Cadex C7200, C7400, C7400ER User Manual

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Page 1

Cadex C7000 Series

Battery Analyzer

User’s Manual

Cadex C7200, C7400 & C7400ER

Cadex Electronics Inc.

22000 Fraserwood Way Richmond, British Columbia Canada V6W 1J6

Tel: +1 604 231-7777 Fax +1 604 231-7755 Web: www.cadex.com E-mail: info@cadex.com

Manual P/N: 89-307-1013 Rev 11 November 2005 Printed in Canada Firmware Version 6.11

Cadex C7000 Series Battery Analyzer i

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Safety Notice

Trademark

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

Copyright © 2005 by Cadex Electronics Inc. All rights reserved. No part of this publication or the firmware controlling Cadex product(s) may be reproduced, transmitted, transcribed, stored in a retrieval system, or translated into any language or computer language in any form or by any means without the express written permission of Cadex Electronics Inc.

Revision Rights

Cadex Electronics Inc. reserves the right to revise this publication and make changes in the contents thereof without obligation to notify any person of such changes. Please contact Cadex Electronics Inc. (service@cadex.com suggestions or corrections.

Disclaimer

While every effort is made to ensure that the information contained in this manual is accurate and up-to-date, Cadex Electronics Inc. does not warrant or guarantee the accuracy of the contents of this manual. Further, Cadex makes no warranties, either expressed or implied, as to the merchantability or fitness for a particular purpose of the Cadex C7400ER) equipment and/or its documentation.

In no event will Cadex or its officers or employees be responsible for any consequential, incidental, or indirect damages (including damages for loss or business profits, business interruption, and the like) arising out of the use or inability to use the Cadex C7000 Series Battery Analyzers (C7200, C7400 and C7400ER) Battery Analyzer equipment and/or its documentation.

C7000

) for

Series Battery Analyzers (C7200, C7400 and

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Safety Notice

Use of Equipment

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

Modification of Equipment

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

Disposal of Waste Electrical and Electronic Equipment (WEEE) in the European Union

This symbol on the product and package indicates that this product must not

be disposed of with unsorted municipal waste. Instead, it is your responsibility

to dispose of WEEE by handing it over to a designated collection point for the

disposal. The separate collection and recycling of waste equipment will help

conserve natural resources and ensure that it is disposed of in a manner that

protects human health and the environment. For more information about

where you can drop off your waste equipment for disposal, please contact

your local municipal office, waste disposal service or wherever you

purchased the product.

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Safety Notice

Radio Interference

This equipment generates, uses and radiates radio frequency energy. If the equipment is not installed and used in accordance with the instructions in this manual, it may cause interference with radio communications. The equipment has been tested and found to comply with the limits for a Class “A” digital device pursuant to Subpart B of Part 15 of the FCC Rules, which are designed to provide reasonable protection against such interference when operated in a commercial environment. Operation of this equipment in a residential area may cause interference, in which case the user is required to take whatever measures needed to correct the interference, at their own expense.

EN55011/EN55022 Warning: This is a Class A product according to EN55011/EN55022. In a domestic environment, this product may cause radio interference, in which case the user, at their own expense, may be required to take adequate corrective measures.

The equipment is designed with adequate safeguards to protect the user from shock and other hazards when used as specified within this document. If the equipment is used in a manner not specified by this documentation, the protection provided by the equipment may be impaired. Please read the documentation and equipment labeling before using the equipment.

The analyzer may be affected by interference from other devices. If the unit is running abnormally, please ensure that the analyzer is moved away from any source of radio interference.

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Safety Notice

Explosion Hazard

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

 Clean battery contacts before servicing. To clean battery contacts, use a lint-

free cotton swab dipped in 100% isopropyl alcohol.

 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



rating of the battery being serviced.

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

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

 Do not attempt to charge non-rechargeable and primary batteries such as

alkaline, carbon-zinc, or non-rechargeable lithium batteries.

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



Do not connect leads from one station to another, or to the case. An electrical



short to any point outside the station bypasses the current regulation loop and may blow a fuse or cause permanent component damage.

 Do not exceed the battery manufacturer’s recommended charge current and

voltage limits for batteries.

Do not remove the adapter from the analyzer while the battery is



running.

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Safety Notice

Charging and Discharging Lithium-ion (Li-ion) Batteries

Lithium-ion (Li-ion) batteries are safe when used as directed. Battery safety cannot be assured when a battery pack is built with individual cells of an unknown nature with a serial and parallel connection. Not all Li-ion cells are suited for multi-cell packs. Only cells that meet tight voltage and capacity tolerances can be used for serial and parallel connection. Mismatched packs are subject to overcharge resulting in venting with flame and fire. Check with the cell manufacturer to see if the cells are suitable for multi-cell packs.

In the past, single Li-ion cells were only available to authorized battery manufacturers. Today, imports are becoming readily available and often fall into the hands of the inexperienced. While most brand name cells are equipped with an internal cell disconnect that permanently opens the current path on high pressure, some brands do not provide this safeguard. Many brands don’t’ use a separator that shuts down the battery when high temperatures are reached. The internal safety features are omitted for cost reasons.

Please follow the following guidelines when charging and discharging lithium-ion cell(s) and packs. Failing to follow these rules could result in venting with flame, explosion, fire and personal injury.

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

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

• Always attach a temperature sensor when charging and discharging the battery. The temperature sensor must disconnect the current on excess temperature.

• Only connect cells that are matched and have the identical state-of-charge.

• Pay special attention when using an unknown brand. Not all brands contain

intrinsic safety features that protect the cell when stressed.

• During experiments, place the test battery into a well-ventilated fireproof container. Never leave the battery unattended while under charge or discharge.

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Safety Notice

Shock Hazard

The Cadex Battery Analyzer contains high-voltage circuits, and can pose a shock hazard when the upper cover is removed. Do not attempt to perform any service procedures on the analyzer other than replacement of the external fuse or internal backup battery (see Chapter 11, Services and Upgrades, page 114).

To reduce the risk of electrical shock hazard, service batteries only when they



are removed and disconnected from their end-use equipment.

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 before opening the cover.

Replace fuses only with fuses of the same type and rating (see Replacing



the Primary (Input) Fuse, page 114).

 Replace the internal backup battery only with the same type of battery (see

Replacing the Backup Battery, page 115). Observe the correct polarity

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

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Warranty & Service

Cadex Electronics Inc. warrants your Cadex Battery Analyzer against defective materials and workmanship for a period of three (3) years from the original purchase date.

The warranty does not cover:

• Damage caused by abusive operation, negligence, accident, or improper installation.

• Damage caused by an attempted repair not authorized by Cadex.

• Cosmetic damage caused by normal wear and tear.

• Damage from external causes such as leakage spills, power fluctuations,

power failure or inadequate shipping.

• Product received without the appropriate model number, serial number, or safety markings.

• Products used for rental purposes.

Warranty Service

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

• Ship the product to the service center with freight, insurance, and customs duties prepaid. The Return Authorization form must be included to obtain warranty service.

• Ensure that the unit(s) is properly packed before shipping, preferably in the original Cadex boxes. Damage caused in transit due to improperly packed items is not covered under warranty. Products returned from warranty service are shipped with freight prepaid by

•

Cadex.

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Warranty & Service

Non-warranty Repairs

Before sending the unit in for service, contact Cadex Technical Support at 1 800 565-5228. If your product is not covered by warranty, the representative will provide the contact information for the nearest service center. You may contact the service center directly to arrange to send the product in for service. A Return Authorization form or number will be provided only if the product is returning to the Cadex Head Office.

• Ship the product to the service center with freight, insurance and customs duties prepaid.

• Ensure that the unit(s) is properly packaged before shipping.

Note

Cadex Electronics Inc. and Cadex authorized service centers require a

Purchase Order or written authorization to proceed with repairs.

Cadex C7000 Series Battery Analyzers ix

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Table of Contents

Chapter 1 Overview.................................................................................................1

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

Connecting to Cadex BatteryShop™................................................................................2

Chapter 2 Getting Started.......................................................................................1

Contents of the Box ..........................................................................................................1

Using this Manual .............................................................................................................1

Conventions ......................................................................................................................3

Direction Keys ...............................................................................................................3

Symbols.........................................................................................................................3

Abbreviations and Acronyms.........................................................................................4

Commonly Used Terms.................................................................................................5

Chapter 3

Components......................................................................................................................7

Front LCD Display Interface............................................................................................10

Lights (LEDs)...............................................................................................................12

Menu Structure................................................................................................................13

Battery Adapters .............................................................................................................14

Operating Principles..............................................................................7

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

Chapter 5

Basic Programs...............................................................................................................22

Auto .............................................................................................................................23

Charge.........................................................................................................................24

Prime ...........................................................................................................................25

QuickTest™.................................................................................................................25

Advanced Programs .......................................................................................................27

SelfDCH (Self-Discharge Test) ...................................................................................29

Life-Cycle.....................................................................................................................30

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Battery Service Programs...................................................................22

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Table of Contents

DCHOnly (Discharge Only) ........................................................................................ 31

ExtPrime (Extended Prime) ........................................................................................ 32

OhmTest ..................................................................................................................... 33

RunTime ..................................................................................................................... 34

Boost...........................................................................................................................36

Learn...........................................................................................................................37

Q-Learn (Quick Learn)................................................................................................ 39

Custom 1, 2, 3, and 4 ................................................................................................. 41

Battery Service Times .................................................................................................... 42

Chapter 6 C-codes (Configuration Codes)......................................................... 43

Basic C-code Parameters .............................................................................................. 44

Program ...................................................................................................................... 44

Target Capacity .......................................................................................................... 45

Chemistry.................................................................................................................... 45

Battery Voltage (Volts)................................................................................................ 45

Battery Rating (mAh) .................................................................................................. 46

C-code Setup Name ................................................................................................... 46

Scaled C-code ............................................................................................................ 46

C-code Matrix ............................................................................................................. 47

Locked C-code............................................................................................................ 47

Extended C-code Parameters........................................................................................ 47

Charge Rate (C-Rate)................................................................................................. 47

Discharge Rate (C-rate) ............................................................................................. 48

Trickle-Charge Rate (NiCd and NiMH only) ............................................................... 49

Recondition Discharge Rate (NiCd and NiMH only)................................................... 49

Capacity Offset ........................................................................................................... 49

Temperature Sensing ................................................................................................. 50

Negative Slope (NiCd and NiMH only) ....................................................................... 51

End of Discharge ........................................................................................................ 51

End of Recondition (NiCd and NiMH only) ................................................................. 52

Charge Method (NiCd and NiMH only)....................................................................... 53

Maximum Standby Voltage (SLA and Li-ion only)...................................................... 53

Maximum Charge Voltage (SLA and Li-ion only) ....................................................... 54

End of Charge (SLA and Li-ion only).......................................................................... 54

Default Extended C-code Settings ................................................................................. 55

Default Extended C-code for NiCd Batteries.............................................................. 55

Default Extended C-code for NiMH Batteries............................................................. 56

Default Extended C-code for SLA Batteries ............................................................... 56

Default Extended C-code for Li-ion Batteries ............................................................. 57

Extended C-code Settings for Special Cases ................................................................ 57

Intrinsically Safe Batteries .......................................................................................... 57

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Table of Contents

Hawker SLA Batteries .................................................................................................58

Gell SLA Batteries .......................................................................................................58

Managing C-codes..........................................................................................................58

Select a C-code...........................................................................................................58

Display a C-code .........................................................................................................59

Change Target Capacity or Program ..........................................................................59

Create or Edit a C-code...............................................................................................59

Add or Edit the C-code Setup Name...........................................................................61

Reset Extended C-code to the Default settings ..........................................................62

Delete a C-code ..........................................................................................................62

Copy a C-code (including QuickTestTM matrix) ............................................................63

Copy all C-codes (and matrices) from One Adapter to Another .................................63

Chapter 7

Date and Time.................................................................................................................65

Company Name ..............................................................................................................66

Sound Options ................................................................................................................66

Voltage Display ...............................................................................................................68

Battery Service Counter..................................................................................................69

System Setup And Options ................................................................65

Connecting to BatteryShopTM or a Printer.......................................................................70

Connecting to BatteryShopTM.......................................................................................70

Connecting Devices to the Serial Port ........................................................................71

Connecting Printers to the Parallel Port (C7400 and C7400ER only) ........................74

Security ...........................................................................................................................75

Security Level Functions .............................................................................................75

Program Parameters.......................................................................................................77

Starting Battery Service...............................................................................................78

Performing an Automatic OhmTest.............................................................................79

Optimizing Charge Time or Capacity ..........................................................................80

Termination Condition on dT/dt...................................................................................80

Saving Program and Target Capacity Settings...........................................................81

Resuming Service After Power Failure .......................................................................82

Short Key Functions ....................................................................................................84

Chapter 8 Reports and Labels .............................................................................85

Automatically Print Reports or Labels.............................................................................88

Automatic Report or Label printing..............................................................................88

Print Reports and Labels ................................................................................................89

Chapter 9

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Events and Data Logs .........................................................................92

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Table of Contents

Logging Events............................................................................................................... 92

Setting up the Event Log ............................................................................................ 92

Using the Event Log ................................................................................................... 93

Logging Data .................................................................................................................. 95

Sample text strings ..................................................................................................... 98

Setting up the Data Log.............................................................................................. 99

Using the Data Log................................................................................................... 101

Chapter 10 Custom Programs ........................................................................... 104

Cycle 1 and Cycle 2 ..................................................................................................... 105

Test............................................................................................................................... 106

IF Statements ........................................................................................................... 107

THEN and ELSE Statements ................................................................................... 108

Phase Done.................................................................................................................. 109

Creating and Editing Custom Programs....................................................................... 109

Sample Custom Program ......................................................................................... 111

Chapter 11 Services and Upgrades................................................................... 114

Replacing the Primary (Input) Fuse ............................................................................. 114

Replacing the Backup Battery...................................................................................... 115

Replacing the Station Fuses ........................................................................................ 119

Upgrading the Firmware............................................................................................... 120

Resetting the System ................................................................................................... 120

Cleaning the Analyzer .................................................................................................. 121

Chapter 12 System Calibration.......................................................................... 122

Calibrating Voltage....................................................................................................... 122

Servicing the Voltage Calibration Adapters.............................................................. 123

Calibrating Adapters..................................................................................................... 123

Adapter Calibration Values....................................................................................... 124

Calibration Values for QuickTestTM........................................................................... 124

Chapter 13

Troubleshooting............................................................................................................ 126

Manual Updates and Other References....................................................................... 130

Solving Problems and Getting Help .............................................. 126

Technical Support ........................................................................................................ 131

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Table of Contents

Appendix A Messages and Warnings ...............................................................132

Non-Coded Messages ..................................................................................................133

By Code ........................................................................................................................134

By Detailed Message ....................................................................................................137

Appendix B

NiCd and NIMH batteries ..............................................................................................156

SLA and Li-ion batteries................................................................................................158

Charge Algorithms.........................................................................156

Appendix C Specifications.................................................................................160

Hardware.......................................................................................................................160

Appendix D Parts and Accessories...................................................................162

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Chapter 1 Overview

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

Product Features

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

• Programmable with a total of 17 programs including:

o Four basic programs: Auto; Charge; Prime and Quicktest™. o Nine advanced programs o Four user-programmable programs.

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

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

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

• Prints battery service reports and battery service labels.

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

software.

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

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Overview

Connecting to Cadex BatteryShop™

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

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

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

To find out how Cadex BatteryShop™ can enhance your battery maintenance system, contact Cadex Electronics Inc (see Connecting to BatteryShop™, page 70).

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Page 17

Chapter 2 Getting Started

Contents of the Box

The Cadex Battery Analyzer package includes these items:

• One Cadex Battery Analyzer

• One IEC320 Power Cord (North American Version)

• One User’s Manual

Using this Manual

The Cadex C7000 Series Battery Analyzer User’s Manual contains the concepts, procedures and other information necessary to operate the Cadex battery analyzer equipped with firmware version 6.11 (see Firmware, page 120). If you do not have version 6.11, contact Cadex to obtain the upgraded version.)

Chapter 1 - Overview provides basic information about product features and connecting the Cadex analyzer to a computer.

Chapter 2 - Getting Started goes through the items that are included with the analyzer and how the manual works. It also explains common symbols, abbreviations, acronyms and commonly used terms.

Chapter 3 - Operating Principles provides information about the Cadex analyzer,

Upgrading the

components, display screen, interface and how to use battery adapters with the analyzer.

Cadex C7000 Series Battery Analyzer 1

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Getting Started

Chapter 4 - Basic Battery Service provides the basic procedures for servicing a battery.

Chapter 5 – Battery Service Programs provides detailed information about all the battery service programs.

Chapter 6 -C-codes (Configuration Codes) provides detailed information on selecting and managing battery parameters (C-Codes).

Chapter 7 - System Setup and Options describes the analyzer’s menu system and provides information about modifying the operation of the analyzer to suit your needs. Refer to this chapter when connecting devices to the analyzer (i.e. printers or a PC with BatteryShop™ software).

Chapter 8 - Reports and Labels provides information about printing battery service reports and labels.

Chapter 9 - Events and Data Logs describes methods of obtaining and graphing detailed voltage/current/temperature/impedance analysis.

Chapter 10 - Custom Programs describes how to create user-defined programs for specialized or advanced applications.

Chapter 11 - Services and Upgrades provides information on servicing the Cadex analyzer, including upgrading the firmware.

Chapter 12 - System Calibration provides instructions for calibrating the analyzer.

Chapter 13 - Solving Problems and Getting Help provides solutions for common problems that may occur when operating the analyzer.

Appendix A - Messages and Warnings provides detailed information on fault codes and messages that appear on the display.

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Page 19

Getting Started

Conventions

Typeface Meaning

SMALL CAPS

BOLD SMALL CAPS Names of keys on the battery analyzer

Bold & Italic

Direction Keys

Symbols

Italics

Menu options to select

Default settings LCD display text

Emphasized words

References to other sections in this manual

Direction keys are represented in this manual as follows:

UP = 

DOWN = 

LEFT = 

RIGHT = 

Caution

Information that, if ignored, can result in damage to the Battery Analyzer, battery adapters or the battery.

Potential shock hazard.

Potential explosion hazard.

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Getting Started

Abbreviations and Acronyms

Abbreviation Name or Term

16k adapters These adapters have the extra memory to handle

matrices for QuickTest™. These adapters are marked “16K” on the rear label.

AWG American wire gauge (a U.S. wire size standard)

LCD Liquid Crystal Display (also called display)

LED Light Emitting Diode (also called light)

Li Lithium-ion and Lithium-polymer battery chemistry

Li-ion Lithium-ion battery chemistry

Li-polymer Lithium-polymer battery chemistry. This chemistry is

treated in the same way as Li-ion.

mA Milli-ampere

mAh Milli-ampere hour

mOhm Milli-ohm

NiCd Nickel-cadmium battery chemistry

NiMH Nickel-metal-hydride battery chemistry

OEM Original equipment manufacturer

PC IBM compatible personal computer

RF Radio frequency

P/N Part number

SoC State of Charge

SoH State of Health

SLA Sealed lead acid battery chemistry

USB Universal Serial Bus

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Getting Started

Commonly Used Terms

Term Explanation

Milliampere Hour

(mAh)

Battery A combination of cells.

Capacity The amount of energy that a fully charged battery is

Configuration

Code (C-code)

Cells Individual items within the battery.

Cycle One charge and discharge sequence, even if the battery

C-Rate A “C” number is a value that is used to calculate charge

Battery capacity or rating. A battery that provides a current of 1000 milliamperes for 1 hour is rated at 1000mAh (or 1Ah).

capable of holding.

Battery parameters stored in battery adapters that tell the Cadex analyzer how to service a specific battery type (see Chapter 6 - C-codes (Configuration Codes) page 43).

is only partially charged or discharged.

and discharge times.

A battery rated at 1000mAh provides 1000mA for one 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 provide 500mA for two hours.

Battery cycle A charge followed by a discharge (or a discharge

followed by a charge). Even when batteries are partially charged and discharged, a cycle is considered to have occurred.

Intrinsically Safe

(I/S)

Batteries with built-in safety protection circuitry. These batteries are used in volatile environments.

Memory Reversible capacity loss in NiCd and NiMH batteries

caused by an increase in the size of crystals formed within the battery.

Matrix The set of battery parameters for a specific battery

model stored during the Q-Learn or Learn process and used for testing batteries of the same model during

QuickTest

Cadex C7000 Series Battery Analyzers 5

. A matrix is stored with a C-Code.

Page 22

Getting Started

Term Explanation

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

current. Reconditioning helps break down large crystals, which develop as a result of memory, to more desirable small sizes often restoring the battery to its full capacity. Applies to NiCd and NiMH only.

Residual Capacity

Capacity remaining in the battery when it is inserted in an analyzer.

Resistance Also called internal resistance. Opposition to current

flow and dissipation of energy in the form of heat.

Self-Discharge Battery capacity lost during storage because of internal

leakage between the positive and negative cell plates.

Smart Battery Battery equipped with circuits that can communicate

with a charger.

State of Charge The current energy content of a battery.

State of Health The battery condition that takes into account its

capacity, resistance and self-discharge.

Target Capacity The capacity level (in percentage of manufacturer-stated

battery capacity) that a battery must display to pass a test of battery capacity. The target capacity is an arbitrary benchmark set by the user. By default it is set to 80% but it can be changed.

Trickle Charge Maintenance charge to compensate for battery self-

discharge.

User Interface The front panel of the analyzer that provides information

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about the status of the analyzer and any batteries being serviced: It consists of the LCD display, the LED indicators and the input keys.

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Chapter 3 Operating Principles

Components

Figure 1: Top and front panel of C7400 & C7400ER battery analyzer

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Figure 2: Top and front panel of Cadex C7200 Battery Analyzer

Component Function

Battery stations Slots where the battery adapter is inserted. The C7400 and

C7400ER has four, the C7200 has two.

Station keys Displays C-codes or details of a service. The C7200 has two,

the C7400 and C7400ER has four

PRINT key Prints labels and reports.

EDIT

key Edits the C-Code (battery parameters)

ESC key Used to exit menus, cancel changes, clear detailed displays.

FN key Provides shortcuts to common functions or special features.

ALT key Provides access to special services.

ENTER

key To save settings, start battery service and enter sub-menus.

key To access a list of options to set up the analyzer.

Numeric keypad To enter passwords or numeric values in a C-Code..

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Component Function

Direction keys Navigate menus, move between fields, select values, view

service details.

LED indicators

View current status of batteries in service (activated when a service starts).

Ready (Green): Service complete and/or battery has passed. Fail (Red): Battery service has failed or there is a fault. Run (Yellow): Service in progress.

LCD display 2x40 character screen to display information on each station

and its details, to view Menu items.

Figure 3: Rear panel of Cadex battery analyzer

Component Function

On/Off Power

To turn the analyzer On and Off.

switch

IEC 320 AC

input

Connect the unit to an AC electrical power source with the IEC 320 power cord (North American version supplied).

Parallel port Not available on the C7200 analyzer.

Connects the unit to a printer or label printer.

RS232 serial

port (9-pin)

Connects a serial printer or label printer. To connect to the serial port of a computer to upgrade the firmware, to use

BatteryShop

or to monitor data.

USB port Not available on the C7200 battery analyzer.

Not functional with current product firmware.

Cadex C7000 Series Battery Analyzers 9

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Component Function

Cooling fan Operates continuously to keep the interior of the analyzer at

an optimum working temperature.

Do not restrict the airflow of the analyzer. Leave the fan opening clear. Fan operation is automatic.

Primary input

fuse

Protects the unit from internal short circuits. Can be replaced (see Replacing the Primary (Input) Fuse, page 114).

Front LCD Display Interface

The LCD display has 2 rows with 40 characters on each row. It has three main states:

• The

Global Display

shows the general status of all four stations (or two stations for the C7200) and any batteries being serviced. This is the default view for the C7400 and C7400ER.

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Page 27

This is the default view for the C7200.

• The Detailed Display provides detailed data about one battery service or station when the appropriate station key is pressed. For example, during a service in

Station 2, a display similar to this sample appears when you press

Note Press  or  to display additional details such as warning codes,

cycles, and program phases.

• The

Menu Display

the

provides access to various functions of the analyzer when

key is pressed (see Menu Structure, page 13).

Cadex C7000 Series Battery Analyzers 11

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ENU

Press the M

key and select menu functions by pressing  or  to scroll through the menu and pressing E For example, this message shows one option in the System Security menu:

Lights (LEDs)

RUN (yellow) On Service in progress.

READY (green) On Service has completed; Battery has passed

FAIL (red) On Battery failed.

NTER when the desired function is displayed.

Light Status Explanation

the service.

Flashing Cold battery. Service resumes when battery

warms up (code 12).

Flashing Hot battery. Service resumes when battery

All Flashing

12 Cadex Electronics Inc.

randomly

cools (code 13).

System failed. Turn the analyzer off and then on. Contact Cadex if the condition persists.

Page 29

Menu Structure

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

System

Security

System

Setup

Program

Settings

Option

Controls

Print Utilities

ENTER

Set Security Change Pass word

Date/Time Serial Port Device Serial Port Settings Parallel Port Device Power Fail Resume Hours Calibrate Adapter Calibrate Voltage

Cus tom Pr ograms Self Discharge Rest LifeCycle Counter Ohmtest Setpoints Automatic Ohmtest Runtime Settings Char ge Optimization dT/dt Termination

Company Name Battery Startup Program/T arget Changes Sound Control Sound Check Voltage Display QuickTest Results Set Service Counter Clear Service Counter

Battery Service Report Battery Label System Setup Report Adapter Setup Report Auto-Print

Figure 4: Menu hierarchy of the Cadex Analyzer

Cadex C7000 Series Battery Analyzers 13

Event Log View Event Log

DOWN key UP key

ENTER

Print Event Log Clear Event Log Events to Log

T, S to scroll,

ENTER to select, ESC to exit.

Page 30

Battery Adapters

Adapters are designed to fit specific battery types and shapes. The snap-lock latch allows easy insertion and removal. There are two types of battery adapters:

Custom Adapters

•

1000 custom adapters available.

Universal Adapters are used when a custom adapter is not available. Pins or

•

alligator clips attach to the positive and negative terminals and include a magnetic temperature sensor.

accommodate a specific battery shape. There are over

Figure 5: Different types of battery adapters

ADAPTER HANDLING PRECAUTIONS

Do not touch the adapter’s gold contacts at the rear or on

•

the analyzer station adapter connector. The static charge can damage microcircuits on the adapter.

Do not remove the adapter from the analyzer while it is

•

servicing a battery. Remove the battery first and then the adapter.

ESD HANDLING PRECAUTIONS: When the adapter is NOT

•

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installed in analyzer:

The battery should not be connected to the

adapter

Do not allow anything to touch the gold

fingers on the adapter connector card

Do not allow anything to touch the adapter

connector in the analyzer's adapter well

Each adapter contains up to ten battery service parameters called Configuration Codes (or C-codes) in non-volatile memory. C-codes will not be lost when adapters are removed and reinserted into any station on the analyzer or when the analyzer is turned off.

Custom adapters are pre-programmed with C-codes for the most common batteries. If a battery C-code is not available, you can program a new C-code or reprogram an existing C-code into the analyzer.

Universal adapters, designed for generic batteries, are programmed with blank Ccodes and will display N

ULL CODE when inserted (see

Create or Edit a C-code

, page 59). Battery adapters can be installed, removed or reprogrammed while other stations are being used. Once the adapter is inserted, the battery station receiving the adapter automatically uses the last selected C-code.

Cadex continuously designs and manufactures adapters for new battery models. A list of current battery adapter models is available in the adapter catalog available inj print or on the Cadex website. Contact Cadex for a current adapter catalog or download a copy from our web site at www.cadex.com. Cadex also designs custom adapters for a wide variety of applications. A Battery Adapter Design Form

can be

downloaded from the Cadex website and used to order a custom adapter.

To insert an adapter

1. Place the empty battery adapter into the battery adapter station, putting the front end in place first.

Cadex C7000 Series Battery Analyzers 15

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2. Press down on the back panel (with the label) until the adapter snaps in place.

The LCD display for the station changes from

NO ADAPT to EMPTY, indicating that

the battery adapter has been inserted but does not contain a battery. The second line of the display indicates the program that was selected in the C-code. If the adapter displays N

ULL CODE, the C-code has not been programmed, (see

Create

or Edit a C-code, page 59).

OBSERVE POLARITY!

Do not connect the Universal adapter to the battery with the leads reversed or insert the battery into the adapter in reverse.

To remove an adapter

1. Remove the battery from the adapter first.

2. Press the latch bar behind the label on the adapter and lift the adapter upwards.

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Chapter 4 Basic Battery Service

This chapter covers the basic procedures for servicing a battery including: turning on the unit; inserting the battery adapter; selecting the correct C-code and program; inserting the battery; confirming the setting; starting service and recording the results.

To service a battery

1. Turn the power on using the ON/OFF power switch on the rear panel. A boot-up screen appears for 5 seconds: It displays the firmware version on the bottom left (in this case, it is V6.00) and the security level (in this case, it has not been set). This screen can also be cleared after 5 seconds by pressing the

ESC key.

2. Insert the battery adapter into a station by sliding the lower-front part of the adapter into the station towards the display. Press the back end down to close with a click. If adapters are inserted in Stations 1 and 4, a display like this appears:

Cadex C7000 Series Battery Analyzer 17

Page 34

If a Universal adapter is used for the first time, N

ULL CODE

appears on the display. You must create a custom C-code (see Create or Edit a C-code, page 59).

3. Insert a battery into the adapter.

BATTERY CONTACTS MUST BE CLEAN BEFORE INSERTING THE BATTERY.

Dirty contacts can increase the resistance in the connection between the adapter and the battery, causing false voltage and current readings and in extreme cases, melting of the contacts. To clean the battery contacts, use a lint-free cotton swab dipped in 100% isopropyl alcohol.

The following message appears when the battery is detected:

Note

You can set up the Cadex analyzer not to display this

message and start service (see Starting Battery Service, page 78).

If the display continues to display an Empty message, this means that the Cadex analyzer is not recognizing the battery. There are a number of reasons this may happen:

Battery is not inserted correctly.

•

Verify that the battery is correctly and firmly inserted into the adapter. Make sure that the contacts on the battery connect with the contacts on the adapter and check for any switches on the battery.

Battery is completely discharged or protection circuits are

•

open. Run the Boost program by pressing the station key and holding it for two seconds (see Boost, page 36).

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4. Press

ENTER

to display the C-codes (see Chapter 6 - C-codes

(Configuration Codes), page 43).

5. If the active C-code (indicated by “*”) is the correct one for the battery you are servicing and all settings in the C-code are correct, go to step 8 to start service otherwise continue to the next step.

6. Select another C-code.

a) Press  or  to scroll through the C-codes in the adapter.

b) Press

ENTER when the correct C-code is displayed. Press ENTER

again to confirm the changes. The selected C-code is now active, and is indicated by “*”.

If you want to change any of the settings in the C-code, you should do it now (see Create or Edit a C-code, page 59).

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

7. If the C-Code is correct, press

8. Press

ENTER again to start the battery service. The yellow (run) light

ENTER to confirm the settings.

appears.

Once the service starts, the display will show the current program status as in the following diagram. For detailed information about messages that appear, (see Appendix A - Messages and Warnings, page 132).

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Page 36

Depending on the battery chemistry and the program selected, service may take anywhere from a few seconds to a few hours. Some programs can take several days or weeks.

If the battery passes after service has completed, the green Ready light comes on. If a battery failed, the red Fail light appears with a Fail code (see Appendix A - Messages and Warnings, page 132):

9. To display details about an ongoing or completed battery service:

a) Press the station key to see the detailed display:

b) Press  to see any applicable warning codes:

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For more information about message codes, including reasons for battery failure and possible solutions (see Appendix A, Messages and Warnings, page 132).

c) Press  to see additional information:

REMOVING LARGE BATTERIES WHILE IN SERVICE

It is NOT recommended to remove very large batteries while it is in service. Large batteries may create arcs that may degrade the performance of the analyzer. If it is necessary, follow these instructions:

Press and release the Alt key and the station key holding the battery. On the screen that appears, press  to select ‘Interrupt’ and press Enter. Remove the battery within 5 seconds.

Cadex C7000 Series Battery Analyzers 21

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Chapter 5 Battery Service Programs

The Cadex analyzer comes with four basic programs, nine advanced programs and four custom programs. These programs measure the battery state of health (SoH), the battery’s capacity and find any anomalies that may affect battery performance. If the battery passes the Auto, Prime or Charge service programs, the battery can stay on the charger and stay fully charged until it is used. If the battery fails, the program terminates with the appropriate fault code.

Basic Programs

The basic programs are Auto, Charge, Prime, and QuickTest™ (for 16K battery adapters only). These programs cannot be edited. Each program performs functions for different purposes:

Program Does this Is used for this

Auto

Charge Applies fast charge only.

Exercises batteries to maintain optimum performance. If the Target Capacity cannot be reached, the battery is reconditioned.

No capacity readings are taken and no discharge is applied.

• Restoring batteries affected by “memory”.

• Performing routine battery maintenance.

• Identifying marginally performing batteries.

• Servicing batteries in unknown condition.

• Verifying battery condition for warranty claim.

• Charging batteries quickly.

• Topping up partially discharged

batteries.

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Program Does this Is used for this

Prime

Repeatedly cycles battery until maximum capacity is

• Preparing new batteries for field use.

reached. If capacity improvement is more than 5% over previous reading,

• Conditioning batteries that have been in storage.

an additional cycle is applied.

QuickTest™ Tests battery SoH by

comparing battery data to

Gives an estimate of battery

•

SoH to help sort batteries.

data from other batteries of the same model stored in the QuickTest™ matrix in the C-code.

• 16K battery adapters only (adapters are identified with a “16K” sticker on the back)

• A matrix is required to run this program (see Q-Learn

Procedure

, page 41).

Auto

Function:

Exercises batteries to maintain optimum performance. This is the recommended program for routine maintenance of batteries. It reconditions NiCd and NiMH batteries that do not reach Target Capacity. Li-ion and SLA batteries are not reconditioned, only exercised. Batteries in use are typically cycled every three months on Auto. If batteries are failing prematurely, increase the frequency of service on the Auto program.

Sequence: The battery is first cycled (charged and then discharged) to determine it’s true capacity. If NiCd and NiMH batteries do not meet the target capacity at the end of the discharge cycle, they are reconditioned to reduce battery memory. Following recondition, the battery is cycled again to determine the recovered or final capacity. The battery is fully charged when the program completes.

SLA and Li-ion batteries are cycled once. If the target capacity is not reached in the first cycle, it is cycled again. Recondition is not performed for Li-ion and SLA batteries.

Cadex C7000 Series Battery Analyzers 23

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Results:

Global display shows battery capacity as a percentage of manufacturers stated capacity for the battery model. Detailed display shows average battery or cell voltage, analyzer charge or discharge current in mA, OhmTest results, battery temperature (if applicable), and duration of service

Batteries in good condition should be greater than the target capacity (by default this is 80%). If batteries fail, check the fault codes for details.

Duration: Approximately 2.5 to 10 hours for NiCd and NiMH, 20 to 40 hours for SLA and 6 to 20 hours for Li-ion using default C-codes.

Charge

Function: Fast charge a battery.

Sequence: A charge cycle is applied to the battery. No capacity readings are

taken (capacity is only obtained if there is a discharge). Because Charge does not perform a full analysis, bad batteries may not be caught and can affect a mission critical application. Use the Auto or Prime program to fully diagnose a battery.

Results: The global display alternates between current average battery, cell voltage and analyzer charge or discharge current (mA) during service and after service. Detailed display also shows OhmTest results, battery temperature (if applicable) and duration of service.

Look for the green Ready LED. It indicates that the battery has been charged. There is no capacity reading taken during a charge. To diagnose faulty batteries the user is required to run Prime, Auto, etc.

Duration: Approximately 1.5 hours for NiCd and NiMH, 10 hours for SLA, and 4 hours for Li-ion using default C-codes.

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Prime

Function: Prepares new or stored batteries for use. A new or stored battery may

require several charge/discharge cycles to form the cells to achieve peak performance.

Sequence:

The program cycles (discharges and charges) the battery until the difference between capacities from one cycle to the next is less than 5%. Up to four cycles are applied until the 5% capacity difference is reached. This allows for batteries that cannot accept a full charge on the first cycle. If the battery is fully discharged, the program starts with a charge. No reconditioning is applied. Some batteries may require several Prime cycles to fully form the cells.

Results: Global display shows final battery capacity percentage. Detailed display shows battery capacity percentages for the last three cycles performed as well as average battery or cell voltage, analyzer charge or discharge current in mA, OhmTest results, battery temperature (if applicable) and duration of service.

Batteries in good condition should be greater than 80% or your target capacity. If batteries fail, check the fault codes for details. If the capacity is low, the battery should be Primed again. In some cases, two or three Prime programs may be required to fully form a battery.

Duration:

Approximately 5 to 10 hours for NiCd and NiMH, from 40 to 80 hours

for SLA, from 12 to 25 hours for Li-ion using default C-codes.

QuickTest™

This firmware (version 6.11) will not display or use a matrix made with firmware version 5.00 or below. Therefore, you will have to run the Learn program again to create a new matrix. Any old matrix will not be displayed if the adapter is used in version 6.11.

Ensure that battery contacts and adapter contacts are clean. Dirty contacts will affect QuickTestTM readings.

Note: QuickTest is available only when you are using 16k battery adapters.

These adapters are marked ‘16K’ on the rear of the adapter.

Cadex C7000 Series Battery Analyzers 25

Page 42

Function:

Before running QuickTest

Learn program (see Learn, page 37). QuickTest

, create a matrix for the battery using the

determines the battery SoH (state of health) that is an approximation of the battery capacity and resistance. If a matrix does not exist for the C-code, (i.e. no batteries of the same model have gone through the Q-Learn or Learn programs) a message appears stating that no

QuickTest first. QuickTest

matrix has been found, and that the Learn program should be run

can still run without a matrix but results are unreliable.

Sequence: The battery is tested to ensure that it has 20% - 90% State of Charge. If not, it applies a charge or discharge for five minutes. The program then performs a sequence of resistance tests, partial charges, discharges and rest. Test results are compared to the matrix to determine the battery state of health.

Results: The Global and detailed display shows the battery condition as “Excellent”, “Good”, “Marginal” or “Poor”. Detailed display also shows average battery or cell voltage, analyzer charge or discharge current in mA, OhmTest results, battery temperature (if applicable) and duration of service.

Duration:

Approximately 5 minutes if the battery SoC (state of charge) is between 20% and 90%. Batteries with a lower or higher SoC require additional time to bring their SoC to between 20% and 90%. For most batteries, this takes about 5 minutes. However, with high-capacity batteries, it may take longer.

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Advanced Programs

Advanced programs include OhmTest; RunTime; Self-Discharge; Life-Cycling; Discharge Only; Extended Prime; QuickLearn (Q-Learn); Learn; Boost and the four programmable custom programs. Unlike basic programs, some advanced programs have settings that can be edited.

Program Does this Is used for this

Self-

Discharge

Reads fully charged battery capacity; recharges and reads the capacity after a programmable wait period.

Life-Cycle This is a destructive test

that continuously cycles a battery until it fails.

Continuously cycles battery until capacity drops below target capacity. Displays initial and final capacity, OhmTest result.

Discharge

Only

Discharges a battery to its end-of-discharge voltage.

(DCHOnly)

• Identifying batteries that may have good capacity but have high self-discharge.

• Verifying battery life cycle. For example, is for use with a single battery to determine the Life Cycle of an entire batch of batteries.

• To verify the life of a new constructed cell.

• Estimating performance time.

Determining residual capacity

•

of battery.

• Preparing batteries for storage.

• Determining battery

performance under load.

Extended

Prime

Applies a 16-hour trickle charge, followed by cycling to obtain peak capacity.

OhmTest Tests internal resistance.

Passes or fails the battery based on the target resistance.

Cadex C7000 Series Battery Analyzers 27

• Preparing new batteries or batteries that have been in extended storage for use.

Checking battery condition.

•

• Determining if the battery

needs to be analyzed further.

Page 44

Program Does this Is used for this

RunTime Simulates a 5/5/90 discharge.

Programmable time and discharge rates per phase.

Boost

Applies a 100mA trickle charge for 3 minutes.

Quick

Learn

(Q-Learn)

This program assumes that a battery has 100% capacity. It profiles the battery and saves the data to the QuickTest™ matrix in the C-code.

Learn Applies a charge-discharge-

charge cycle to determine battery capacity, profiles the battery, saves the data to the QuickTest™ matrix in the Ccode.

• Testing battery runtime for communications equipment.

• Reactivating batteries that are not recognized by the Cadex analyzer because of low voltage or an open protection circuit.

• Rapidly establishing an accurate QuickTest™ matrix based on the SoH of a new battery that is known to be good.

• 16K battery adapters only. (16K adapters have an identifying sticker on the back.)

• Establishing or modifying QuickTest™ matrix using a spectrum of batteries with various SoH.

• Increasing QuickTest™ accuracy (confidence grade) for a given battery type.

Custom

1,2,3,4

Allows the user to create specific programs (see Chapter 10 - Custom Programs, page 104).

28 Cadex Electronics Inc.

• 16K battery adapters only. (16K adapters have an identifying sticker on the back.)

Accommodates specialized

•

requirements.

Page 45

SelfDCH (Self-Discharge Test)

Function: Identifies the self-discharge or the amount of charge a battery loses if it

is left alone for a period of time. The standard time is 24 hours.

Sequence: The battery is charged and discharged to obtain its first capacity. The battery is then charged and left for a 24-hour rest period (instructions to change this time are given below). During this time, the battery loses energy through selfdischarge. After 24 hours, the battery is discharged to determine the second capacity. The difference between the second and first capacity is the selfdischarge.

Results: Press the station key to view the detailed display then press  to view the self-discharge rate (given as a percentage). A battery with low self-discharge has less than 15% self-discharge. A battery that has more than 15% selfdischarge may have soft cells and may not be able to provide the required usetime.

Global display shows battery capacity percentage. Detailed display shows battery capacity percentages for the last three cycles performed. It also displays average battery or cell voltage; analyzer charge or discharge; current in mA; OhmTest results; battery temperature and duration of service.

Duration: Approximately 30 hours for a NiCd battery using default C-codes.

To change the Self-Discharge time

1. From the global display, press

2. Press  or  to scroll to

3. Press  or  to scroll to

PROGRAM SETTINGS, then press ENTER.

SELF DISCHARGE REST, then press ENTER.

4. Press  or  or use the number pad to select the self-discharge period.

Cadex C7000 Series Battery Analyzers 29

Page 46

5. Press

6. Press  or  to scroll to

7. Press

ENTER

ESC twice to return to the global display.

YES

to accept changes and press

ENTER

Life-Cycle

This is a “destructive” test that continuously cycles a battery until it fails. Do not run this program on a battery you need to use.

Function: Determines total battery life by the number of cycles. Checks whether

the battery meets the standard life for its chemistry. This is an accelerated aging test and the battery cannot be renewed after this test.

Sequence:

The battery is charged and discharged continuously until the battery

fails (i.e. battery capacity falls below target capacity) or the maximum number of cycles has been reached.

Results: Global display shows failure-warning message. Detailed display shows percentage capacity for the first cycle and the last three cycles run. It also displays: average battery or cell voltage; analyzer charge or discharge current (shown in mA); OhmTest results; battery temperature and duration of service.

An additional display screen (press  from detailed display) shows cycle number, percentage of battery capacity achieved and OhmTest results for the first and last cycles run.

Look for the number of cycles (a cycle is a charge followed by a discharge). Batteries should provide the number of cycles as specified by the manufacturer. Typically, with a target capacity of 80%, NiCd batteries should provide about 1500 cycles, NiMH 500 cycles, Li-ion 500 cycles, and SLA 300 cycles.

Duration:

Approximately one month or more depending on the chemistry.

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To edit the Life Cycle Test settings

The program uses the target capacity set in the C-code to determine when the program should end (see Target Capacity, page 45). To terminate the program after a certain number of cycles, do the following:

1. From the global display, press

2. Press  or  to scroll to

3. Press  or  to scroll to

MENU.

PROGRAM SETTINGS, then press ENTER.

LIFECYCLE COUNTER, then press ENTER.

4. Press  or  or use the number pad to select the number of cycles.

5. Press press

6. Press

ENTER

ESC twice to return to the global display.

. Press  or  scroll to

YES

to accept changes and

DCHOnly (Discharge Only)

Function: The DCHOnly program determines the residual capacity of a battery,

prepares batteries for storage and checks battery performance under load.

To determine battery capacity, fully charge the battery using the Charge program before running the Discharge only program.

Sequence: The battery is discharged until its voltage reaches the

DISCHARGE

Results:

setting in the C-code.

Detailed display shows battery capacity as a percentage of

END OF

manufacturer’s stated capacity for the battery model. It also shows average battery or cell voltage; analyzer charge or discharge current (in mA); battery temperature and duration of service. Look for the green ready LED. The battery capacity is measured during a discharge and if the battery is partially discharged, the capacity may be lower than the target capacity. This may give a Fail Code 115 or 116. The battery is not necessarily poor.

Cadex C7000 Series Battery Analyzers 31

Page 48

Duration:

Approximately 1 hour for a NiCd battery discharged at default C-code

settings.

To edit the Discharge Only settings

The Discharge Only test settings cannot be edited. However, the program uses the

END OF DISCHARGE setting in the C-code (see End of Discharge, page 51).

Smart batteries (often used in laptops) should not be stored in a fully discharged state.

If the battery’s voltage drops below the level required by the processor within the battery, information can be lost. In some cases, this data loss can leave the battery permanently unusable.

ExtPrime (Extended Prime)

Function: Exercises a battery that has been in storage or unused for a long time

(typically three months or more).

Sequence: The battery is charged for 16 hours on the

TRICKLE CHARGE setting in the

C-code. The battery is then continually cycled (charged and discharged) up to five times until the difference between the capacities achieved from one cycle to the next is less than 5%.

Results:

Global display shows final battery capacity percentage. Detailed display shows battery capacity percentages for the last three cycles performed. It also shows average battery or cell voltage; analyzer charge or discharge current (in mA); OhmTest results; battery temperature and duration of service.

Duration: Approximately 24 hours for a NiCd battery charged and discharged at

1.00 C.

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OhmTest

This OhmTest program uses a method similar to the IEC “DC” method to determine the battery resistance. The results tend to be higher than analyzers with firmware version 5.00 and below. Therefore, the OhmTest results cannot be compared with results from analyzers with older firmware versions.

Ensure that battery contacts and adapter contacts are clean. Dirty contacts will affect OhmTest readings.

Ensure battery has a high state of charge (SoC). If battery SoC is less than 50%, OhmTest readings become less consistent.

Calibrate the adapter before performing an OhmTest.

Function: This program is similar to the IEC “DC” method of resistance

measurement. It is recommended to have the battery with a high state of charge (i.e. fully charged) to provide values. Low state of charge may produce poor or low values. The OhmTest program determines the internal resistance of a battery and passes or fails the battery based on the estimate of the battery capability to handle load. Setting an

OHMTEST SETPOINTS. It provides an

OHMTEST SETPOINT is

described below.

Sequence: The program tests battery resistance and compares the result with the analyzer’s

OHMTEST SETPOINTS

for the battery chemistry. If the result is below this

threshold, the program fails the battery.

Results

: Global display shows internal resistance in milliohms (mΩ). Detailed display also shows average cell voltage; analyzer charge or discharge current (in mA); battery temperature and duration of service.

If the value is above the analyzer’s OhmTest setpoint threshold, the battery fails the OhmTest and should be replaced. If the battery passes, run the Auto or Prime program on the battery to determine whether there are other faults.

Compare several good and bad batteries to determine a suitable

SETPOINT

Cadex C7000 Series Battery Analyzers 33

. Some industries use 500milliohms as a pass/fail mark.

OHMTEST

Page 50

Duration

: 15 seconds for all chemistries.

To edit the OhmTest Setpoint

1. From the global display, press

2. Press  or  to scroll to

3. Press  or  to scroll to

4. Press  or  or use the number pad to set the OhmTest setpoint for the first battery chemistry type.

The default setpoint is 1000mΩ but you can choose any setting between 0 and 4000mΩ.

5. Press  or  to move to the next battery chemistry type.

6. Repeat steps 4 and 5 until the OhmTest setpoint for all battery chemistries are set appropriately.

MENU.

PROGRAM SETTINGS and then press ENTER.

OHMTEST SETPOINTS and then press ENTER.

7. Press

ENTER

8. Press  or  to scroll to

9. Press

ESC twice to return to the global display.

YES

to accept changes and press

ENTER

RunTime

Function

: The RunTime program simulates battery run-time by repeatedly running three different loads until the battery reaches the end-of-discharge setting in the C-code. These loads are often called the standby, talk and receive time. You can set the load current (as a percentage of the Discharge Rate) and time (in minutes) for each of the three loads so that the load cycles simulate the equipment in which the battery is used.

34 Cadex Electronics Inc.

Page 51

Sequence: The battery is charged. The program then repeatedly runs three different loads (see instructions below to set these loads) until the battery is fully discharged (i.e. The end-of-discharge setting in the C-code is reached).

Results:

The detailed display shows the battery run-time (hours and minutes). It also shows battery or cell voltage; analyzer charge or discharge current (in mA); OhmTest results; battery temperature and duration of service.

Duration: Approximately 8 – 10 hours for a NiCd battery using default C-codes.

To edit the RunTime settings

1. From the global display, press

2. Press  or  to scroll to

3. Press  or  to scroll to

MENU.

PROGRAM SETTINGS

RUNTIME SETTINGS and then press ENTER.

and then press

ENTER

4. The cursor is at Discharge 1 (the first load).

5. Press  or  or use the number pad to set a load between 1 and 100 for the Discharge %. This is a percentage of the Discharge Rate in the C-Code. The default is 100.

6. Press  to move to Minutes – the time this load is applied. Press  or  or use the number pad to set the time between 1 and 59 minutes. The default is 1.

7. Press  to move to the load setting for the Discharge 2 (second phase). Repeat steps 4 and 5.

8. Press  to move to the load setting for the Discharge 3 (third phase). Repeat steps 4 and 5.

9. Press

10. Press  or  to scroll to

Cadex C7000 Series Battery Analyzers 35

ENTER to save the settings.

YES to accept changes and press ENTER.

Page 52

11. Press

ESC

twice to return to the global display.

Boost

Warning!

The Boost program overrides some of the analyzer’s built-in safety measures to recognize a battery. Do not attempt to Boost a battery if the polarity, chemistry, voltage and capacity (mAh) are not known. You must also ensure that battery polarity is correct before you attempt to run Boost. For this reason, it is NOT recommended to use a Universal Adapter with Boost.

Failure to follow these precautions may result in serious damage to the Cadex unit and/or the battery.

Function:

Reactivates batteries with open or shorted protection circuits or with voltage so low that the Cadex analyzer does not recognize them or gives a ‘Shorted’ (Code 121) message when they are inserted in battery adapters.

Sequence: The battery is trickle-charged for three minutes at 100mA. The Program can be terminated at any time by pressing the Esc key. Look for stable current and voltage readings during the Boost program. If they are intermittent, the battery may be poorly connected, battery protection circuit may be damaged or the battery is inoperable. Normal battery service will start after Boost has reached more than 0.30V/cell on NiCd and NiMH batteries and more than 2.5V for Li-ion batteries. If Boost does not raise the voltage to detectable levels, apply the Boost program again.

Results: If the Boost is successful, the Cadex analyzer recognizes the battery and indicates on the global display that a battery is inserted in the battery adapter.

Duration:

3 minutes (user may repeat if unsuccessful).

To run the Boost program

1. Insert the battery adapter in a battery station.

2. Insert the battery in the battery adapter.

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If the battery needs to be boosted, the global display for the station may show one of two things:

i. It may continue to display the

EMPTY message, indicating that the

Cadex analyzer has not recognized the battery.

ii. It may display a

SHORTED (Code 121) message for the battery.

3. Press the station key and hold until a warning message appears reminding you to check battery polarity (about 2 seconds).

4. If polarity is correct, press

ENTER to continue.

Depending on how your analyzer is set up (see To set user input required by the Cadex analyzer before battery service begins, page 78), you may need to press

ENTER

again to accept the C-code

settings.

The Boost program starts, and

BOOST

appears as the active program.

The program runs about 3 minutes and provides a 100mA charge.

5. Press ESC any time during the Boost to terminate the program.

If the Boost is successful, the global display changes to the active program name to show that the Cadex analyzer now recognizes the battery.

If the Boost is unsuccessful, you can repeat this procedure until it is successful or until you are convinced that the battery cannot be restored.

To edit the Boost settings

The Boost test program has no settings that can be edited. Boost current is fixed at 100mA for three minutes.

Learn

This firmware (version 6.11) will not display or use a matrix that was made in firmware version 5.00 or below. Therefore, you will have to run

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the Learn program again to create a new matrix. Any old matrix will not be displayed if the adapter is used in version 6.11.

Ensure that battery contacts and adapter contacts are clean. Dirty contacts will affect QuickTestTM readings.

Function: Learn creates and stores a modifiable matrix into a C-code for use by

QuickTest

Sequence: The Learn program applies several charges, discharges and OhmTests to obtain a battery profile. The profile contains the battery’s C-code. The C-code is then saved as a matrix used for running the QuickTest

program.

Results:

Detailed display shows three decreasing capacity percentages as well as average cell voltage; analyzer charge or discharge current (in mA); OhmTest results; battery temperature and duration of service. The C-code display screen shows a T in the upper right-hand corner to indicate that a C-code, saved as a

matrix, has been stored for using with the QuickTest

program.

Duration: 4 – 8 hours depending on battery capacity and default C-codes.

Learn Limitations

Learn is available only on 16K battery adapters. ‘16K’ is marked on the rear

•

label of the adapter.

• Only custom adapters should be used. Universal adapters such as the

Universal Alligator Clips Adapter (07-110-0115), the Claw (07-110-0170) and the FlexArm (07-110-0180) are

NOT

recommended. These adapters can

create inaccurate results due to resistance errors.

• Learn and QuickTest

cannot be used with the following batteries:

SLA batteries greater than 2Ah (2000mAh).

Some 1-cell (1.20V) and 2-cell (2.40V) NiCd and NiMH batteries.

o Batteries with resistance above 800mΩ (as measured by OhmTest). It is

advisable to run an OhmTest to determine battery resistance prior to running the Learn program.

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o Batteries that disconnect, reset or give failures while running the Learn

program.

Batteries that cannot accept a charge rate and discharge rate of at least

1.00C. These batteries tend to give errors if they are serviced on the analyzer using the Auto or Prime programs.

Learn Procedure

If you are using a battery that has not been used for two months or more, run the Prime program on the battery prior to running the Learn program.

Calibrate the adapter and ensure that the C-Code for the battery is correct. Take a good battery (over 80% capacity) and run through the Learn program. After the Learn program is complete, take the battery and while it is in the same adapter,

run the QuickTest

program. The final SoH (state of Health) result should be within the range of the actual battery capacity. If not, erase the battery matrix (press F

N and then press 2) and start over. Once successful, test other batteries

with the same capacity, if possible, to ensure that the SoH readings are within an acceptable range.

To create the most effective matrix, repeat the above steps with more batteries. It is recommended to run the Learn program on at least three batteries: one with a capacity above 90%; one with a 70-80% capacity and finally one at 70% capacity. The batteries can be run through the Learn program in any order.

The battery matrix will be erased if anything in the C-code is changed except for the target capacity and the actual program (i.e Auto, Charge, Prime, QuckTest or any of the other programs).

Q-Learn (Quick Learn)

Function: Q-Learn creates and stores a matrix into a C-code for use by

QuickTest

. The Q-Learn program is only run once on a battery. For more

accurate results, running the Learn program is recommended.

Sequence: This program assumes that the battery has 100% capacity. If a battery has lower capacity, it will not make a correct matrix. The program consists

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of a charge and a discharge and the OhmTest. The data obtained from the program profiles the battery’s SoH, saving the battery’s C-code as a matrix.

Results: Detailed display shows the battery’s average cell voltage; analyzer charge or discharge current (in mA); OhmTest results; battery temperature and duration of service. If Q-Learn is successful, the C-code will display a T in the upper right-hand corner to indicate that a QuickTest

matrix has been created.

Duration: Approximately 5 minutes for all batteries with a SoC (state of charge) level between 20% and 90% of battery capacity. Batteries with a SoC level lower than 20% or greater than 90% require additional time to bring their SoC to between 20% and 90%. For most batteries, this takes an additional 5 minutes but in some cases, especially with high-capacity batteries, it may take longer.

Q-Learn Limitations:

• Q-Learn assumes that the battery’s capacity is 100%. If a battery’s capacity is less than 100%, it will give erroneous results.

• Q-Learn should only be used for

one

battery. For more accurate results, run

the Learn program on three different batteries with varying capacities.

• Q-Learn is available only on 16K battery adapters. ‘16K’ is marked on the rear label of the adapter.

• Only custom adapters should be used. Universal adapters such as the Universal Alligator Clips Adapter (07-110-0115), the Claw (07-110-0170) and the FlexArm

(07-110-0180) are NOT recommended. These adapters will

give inaccurate results due to resistance errors.

• Q-Learn and QuickTest

cannot be used with the following batteries:

o SLA batteries greater than 2Ah (2000mAh).

o 1-cell (1.20V) and 2-cell (2.40V) NiCd and NiMH batteries.

Batteries with resistance above 800mΩ (as measured by OhmTest). It is

advisable to run OhmTest on any battery that is run through the Q-Learn program.

Batteries that disconnect, reset or give failures while running the Learn or

Q-Learn programs.

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o Batteries that cannot accept a charge rate and discharge rate of at least

1.00C. These batteries tend to give errors if they are serviced on the analyzer using the Auto or Prime programs.

Q-Learn Procedure

Calibrate the adapter and ensure that the C-Code for the battery is correct. Take several batteries with 100% capacity or over. Confirm the capacity by servicing the batteries on the Prime program. Note the final capacity and resistance readings. Take the battery with the highest capacity greater) and the highest resistance

and run this battery through the Q-Learn

(ensure that it is 100% or

program. After the Q-Learn program is complete, take the same battery in the same adapter and run it through the QuickTest

program. The final SoH (state of

Health) result should be 100%. If the result is less than 100%, erase the battery

matrix (press F

and then press 2) and start over. When a successful result has been obtained (100%), test the other batteries with the same capacity to ensure that the SoH readings are within an acceptable range.

The battery matrix will be erased if anything in the C-code is changed except for the target capacity and the actual program (i.e Auto, Charge, Prime, QuckTest or any of the other programs).

Custom 1, 2, 3, and 4

By default, custom programs are blank when the Cadex analyzer is shipped from the factory (see Chapter 10 - Custom Programs, page 104).

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Battery Service Times

The following table displays the approximate service times at default charge and discharge rates.

NiCd, NiMH SLA Li-ion

Auto

2.5 – 10 hours 20 – 40 hours 6 – 20 hours

Charge 1.5 hours 10 hours 4 hours

Prime

5 – 10 hours 40 – 80 hours 12 – 25 hours

QuickTest™ All chemistries: approximately 5 minutes

OhmTest

15 seconds 15 seconds 15 seconds

Runtime Duration depends on settings

Self-

30 hours 60 hours 50 hours

Discharge

LifeCycle 1500 cycles (NiCd)

500 cycles (NiMH)

Discharge

1 hour 20 hours 4 hours

200 – 500 cycles

1000 cycles

Only

Extended

21 – 26 hours 56 – 96 hours 28 – 41 hours

Prime

Quick Learn All chemistries: 2-5 minutes

Learn All chemistries: 4 – 8 hours

Boost

Custom

1, 2, 3, 4

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All chemistries: 3 minutes

Duration depends on settings

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Chapter 6 C-codes (Configuration Codes)

Battery information such as chemistry, voltage and rating needs to be programmed into the adapter so the analyzer knows how to service A battery. This information is called the C-code. Up to 10 C-Codes can be stored on each adapter. Once a C-Code has been entered, the information is stored permanently in the adapter memory where it can be displayed; selected; created; copied; edited and deleted (see Managing C-codes, page 58). The adapter can be moved between stations*and the C-Code remains within the adapter.

Note A C-code cannot be edited or changed while a battery is serviced.

Custom battery adapters come pre-programmed with the most common battery Ccodes compatible with the adapter. Universal adapters such as 07-110-0115

(Smart Cable) and 07-110-0180 (FlexArm

) are shipped with no C-Codes and will display NULL CODE when inserted into the analyzer. Create a C-code to clear the NULL CODE message (see Managing C-codes, page 58).

Each C-code is divided into three parts:

• Basic C-codes include program; target capacity; chemistry; voltage and

capacity. The C-code setup name, if specified, is displayed on the LCD screen along with basic parameters. If a C-code is locked, scaled or has a matrix, it is indicated on the display by an ‘L’, ‘S’ or ‘T’ respectively. The battery chemistry, voltage and capacity are required in order to start servicing a battery.

• An extended C-code, which consists of charge/discharge C-rate, trickle-

charge rate, recondition settings and other parameters are needed to service

* It is recommended to calibrate battery adapters whenever they are moved from one

analyzer to another (see Calibrating Adapters page 132).

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a battery. The types of parameters depend on the battery chemistry described in the following table. In general, extended parameters can be left at their default settings.

• A matrix contains the battery C-Code information for running the QuickTest program. Running the Learn or Q-Learn program produces the matrix. Matrix information cannot be seen on the analyzer, however, an inverse T in the top right hand corner of the LCD screen, when the Basic C-code is displayed, will indicate that a matrix has been stored. The matrix is deleted if any part of the C-code, apart from the target capacity or program and is changed (i.e. Auto, Charge, Prime, QuickTest

or any of the other programs).

• An adapter can save up to 10 C-Codes. Each C-Code is unique and has the following characteristics:

C-Code # Basic C-Code Extended C-Code Matrix

C1 CC1 EEEE1 MMMMMMM1

C2 CC2 EEEE2 MMMMMMM2

C3 CC3 EEEE3 MMMMMMM3

C4 CC4 EEEE4 MMMMMMM4

C5 CC5 EEEE5 MMMMMMM5

C6 CC6 EEEE6 MMMMMMM6

C7 CC7 EEEE7 MMMMMMM7

C8 CC8 EEEE8 MMMMMMM8

C9 CC9 EEEE9 MMMMMMM9

C10 CC10 EEEE10 MMMMMMM10

Basic C-code Parameters

Basic C-code parameters appear on the first detailed screen whenever a battery adapter is inserted in a station and the station key is pressed.

Program

The Program parameter specifies which of the programs is to be run (see Battery Service Programs, page 22).

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Target Capacity

The target capacity parameter (displayed as T

ARGET

on the analyzer LCD screen) is displayed as a pass/fail mark. Batteries must achieve the target capacity to “pass”. In the Auto program, if a battery capacity is less than the Target Capacity, the battery is reconditioned.

You can set the target capacity anywhere from 50% to 150% of nominal capacity. These values are recommended for most uses:

90% Maintains batteries for critical applications that require maximum

energy reserve and high reliability. Fewer batteries will pass.

80% Recommended (default) setting that 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.

Target capacity is a pass/fail benchmark only. It does not determine the level to which a battery is charged; it only provides an arbitrary point to which to compare actual battery capacity. For example, a battery with a 90% capacity will pass if the target capacity is set at 80% but fail if the target capacity is 100%. The batteries are always fully charged.

Chemistry

The chemistry parameter refers to the battery chemistry. The chemistry is labeled on the battery. The analyzer works with: NiCd (Nickel-cadmium); NiMH (Nickelmetal-hydride); Li-ion (for Lithium-ion and Li-Polymer) and SLA (Sealed Lead Acid). For Lithium Polymer batteries, use Li-ion.

Battery Voltage (Volts)

The Battery Voltage parameter refers to the terminal voltage of the battery. The voltage is often labeled on the battery. On the C7200 and C7400, the maximum voltage is 14.4V for NiCd, NiMH and Li-ion batteries. The maximum voltage is 14V for SLA batteries. The C7200 and C7400 cannot be modified to handle batteries greater than 14.4V. The maximum voltage on the C7400ER is 28.8V for NiCd and

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NiMH batteries and 36V for SLA and Li-ion batteries. The voltage is based on a nominal cell voltage of 1.2V/cell for NiCd and NiMH batteries, 2V/cell for SLA batteries, and 3.6V/cell for Li-ion batteries.

On some NiCd and NiMH batteries, manufacturers may rate the voltage based on

1.25V/cell rather than 1.2V/cell. For example, the batteries may have a stated voltage of 7.5V or 12.5V. To obtain the correct voltage, multiply this voltage by

0.96. These voltages are definitions only (in fact, battery voltage varies depending on the state of charge) and do not affect test results. You can also set the Cadex analyzer to display voltage as either 1.2V/cell or 1.25V/cell (see Voltage Display, page 68).

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.

Battery Rating (mAh)

The battery rating parameter is the nominal capacity or the capacity specified by the manufacturer. These are also indicated on the battery or may be obtained from the manufacturer.

Available settings: 100 – 24,975mAh in increments of 25mAh.

If a battery rating is provided in Watt-Hours (Wh), divide it by the battery voltage to obtain the mAh rating. For example, a 5Wh battery is 0.7Ah (700mAh).

C-code Setup Name

The C-code setup name might be the battery model number or some other name

LT-EDIT

that helps users identify the C-code or the battery it defines. Use access the C-code name and F

-0 to clear the text.

Scaled C-code

Due to the power limitations on the analyzer, if a C-code requires a higher charge or discharge rate than the analyzer is capable of, it automatically scales the C-

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code. An inverse S on the top-right hand corner of LCD screen when the basic Ccode is displayed will indicate a scaled C-code.

C-code Matrix

When a C-code matrix has been stored to perform a QuickTest the top-right-hand corner of the LCD screen will display along with the basic Ccode.

Locked C-code

Cadex locks some C-codes at the request of the battery manufacturer. An inverse L on the top-right hand corner of the basic C-code display indicates a locked Ccode. These C-codes cannot be edited but they can be deleted.

, an inverse T in

Extended C-code Parameters

In general, extended C-Code parameters can be left on their default settings. If, however, you are creating or editing C-codes for Smart Cable Adapters or certain types of batteries (for example, intrinsically safe batteries or Hawker SLA batteries), you should pay close attention to the extended C-code parameter settings (see Extended C-code Settings for Special cases, page 55).

Charge Rate (C-Rate)

A battery with 1000mAh capacity that is charged at 500mA has a charge C-Rate of 0.50C. A lower charge C-rate reduces the charge current and increases service time. Maximum current is 4000mA (6000mA for the C700ER) for batteries with a stated cell voltage of up to 7.2 V. Maximum current is reduced for batteries with higher nominal voltage. For example, on the C7200, the charge rate for a 14.4V battery will be automatically scaled to 2000mA. An inverse S (scaled C-code) will be displayed on the basic C-code screen.

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Discharge Rate (C-rate)

A battery with 1000mAh capacity that is discharged at 500mA is discharged at

0.50C. A lower discharge C-rate reduces the discharge current and increases service time. Maximum current is 4000mA (6000mA for the C7000ER). The discharge rate is reduced for batteries with higher nominal voltage (for example, 2400mA for a 14.4V battery on the C7200). For a single-cell NiCd or NiMH battery, the maximum discharge is 2500mA.

Default Charge and Discharge Rates

NiCd

: Standard NiCd batteries up to 1800mAh can be charged and discharged at rate of 1.00C. Cadex recommends a C-rate of 0.70C or 0.50C for batteries above these mAh ratings. The default setting for NiCd is 1.00C. For 1.2V and 2.4V batteries, the default charge rate is 0.30C to maintain normal temperatures.

NiMH

: NiMH batteries produce heat during Charge and Discharge. The default charge rate is 0.50C if Temperature Sensing is Disabled. In addition, due to the very fine negative slope, the current is cut in half twice towards the end of the charge cycle to ensure that the battery is fully charged (the current is not reduced if the Charge rate is at 0.10C). If temperature sensing is Disabled, a rest period is applied before the current is cut to allow for the battery to cool. This lengthens the service time. For 1.2V and 2.4V batteries, the default rate is 0.30C to maintain cooling. If the battery gets hot during charge, reduce the Charge rate to 1000mAh or less.

SLA

: Battery manufacturers rate the SLA at a 20-hour discharge (0.05C). This slow discharge is not practical when analyzing SLA batteries so the analyzer uses a default 0.30C Charge and 0.10C (10-hour) discharge. Due to this higher discharge rate, the battery will give a lower capacity. Refer to the manufacturers specification for the battery rating at the 10-hour discharge and adjust the battery rating (capacity) or Capacity Offset to compensate for the higher discharge rate.

Li-ion

: Most Li-ion (and Li-Polymer) batteries can accept a 1.00C Charge and

Discharge rate. This is the default Charge and Discharge Rate.

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Trickle-Charge Rate (NiCd and NiMH only)

The Trick Charge Rage parameter defines the charge level required to maintain the charge on a NiCd or NiMH battery after service is complete.

Available settings: 1% – 10% of the rated capacity.

Default Trickle Charge Rate

The recommended and default rate for NiCd and NiMH is 2%. This rate compensates for any self-discharge and maintains temperature. During Trickle Charge, the battery should remain cool and battery temperature should be less than 5

C above ambient temperature. If the battery feels warm, reduce the trickle

charge.

Recondition Discharge Rate (NiCd and NiMH only)

The Recondition Discharge Rate parameter refers to a slow, gradual discharge applied during reconditioning after the battery reaches the end-of-discharge voltage. During this process, the crystalline build-up (memory) on the cell plates dissolves and the battery often restores itself.

Available settings: 2% – 20% of discharge rate setting, in increments of 2%.

Default Recondition Discharge Rate

The recommended Recondition and Discharge default rate for NiCd and NiMH is 12%. This provides the best compromise between speed, effectiveness and safety. The setting is small enough to avoid damage if cell reversal occurs and is large enough to achieve a reasonable, short Recondition Discharge time.

Capacity Offset

The Capacity Offset parameter adds its value to the capacity readings. It is used for SLA batteries to compensate for capacity variation when a battery is discharged at a higher or lower rate than specified by the manufacturer. This

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offset is changed based on manufacturer recommendations. It is not mandatory to add the Capacity Offset.

Available settings: -50% to +49%

Default Capacity Offset

SLA batteries are often rated based on a 20-hour (0.05C discharge). This discharge is slow and is not practical when analyzing SLA batteries. The default setting for Discharge is 0.10C (10-hours). Since this is a higher value, the capacity will be less. Refer to the manufacturer specifications for the battery rating at the 10-hour discharge and adjust the Capacity Offset or battery rating (capacity) to compensate for the higher discharge rate. The Capacity Offset merely adds to the capacity if the battery and does not improve battery capacity in any way. The default capacity offset is 00% for all chemistries.

Temperature Sensing

For safety purposes, temperature sensing cannot be disabled for Li-ion batteries. If disabled is selected, temperature is not displayed during service.

The Temperature Sensing parameter defines the temperature range within which the battery is serviced (effective only for batteries or adapters equipped with a temperature sensor). The temperature sensor measures the battery temperature either internally or externally. If battery temperature exceeds the maximum threshold, service is suspended until the battery’s temperature drops to 5

the threshold. If the battery’s temperature is below the minimum threshold, service is suspended and the battery is trickle charged until minimum temperature is reached.

Default Temperature Sensing

Adapters with temperature sensor: 5

C-45oC.

C below

Adapters without a temperature sensor: Disabled (not for Li-ion batteries)

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The recommended setting is 5oC-45oC, which is the ideal battery service temperature range. For NiMH batteries, it is recommended to activate temperature sensing to speed up service. If temperature sensing is disabled, the analyzer automatically applies resting periods to allow NiMH batteries to cool down, which lengthens the service time.

Negative Slope (NiCd and NiMH only)

The Negative Slope parameter is a measure of the voltage drop that occurs when the battery reaches full charge. The charge cycle is terminated when the voltage drop reaches the set value.

Available settings: 8mV/cell – 64mV/cell

Default Negative Slope

For 1.2V - 2.4V batteries: 24mV/cell

For 3.6V – 36V batteries: 8mV/cell

Always use the lowest possible negative slope setting. Increasing the negative slope setting delays charge termination causing the battery to heat up at the end of charge. Decreasing the negative slope may terminate charge prematurely if the battery has voltage fluctuations due to instability.

End of Discharge

The End of Discharge is a parameter that is chemistry-dependent. It defines the threshold point at which the discharge cycle is terminated.

Available settings:

• 0.76 – 1.12V/cell (NiCd, NiMH)

• 1.36 – 1.95V/cell (SLA)

• 2.30 – 3.20V/cell (Li)

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Default End of Discharge

Most battery-powered devices are designed to operate at the default settings provided below. However, some devices may have a higher or a lower cut-off value, so these values may have to be adjusted if the battery capacity is being compared to the device it’s being used in. Refer to the manufacturer settings for these cases.

NiCd and NiMH: 1.00V/cell.

SLA: 1.75V/cell. This value can vary depending on the Discharge rate used. Refer

to the manufacturer specifications.

Li-ion: 3.00V/cell. A good number of Li-ion batteries have 2.50V/cell as the End of Discharge setting. Refer to the manufacturer specifications.

End of Recondition (NiCd and NiMH only)

The End of Recondition parameter defines the threshold point at which the reconditioning cycle is complete. This recondition is most effective on NiCd batteries. This threshold point leaves the battery discharged.

Available settings:

•

DISABLED

• 0.40 – 0.80 V/cell

Default End of Recondition

The minimum required setting to restore a NiCd battery affected by “memory” is

0.60V/cell. The Cadex analyzer uses 0.40V/cell. SLA and Li-ion batteries cannot be conditioned with a deep discharge.

SMART BATTERIES SHOULD NOT BE RECONDITIONED.

Select

DISABLED

for the End of Recondition when servicing a smart battery.

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If the battery’s voltage drops below the level required by the processor within the battery, valuable information can be lost. In some cases, this data loss can leave the battery permanently unusable.

Charge Method (NiCd and NiMH only)

This parameter determines how NiCd and NiMH batteries are charged. The reverse load method intersperses discharge pulses during charge and trickle charge to keep batteries cool and promote the recombination of gases.

Available settings:

DC CHARGE

•

NO REV LOAD

• Reverse Load 5% – 12%

Default Charge Method

Best results have been achieved using the default Rev. Load 9%. DC Charge is used for batteries that cannot accept a pulse charge (some intrinsically safe batteries fall into this category). NO REV LOAD is a charge pulse without the reverse pulse.

Maximum Standby Voltage (SLA and Li-ion only)

The Maximum Standby Voltage parameter determines the voltage that SLA and Li-ion batteries are maintained at when fully charged, after service is complete. A charge current of approximately 0.10C maintains the Maximum Standby Voltage. If the battery voltage exceeds the Maximum Standby Voltage, the current is reduced or eliminated until battery voltage drops below the Maximum Charge Voltage. This parameter must be set to be lower than the Maximum Charge Voltage.

Available settings:

• 2.15 – 2.45V/cell (SLA)

3.90– 4.35V/cell (Li-ion)

•

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Default Maximum Standby Voltage

SLA: 2.25V/cell

Li-ion: 4.05V/cell

Refer to the manufacturer’s specifications for proper settings. If the battery generates heat during prolonged storage on the analyzer after service has been completed, remove the battery from the analyzer.

Maximum Charge Voltage (SLA and Li-ion only)

The Maximum Charge Voltage parameter defines the voltage threshold of SLA and Li-ion batteries that must be maintained until the End of Charge conditions are reached. The charge current drops while the maximum charge voltage is maintained.

Available settings:

• 2.20 – 2.65V/cell (SLA)

3.90 – 4.35V/cell (Li-ion)

•

Default Max. Charge Voltage

SLA

: 2.40V/cell.

Li-ion

: 4.2V/cell.

Refer to the manufacturer’s specifications for proper settings as these values vary depending on the charge rate used and the ambient temperature.

End of Charge (SLA and Li-ion only)

The End of Charge parameter defines the rate of charge the analyzer uses to determine if the battery is fully charged. When the charge current drops below the End of Charge setting while maintaining the Maximum Charge Voltage, the battery is considered fully charged.

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The Charge Optimization setting affects the way the end-of-charge setting is used during a charge (see Optimizing Charge Time or Capacity, page 80).

Available settings: 0.01 C – 0.10 C

Default End of Charge

SLA and Li-ion: 0.05C. Refer to the manufacturers specification for proper setting as these values vary depending on the charge rate being used. For some batteries, a lower setting is required to ensure adequate charge.

Default Extended C-code Settings

This section lists the default extended C-code parameter values for each of the four battery chemistry types.

Default Extended C-code for NiCd Batteries

Parameter Default Setting

Charge 1.00 C

Trickle 5%

Discharge 1.00 C

Recondition 12%

Capacity Offset 0%

Temperature Sensing 0ºC – 45 C

Negative Slope 8mV/cell, 16mV/cell for 1.2V and 2.4V

batteries

End of Discharge 1.00V/cell

End of Recognition 0.40V/cell

Charge Method Reverse Load 9%

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Default Extended C-code for NiMH Batteries

Parameter Default Setting

Charge 1.00 C

Trickle 2%

Discharge 1.00 C

Recondition 12%

Capacity Offset 0%

Temperature Sensing 0ºC – 45 C

Negative Slope 8mV/cell, 16mV/cell for 1.2V and 2.4V

batteries

End of Discharge 1.00V/cell

End of Recognition 0.40V/cell

Charge Method Reverse Load 9%

Default Extended C-code for SLA Batteries

Parameter Default Setting

Charge 0.30 C

Discharge 0.10 C

Capacity Offset 0%

Temperature Sensing 0 C – 45 C

Max. Standby Voltage 2.25V/cell

Max. Charge Voltage 2.40V/cell

End of Charge 0.05 C

End of Discharge 1.75V/cell

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Default Extended C-code for Li-ion Batteries

Parameter Default Setting

Charge 1.00 C

Discharge 1.00 C

Capacity Offset 0%

Temperature Sensing 0 C – 45 C

Max. Standby Voltage 4.05V/cell

Max. Charge Voltage 4.20V/cell

End of Charge 0.05 C

End of Discharge 3.00V/cell

Extended C-code Settings for Special Cases

This section lists recommended parameter settings for specific types of batteries, where the recommended settings are different from the default settings.

Intrinsically Safe Batteries

Before servicing intrinsically safe (I/S) batteries, set the following C-code parameters as specified:

Parameter Setting

Charge 0.10 C*

Discharge 0.10 C*

Charge Method DC charge

End of Discharge 0.96V/cell

* Recommended settings. You can try setting the charge and discharge rates to higher

values to speed up servicing; however, if fault codes appear, you must lower the rates.

Cadex C7000 Series Battery Analyzers 57

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Hawker SLA Batteries

Before servicing Hawker SLA batteries, set the following C-code parameters as specified below (any parameters not listed here should be left at their default settings):

Max. Standby Voltage 2.35V/cell

Max. Charge Voltage 2.60V/cell

End of Discharge 1.62V/cell

Gell SLA Batteries

Use the SLA default settings for Gell batteries.

Parameter Setting

Discharge 0.40 C

Managing C-codes

If the selected and the appropriate parameters entered before a battery is inserted or before battery processing begins (see To set the user input required by the

Cadex analyzer before battery service begins

Note QuickTest

Select a C-code

ASK FOR BATTERY C-CODE

stored in battery adapters as part of the C-code and can be copied to other adapters. However, any change made to the C-code (except target capacity and selected program) erases the stored QuickTest

1. From the global display, press the station key.

2. Press  or  to scroll to the C-code you want to select.

option is set to

YES

, the desired C-code must be

, page 78).

matrices created by the Q-Learn and the Learn programs are

matrix.

3. Press

4. Press  or  to scroll to

58 Cadex Electronics Inc.

ENTER

YES

to accept changes and press

ENTER

Page 75

5. Press

ESC

twice to return to the global display.

The “*” appears beside the C-code number on the display to indicate that the Ccode is active.

Display a C-code

1. From the global display, press the station key.

2. Use the  or  key to scroll to the C-code you want to display. Basic C-code parameters appear on the same screen.

3. Press  or  to scroll through the extended C-code parameters.

4. When you are finished viewing the C-code parameters, press once or twice to return to the global display.

Change Target Capacity or Program

ESC

1. From the global display, press the station key.

2. Press

EDIT.

3. Press  or  to scroll to the desired program.

4. Press  or  to move to the target capacity field.

5. Press  or  or use the keypad to enter the desired target value.

6. Press

ENTER.

7. Press  or  to scroll to

8. Press

ESC

Create or Edit a C-code

1. From the global display, press the station key.

YES to accept changes and press ENTER.

twice to return to the global display.

Cadex C7000 Series Battery Analyzers 59

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2. Use the  or  key to scroll to an empty C-code or to the C-code you want to edit.

An empty C-code contains no battery chemistry

(TYPE) and VOLTS and

mAh are set to 0.

3. Press

EDIT.

4. Select the program you want to run:

a) Press  or  to scroll to the basic program you want to run.

b) Press  to select the program and move to

TARGET

a) Press  or  to scroll through the basic programs to

ADVANCED.

b) Press .

c) Press  or  to scroll to the advanced program you want to run.

d) Press  to select the program and move to

At any time from this point, you can press

ENTER

TARGET

to save your

changes and stop editing the C-code parameters.

5. Press  or  or use the keypad to enter the required target capacity (see Target Capacity, page 45).

6. Press  to move to

TYPE.

7. Press  or  to scroll to the appropriate battery chemistry for the C- code.

8. Press  to move to

9. Press  or  or use the keypad to enter the voltage ( battery to be serviced (see

60 Cadex Electronics Inc.

VOLTS

Battery Voltage (Volts)

VOLTS) of the

, page 45).

Page 77

10. Press  to move to mAh.

11. Press  or  or use the keypad to enter the battery capacity in milliampere hours (mAh) (see Battery Rating, page 46).

12. Press

ENTER.

13. To leave the extended C-code parameters at the default settings:

a) Press

b) Press  or  to scroll to

ENTER

ENTER again.

YES

to accept changes and press

To edit the extended C-code parameters (not usually required):

a) Press .

b) Edit the extended C-code settings (see Extended C-code

Parameters, page 47).

• Press  or  to move between C-code settings.

• Press  or  or use the keypad to change the settings as

required.

c) Press

d) Press  or  to scroll to

ENTER.

14. Press

The message

ENTER

ESC twice to return to the global display.

YES to accept changes and press

CHANGES ACCEPTED appears on the display.

Add or Edit the C-code Setup Name

1. From the global display, press the station key.

Cadex C7000 Series Battery Analyzers 61

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2. Press  or  to scroll to the C-code for which you want to edit or add the setup name.

3. Press

ALT, and then press EDIT.

4. Press  or  to scroll through upper case letters, lower case letters, punctuation marks, numbers, and a space (which looks like an underscore) to select characters for the setup name.

5. Press  or  to move the cursor between character positions within the setup name. There are ten positions available.

6. Press

7. Press  or  to scroll to

8. Press

ENTER

ESC twice to return to the global display.

YES

to accept changes and press

Reset Extended C-code to the Default settings

1. From the global display, press the station key.

ENTER

2. Use the  or  key to scroll to the C-code whose extended parameters you want to reset.

3. Press

4. Press  or  to scroll to

5. Press

FN and then press 1.

YES to accept changes and press

ESC

twice to return to the global display.

ENTER

(see Default Extended C-code Settings, page 55).

Delete a C-code

1. From the global display, press the station key.

2. Use the  or  key to scroll to the C-code you want to delete.

62 Cadex Electronics Inc.

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3. Press FN and then press 0.

4. Press  or  to scroll to

ESC

5. Press

twice to return to the global display.

Copy a C-code (including QuickTest

1. Ensure both adapters are inserted in the Cadex analyzer. Neither adapter should contain a battery. The source adapter (the adapter with the C-code to be copied) can also be the target adapter (the adapter that will receive the copied C-code.)

2. From the global display, press the station key for the source adapter.

3. Use the  or  key to scroll to the C-code you want to copy.

4. Press

FN, and then press 3.

5. Press the station key for the target adapter. (This can be the same as the source adapter.)

YES

matrix)

to accept changes and press

ENTER

6. Use the  or  key to scroll to the C-code you want to overwrite (usually an empty C-code).

An empty C-code contains no

TYPE information and VOLTS and MAH

are set to 0.

7. Press

8. Press  or  to scroll to

9. Press

ENTER.

YES

to accept changes and press

ESC

twice to return to the global display.

ENTER

Copy all C-codes (and matrices) from One Adapter to Another

1. Ensure that both adapters are inserted in the Cadex analyzer. Neither adapter should contain a battery.

Cadex C7000 Series Battery Analyzers 63

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2. From the global display, press FN, and then press 6.

3. Press the station key for the station containing the Target adapter.

4. Press  or  to scroll to

5. Press

ESC twice to return to the global display.

YES to accept changes and press ENTER.

64 Cadex Electronics Inc.

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Chapter 7 System Setup And Options

You can customize a number of global settings on the Cadex analyzer. You can set the date, time, company name, view the event log and print reports or labels.

Date and Time

1. From the global display, press MENU.

2. Press  or  to scroll to

3. Press  or  to scroll to

SYSTEM SETUP and then press ENTER.

DATE/TIME

and then press

ENTER

4. Enter the date and time information:

5. Press  or  to move between fields (year, month, day, hour, minute, and second).

6. Press  or  or use the number pad to enter the correct date and time information for each field.

7. Press

ENTER

8. Press  or  to scroll to

9. Press

ESC

YES

to accept changes and press

twice to return to the global display.

ENTER

Note The analyzer is shipped with the date and time set for the Pacific

Standard Time (PST) (GMT-8).

Cadex C7000 Series Battery Analyzers 65

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Company Name

1. From the global display, press

2. Press  or  to scroll to

3. Press  or  to scroll to

OPTION CONTROLS

COMPANY NAME and then press ENTER.

and then press

ENTER

4. Enter the company name:

5. Press  or  to scroll through upper-case letters, lower-case letters, punctuation marks, numbers, and a space (which looks like an underscore) to select characters for the program name.

6. Press  or  to move the cursor between character positions within the program name. There are twenty positions available.

7. Press

8. Press  or  to scroll to

ENTER.

YES to accept changes and press ENTER.

9. Press

Sound Options

The Cadex analyzer uses several sounds to alert users to various events. You can control whether or not sounds are played and you can assign sounds to specific events when the sound control is on.

There are two kinds of events sound alerts can be assigned to. These are key press events and alert events. When key press sounds are on, you hear a click every time you press a key on the Cadex analyzer and you hear one or more tones every time an action or program is completed.

To turn sounds

1. From the global display, press

ESC twice to return to the global display.

ON or OFF

MENU.

66 Cadex Electronics Inc.

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2. Press  or  to scroll to

3. Press  or  to scroll to

4. Press  or  to turn the key press sound on (

5. Press  or .

6. Press  or  to turn the alert sounds on (

7. Press

ENTER.

8. Press  or  to scroll to

9. Press

ESC twice to return to the global display.

To hear sounds assigned to events

1. From the global display, press

OPTION CONTROLS

SOUND CONTROL

YES

to accept changes and press

MENU.

, and then press

and then press

YES

) or off (NO).

YES) or off (NO).

ENTER

2. Press  or  to scroll to

3. Press  or  to scroll to

OPTION CONTROLS

SOUND CHECK

and then press

ENTER

4. Press  or  to scroll to the event for which you want to hear the assigned sound, and press

ENTER.

The Cadex analyzer plays the sound or tone(s) assigned to the selected event. If you do not hear anything, sounds have been turned off.

5. Repeat step 4 for all events whose assigned sounds you want to hear.

ESC

6. Press

twice to return to the global display.

Cadex C7000 Series Battery Analyzers 67

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Voltage Display

You can choose to display voltage as total battery (terminal), voltage (volts) or individual cell voltage (V/Cell). If voltage display is set to V/cell, you must multiply the displayed voltage by the number of cells in the battery to find the voltage for the battery.

On some NiCd and NiMH batteries, manufacturers may rate their batteries based on 1.25V/cell rather than 1.2V/cell. You can specify whether you want voltage displayed as 1.2V/cell or 1.25V/cell, (see

To set the voltage display mode

Battery Voltage (Volts)

, page 45).

1. From the global display, press

2. Press  or  to scroll to

3. Press  or  to scroll to

MENU.

OPTION CONTROLS

VOLTAGE DISPLAY

and then press

ENTER

4. Press  or  to scroll to the required setting:

YES

•

sets the Cadex analyzer to display the voltage of individual

cells within the battery (V/Cell).

•

NO sets the Cadex analyzer to display the terminal voltage for the

battery as a whole (Volts).

5. Press  or  to move to the NiXX field.

6. Press  or  to select 1.20 or 1.25 volts per cell to display for NiCd and NiMH batteries.

7. Press

ENTER

8. Press  or  to scroll to

9. Press

68 Cadex Electronics Inc.

YES to accept changes and press ENTER.

ESC twice to return to the global display.

Page 85

Battery Service Counter

You can program the Cadex analyzer to notify you after it has serviced a specified number of batteries. This can be useful, for example, as a prompt to remind you to perform routine maintenance tasks such as voltage calibration.

You can also restart the count from 0 (zero).

To set the battery service counter

1. From the global display, press

2. Press  or  to scroll to

3. Press  or  to scroll to

ENTER.

4. Press  or  or use the number pad to enter the number of batteries you want the Cadex analyzer to service before it notifies you.

Set the number to 0 to disable the battery service counter.

5. Press

ENTER.

6. Press  or  to scroll to

7. Press

ESC twice to return to the global display.

To restart the battery service count

MENU.

OPTION CONTROLS and then press ENTER.

SET SERVICE COUNTER

YES to accept changes and press ENTER.

and then press

1. From the global display, press

2. Press  or  to scroll to

3. Press  or  to scroll to

ENTER.

4. Press

Cadex C7000 Series Battery Analyzers 69

ENTER.

MENU.

OPTION CONTROLS and then press ENTER.

CLEAR SERVICE COUNTER and then press

Page 86

5. Press  or  to scroll to

ESC

6. Press

twice to return to the global display.

YES

to accept changes and press

ENTER

Note This option is not the same as setting the battery service counter to 0.

When the service counter is set to 0 using the

SET SERVICE COUNTER

option, it is disabled. When you use this option to clear the battery service counter, you are restarting the service count from 0.

To display the number of batteries serviced

This option displays both the total number of batteries serviced and the number of batteries serviced in a session (a session is ended when the service counter is cleared).

1. From the global display, press

2. Press

ESC to return to the global display.

, and then press 5.

Connecting to BatteryShopTM or a Printer

The Cadex analyzer has a parallel port and an RS232 DB-9-pin female serial port, which you can use to connect the battery analyzer to a printer, label printer or computer. You may need to use a customized cable to connect to the analyzer. The USB port is only available on the C7400 and C7400ER but it is currently not activated.

Other devices may work with the Cadex analyzer but they are not guaranteed to do so. Cadex is not responsible for any problems or technical support arising from trying to use any printing devices other than those supported.

Connecting to BatteryShop

To set the analyzer up for BatteryShop

, do the following:

70 Cadex Electronics Inc.

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 Connect the cable that is provided with BatteryShopTM to the 9-pin serial RS-

232 port on the analyzer. If necessary, use a 25-9 pin converter that is supplied with BatteryShop

to connect the other end to the PC serial port.

 Change the analyzer from

 Press F

 Press E

N and then press 9 and select TERMINAL.

NTER to save the settings.

STANDALONE

mode to

BATTERYSHOP

mode,

 These steps are sufficient to set up the analyzer for use with BatteryShop

Refer to the BatteryShop

users manual for details.

Connecting Devices to the Serial Port

The serial port on the Cadex analyzer connects the unit to a computer so you can run BatteryShop™ or transfer service data to a computer. You can also connect supported label printers through the serial port.

The Cadex analyzer supports the following devices on the serial port:

• Dymo-CoStar SE250 or SE300 label printer (choose

LABEL MAKER

device setting) for printing bar-code labels and battery labels. This is the only label printer that is supported. Use the cable that comes with the printer to connect to the analyzer serial port and set the port to

LABEL MAKER.

Instructions on

setting the port are provided below.

• Set the analyzer to software. Use the cable that comes with the software to connect to the analyzer serial port and set the port to the port are provided below.

Note: To toggle between

and then press

• A PC can be used to manually monitor battery data. Use the cable supplied with BatteryShop™ to connect to the analyzer serial port or make one using the configuration described shown in Typical Serial Cable Pin

Cadex C7000 Series Battery Analyzers 71

BATTERYSHOP mode to use the unit with BatteryShop™

BATTERYSHOP. Instructions on setting

BATTERYSHOP mode and STANDALONE mode press FN,

Page 88

Configurations, page 73. A standard serial cable

will not work

. Set the

serial port settings to match the PC port.

The Cadex analyzer offers these settings for the serial port:

Option Available Settings Default

Baud Rate 1200, 2400, 4800, 9600, 19200 9600

Handshake NONE, CTS/RTS, X ON/X OFF CTS/RTS

Data Bits 7, 8 8

Stop Bits 1, 2 1

Parity NONE, ODD, EVEN NONE

To specify and set up the device connected to the Cadex analyzer serial port

1. From the global display, press

2. Press  or  to scroll to

MENU.

SYSTEM SETUP and then press ENTER.

3. Press  or  to scroll to

SERIAL PORT DEVICE and then press ENTER.

4. Press  or  to scroll to the device to connect to the serial port:

• Use

BATTERYSHOP to use the unit with Cadex analyzer

BatteryShop™ software.

• Use

TERMINAL to connect to a computer you want to use to

display and analyze service data (see

LABEL MAKER

to connect to a Dymo-CoStar SE300 label

Logging Data

, page 95)

printer.

• Use

PRINTER to connect to a serial dot matrix Epson compatible

printer. Since serial printers are no longer available, use the parallel port or use a SP-2 converter if the parallel port is not available (see Appendix D - Parts and Accessories, page 162)

DISABLED if you do not want to connect a device using the serial port.

•

5. Press

ENTER.

72 Cadex Electronics Inc.

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6. Press  or  to scroll to

7. Press  to scroll to

SERIAL PORT SETTINGS

YES

to accept changes and press

step is not required if connecting to BatteryShop

and then press

or using the Dymo-

ENTER

. This

CoStar SE300 label printer.

8. Enter the required settings as specified in the device user’s manual (see above for available options):

Press  or  to move the cursor from option to option.

•

• Press  or  to scroll through available settings.

9. Press

10. Press  or  to scroll to

11. Press

ENTER.

YES

to accept changes and press

ESC twice to return to the global display.

ENTER

Typical Serial Cable Pin Configurations

Note: Do not use these configurations for the Dymo SE300 printer. Use the cable that is supplied with the printer instead.

DB-9 to DB-25

DB-9

DB-25

Note When connecting to a serial

printer, it may also be necessary to

RD 2 — 2 TD

TD 3 — 3 RD

CTS 8 — 4 RTS

RTS 7 — 5 CTS

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.

SG 5 — 7 SG

Cadex C7000 Series Battery Analyzers 73

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DB-9 to DB-9

DB-9 DB-9

Note When connecting to a serial

printer, it may also be necessary to

RD 2 — 3 TD

TD 3 — 2 RD

jumper pins 6 (DSR), 1 (DCD), and 4 (DTR) together on the printer’s DB-9

CTS 8 — 7 RTS

RTS 7 — 8 CTS

connector. Other jumpers may be also required. Check your printer manual for specific information.

SG 5 — 5 SG

Connecting Printers to the Parallel Port (C7400 and C7400ER only)

Supported printers can be connected directly to the analyzer’s parallel using a parallel cable. You must specify which device is connected to the Cadex analyzer parallel port.

The Cadex analyzer supports the following device on the parallel port:

• Epson-compatible dot matrix parallel printers for printing reports and labels using the Parallel port (choose printer device setting).

To specify the device to connect to the Cadex analyzer parallel port

1. From the global display, press

MENU.

2. Press  or  to scroll to

3. Press  or  to scroll to

ENTER

4. Press  or  to scroll to the device you want to connect to the parallel port:

• Use

printer.

• Use

parallel port.

74 Cadex Electronics Inc.

SYSTEM SETUP and then press

PARALLEL PORT DEVICE

and then press

ENTER

PRINTER

DISABLED if you do not want to connect a device using the

to connect to an Epson FX-850-compatible parallel

Page 91

5. Press

6. Press  or  to scroll to

7. Press

Security

The Cadex analyzer offers three security levels for protection against tampering: Level 0 (off), Level 1 (low), and Level 2 (high). Level 0 is the default. Depending on the security level chosen, you may have to enter the password for some features.

A password must have at least three digits.

Security Level Functions

The table below shows functions that require a password at each of the three

ENTER

ESC

YES

to accept changes and press

twice to return to the global display.

ENTER

security levels:

Functions Level 0

Services Start Services

C-code Edit C-codes

Select C-codes

System

Setup

Program

Settings

Change Time/date

Select Serial and

Parallel Port devices

Perform

Calibration

Change Program Settings

(Off)



Level 1 (Low)



Level 2 (High)

    

 

  





  



Cadex C7000 Series Battery Analyzers 75

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Option

Controls

Utilities

Functions Level 0

(Off)

Change Battery startup options

Change Company

name

Change Sound control options

Change Voltage

display options

Select battery service report

Select battery

label

Select System setup report

Set Auto-print

options

  



  



  

Level 1 (Low)



Level 2 (High)



Print All Reports

Event Log Clear event log

Set up events to

log

To set the level of security

1. From the global display, press

2. Press  or  to scroll to

3. Press  or  to scroll to

4. Press  or  or use the number pad to enter the desired security level (0, 1, or 2).

   



  

MENU.

SYSTEM SECURITY

SET SECURITY

and then press

ENTER

76 Cadex Electronics Inc.

Page 93

5. If required, enter the password using the number pad and press

ENTER

6. Press  or  to scroll to

7. Press

ESC twice to return to the global display.

To change the password

1. From the global display, press

2. Press  or  to scroll to

3. Press  or  to scroll to

4. Enter the old password using the number pad and then press

5. Enter the new password, and then press

6. Enter the new password again to confirm and then press

The message password change was successful.

YES

to accept changes and press

MENU.

SYSTEM SECURITY

CHANGE PASSWORD

PASSWORD ACCEPTED appears on the display if your

and then press

ENTER.

ENTER

ENTER.

7. Press

ESC

twice to return to the global display.

If you lose or forget your password, contact Cadex Technical Support at 1 800 565-5228 ext. 315 with your company name and the serial number of your Cadex analyzer.

Program Parameters

There are a number of settings available that affect the way the Cadex analyzer functions in most or all of its programs.

Cadex C7000 Series Battery Analyzers 77

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Starting Battery Service

By default, when you insert a battery in a battery adapter in the Cadex analyzer, you must verify the C-code settings before the service is performed. This verification can be turned off so users can run a battery service as soon as a battery is inserted. You can set the options as follows:

• The Cadex analyzer asks for Battery ID number and asks you to verify settings.

• The Cadex analyzer asks for Battery ID number only.

• The Cadex analyzer asks you to verify C-code settings only (default).

• The Cadex analyzer starts the program in the active C-code without asking for

input.

To set user input required by the Cadex analyzer before battery service begins

1. From the global display, press

2. Press  or  to scroll to

3. Press  or .to scroll to

MENU.

OPTION CONTROLS and then press ENTER.

ASK FOR BATTERY ID #

4. Press  or  to scroll to the required setting:

YES

•

sets the Cadex analyzer to ask for the Battery ID number.

• NO (default) sets the Cadex analyzer not to ask for Battery ID

number.

5. Press  or .to scroll to

ASK FOR BATTERY C-CODE

5. Press  or  to scroll to the required setting:

YES sets the Cadex analyzer to ask the user to verify C-code

•

settings.

78 Cadex Electronics Inc.

Page 95

•

(default) sets the Cadex analyzer not to ask for the battery

C-code.

6. Press

7. Press  or  to scroll to accept changes and press

8. Press

ENTER.

ENTER

ESC twice to return to the global display.

Performing an Automatic OhmTest

Every time the Cadex analyzer runs a charge cycle, it can automatically perform an OhmTest on the battery as well (except when the charge cycle is being performed as part of a custom program). You can choose whether or not to perform the automatic OhmTest.

Note Automatic OhmTest cannot be turned on or off using the following

programs: QuickTest

, Q-Learn, Learn and Life-Cycle. OhmTest is

included in these programs and the settings cannot be changed.

To turn Automatic OhmTest on or off

1. From the global display, press

2. Press  or  to scroll to

3. Press  or  to scroll to

PROGRAM SETTINGS

AUTOMATIC OHMTEST

and then press

ENTER

4. Press  or  to scroll to the required setting:

YES (default) sets the OhmTest to run automatically before every

•

charge cycle (except during custom programs).

•

5. Press

6. Press  or  to scroll to

Cadex C7000 Series Battery Analyzers 79

turns off the automatic OhmTest.

ENTER

YES

to accept changes and press

ENTER

Page 96

7. Press

ESC

twice to return to the global display.

Optimizing Charge Time or Capacity

The end of charge conditions can be modified, (see Appendix B – Charge Algorithms, page 156).

To select the charge optimization option

1. From the global display, press

2. Press  or  to scroll to

3. Press  or  to scroll to

4. Press  or to move to between N SLA

AND

PTIMIZATION

LI O

MENU.

PROGRAM SETTINGS and then press ENTER.

CHARGE OPTIMIZATION and then press ENTER.

ICD AND

NIMH

OPTIMIZATION

and

5. Press  or  to the required setting (see Appendix B – Change

Algorithms

TIME

•

CAPACITY.

6. Press

7. Press  or  to scroll to

8. Press

, page 156)

(default).

ENTER.

YES to accept changes and press ENTER.

ESC

twice to return to the global display.

Termination Condition on dT/dt

The Termination Condition on

DT/DT

parameter sets the temperature a battery can reach before it will terminate or reduce the charge current. If a battery temperature rises more than the

DT/DT the charge current is either reduced or charge is

completed (see Appendix B – Charge Algorithms, page 156).

80 Cadex Electronics Inc.

Page 97

To select the charge optimization option

1. From the global display, press

2. Press  or  to scroll to

3. Press  or  to scroll to

PROGRAM SETTINGS

DT/DT TERMINATION and then press ENTER.

and then press

ENTER

4. Press  or  to the required setting (see Appendix B – Charge Algorithms, page 156)

• 2

•

• 2

5. Press

6. Press  or  to scroll to

7. Press

C RISE PER: 2 MINUTES

C RISE PER: 3 MINUTES (default)

C RISE PER: 4 MINUTES

ENTER.

YES

to accept changes and press

ESC

twice to return to the global display.

ENTER

Saving Program and Target Capacity Settings

By default, when you make changes to program and target capacity settings, they are saved as part of the C-code stored in the battery adapter.

You can choose to have the Cadex analyzer save these changes to the battery station rather than to the C-code. Settings saved to the station are independent of setting battery adapter inserted in the station. Program and target capacity settings programmed into the analyzer station will override the C-codes programmed in the adapter.

Saving program and target capacity is useful if you have several Cadex analyzer units and want to dedicate a unit to one or two specific programs and target capacities.

Cadex C7000 Series Battery Analyzers 81

Page 98

To set the method of saving changes to program and target capacity

1. From the global display, press

2. Press  or  to scroll to

3. Press  or  to scroll to

ENTER.

OPTION CONTROLS and then press ENTER.

PROGRAM/TARGET CHANGES and then press

4. Press  or  to scroll to the required setting:

• C-

CODE (default) saves any changes made to the program

settings or the target capacity to the active C-code.

STATION saves any changes made to the program settings or the

•

target capacity to the battery station. These changes override any settings in the active C-code.

5. Press

6. Press  or  to scroll to

7. Press

ENTER.

YES to accept changes and press ENTER.

ESC twice to return to the global display.

Note If you want to use all of the settings from the active C-code, this option

must be set to C-

CODE

. Setting it to C-

CODE

will erase all settings saved to

the stations.

Resuming Service After Power Failure

If there is a power failure, the back-up memory in the analyzer keeps service data for one hour. If the power failure lasts less than an hour, battery service resumes from where it left off. If the power failure lasts longer than one hour, the battery resumes from the beginning. This time can be modified:

To change the Power Failure Resume Hours

1. From the global display, press

82 Cadex Electronics Inc.

MENU.

Page 99

2. Press  or  to scroll to

3. Press  or  to scroll to

ENTER

SYSTEM SETUP

POWER FAILURE RESUME HOURS

, press

4. Press  or  to scroll to the required setting:

5. Press

6. Press

ENTER. Press ENTER again to save the settings.

ESC twice to return to the global display.

ENTER

, press

Cadex C7000 Series Battery Analyzers 83

Page 100

Short Key Functions

Common functions can be set with the Fn or Alt with number key.

From Edit Display From Global Display

Fn-0

Fn-1

Fn-2

Fn-3

Fn-6

Fn-9

Alt-

Edit

Deletes C-Code

Resets extended C-Code

to default settings

Erases QuickTest

matrix

Copies single C-Code

Copies all C-Codes from

one adapter to another

Protects a Matrix from

changes. Indicated by ‘P’

in C-Code

Enters unique names

for C-Codes

Fn-5

Fn-7

Fn-8

Fn-9

Alt-0

Stn Key

Alt-Stn

Key

Views Service Counter

Views Firmware Version

Calibrates Station

Toggles between stand alone

and BatteryShop

mode

Resets defaults and

restarts unit

3 second key press

starts Boost

Select ‘Restart’ to restart

service. Select ‘Interrupt’ – the

station will interrupt to remove

84 Cadex Electronics Inc.

a battery while it is in service.

Cadex C7200, C7400, C7400ER User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual