

• Fax: [phone]

• Email: [e-mail]

• Mail: Cadex Electronics Inc.

22000 Fraserwood Way
Richmond, BC
Canada V6W 1J6

Attn: Product Support

79

Safety Notice and Warranty

Radio Interference

This equipment generates, uses and can radiate radio frequency energy and if not
installed and used in accordance with the instruction manual, may cause interference to
radio communications. It 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, at his own expense will be required to take whatever
measures required to correct the interference.

EN55022 Warning: This is a Class A product according to EN55022. In a domestic
environment this product may cause radio interference in which case the user 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 documentation. If the equipment is
used in a manner not specified by the documentation, the protection provided by the
equipment may be impaired. Please read the documentation and equipment labeling
before using the equipment.

80 C7000 & 7000ER Battery Analyzer V3.5

Explosion Hazard

Batteries can burst if treated improperly . Follow these precautions at all times.
" Clean battery contacts before servicing. Press the battery firmly into the

adapter to ensure a good connection.

" Ensure that the selected C-Code is correct for the chemistry , voltage, and

current rating of the battery being serviced.

" Observe battery temperature. Stop service if battery becomes very hot.

Service batteries between 0
outside this temperature range may cause damage to the battery. Allow cold
batteries to warm up and hot batteries to cool before charging.

" Use only a grounded AC outlet to power the analyzer.

# Do not attempt to charge non-rechargeable batteries such as alkaline, carbon-

zinc, or non-rechargeable lithium.

# Do not short the positive and negative battery terminals together at any time.

o

C (32oF) and 60oC (140oF). Fast-charging

16

# 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 cause a fuse to blow.

# Do not exceed the manufacturer’s recommended charge current and voltage

limits for batteries.

# Do not restrict the airflow of the analyzer. Leave the fan opening clear. Fan

operation is automatic.

81

Shock Hazard

The C7000/C7000ER Battery Analyzer contains high-voltage circuits, and can pose a
shock hazard when the upper cover is removed.

procedures on the analyzer other than replacement of the fuses or internal backup battery.

" Use the analyzer only as specified in the documentation. Other uses may impair

the protection provided by the unit.

" Use only a grounded AC outlet to power the analyzer.
" 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 (30 minutes for the C7000ER) before opening the cover.

" Replace fuses only with fuses of the same type and rating.
" Replace the internal backup battery only with the same type. Observe the correct

polarity when installing the backup battery . Discard the used battery according to the
battery manufacturer’s instructions.

Do not attempt to perform any service

82 C7000 & 7000ER Battery Analyzer V3.5

Warranty & Services

Cadex Electronics Inc. warrants the Cadex C7000 and C7000ER Battery Analyzers
against defective materials and workmanship for a period of two (2) years from the
original purchase date.

The warranty does

• Any damage due to abusive operation, negligence, accident or improper

installation.

• Any damage caused by an attempted repair not authorized by Cadex.

• Cosmetic damage caused by normal wear and tear.

• External causes of damage such as leakage spills, power fluctuations or

failure, or shipping.

• Product received without the appropriate model number, serial number or

safety markings.

• Product used for rental purposes.

Obtaining Warranty Service

1. Contact Cadex T echnical Support. If the service representative has

determined that your product needs to be returned for service or replacement,
the representative will fax or provide a Return Authorization number with the
location of the nearest service center.

not

Safety Notice and Warranty 16

cover

2. Ship the product to the service center with freight, insurance and customs

duties prepaid. Include the Return Authorization number provided by Cadex or
the service center.

All products must be returned with a Return

Authorization number supplied by Cadex or a Cadex service center.

Products returned from warranty service will be sent with freight prepaid by Cadex.

Non-warranty Repairs

Cadex will provide an estimate and will proceed with the repairs only after you have
provided a written authorization or a Purchase Order number. You will also need a
Return Authorization number.

83

A

abbreviations and acronyms, 6

See

adapters.
Adapters, Voltage Calibration, 44
Auto-Print, 48, 49

Battery Adapters

B

backup battery, replacing, 71–72
bar code scanner, 4
bar codes, 1, 20
Battery Adapters, 10, 27

Custom Adapters, 10
Dual-station Adapters, 10
inserting, 17
removing, 18
Smart Cable Adapters (Universal

Adapters), 3, 10, 11, 18, 27

battery configuration codes.

Codes
Battery ID, 20, 48
BatteryShop, 1, 3, 9, 33

See

C

C-Codes, 1, 11, 27

active, 17, 20, 48
Basic, 27
Extended, 27, 28, 32
managing, 30

viewing, 17, 30
calibrations, 15, 44-45
commands, 15
commonly used terms, 7
components, 8
Custom Programs, 33

creating or modifying, 40

D

display, 12, 13

C-

E

Event Log, 50

log events, 51
managing, 51

F

features, 1
firmware upgrade, 2, 3
firmware version, viewing, 15
function keys, 15
fuses.

See

primary fuses, replacing;

station fuses, replacing

I

IEC320 Power Cord, 5, 72
internal resistance, 22

threshold, 22, 25

intrinsically safe (I/S), 7

settings, 31

K

keys, functions of, 8

L

labels, 1, 4, 48

printing, 15, 49

LCD.

See

display

LEDs.

See

lights
Li-Ion, 6, 10, 27
lights, 16

M

memory, 7, 21
menu, 14
messages, 52

by code, 63–65
by detail, 53–62

84 C7000 & 7000ER Battery Analyzer V3.5

Index

O

OP-70, 9
OP-72, 4, 9, 20
option boards, 9, 71

P

parallel ports, 11, 47

device settings, 47
password requirement, 41
passwords, changing, 42
peripherals, 4
primary fuses, replacing, 67, 68
print utilities, 48
programs

Basic Programs, 21

selecting, 18, 24

Specialty Programs, 22
program settings, editing, 25

R

recondition, 7, 21
reports, 1, 4, 48

printing, 15, 49
Residual Capacity, 7, 22

S

safety notice, 81
security, 41

removing, 42

setting, 42
serial cable pin configurations, 46–47
serial ports, 11, 46

device settings, 47

settings, 46
service duration, 26
service procedures, 17-19

batteries with bar code, 20

services and upgrades, 66
Smart Batteries, 1, 7

storage of, 21, 22
specifications, 73-74
station fuses, replacing, 69, 70
system, resetting, 3
system information, setting up, 44
system setup, 43

T

Target Capacity, 7, 23

setting, 19, 24
Technical Support, 78
troubleshooting, 75

U

upgrade to firmware V3.5, 3
upgrades.

See

services and upgrades

W

warnings, 52

by code, 63–65

by detail, 53–63
warranty, 83–84

85