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
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
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
ii Cadex Electronics Inc.
Safety Notice
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.
Cadex C7000 Series Battery Analyzers iii
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.
iv Cadex Electronics Inc.
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.
Cadex C7000 Series Battery Analyzers v
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.
vi Cadex Electronics Inc.
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.
Cadex C7000 Series Battery Analyzers vii
Warranty & Service
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.
viii Cadex Electronics Inc.
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
Table of Contents
Table of Contents
Chapter 1 Overview.................................................................................................1
Product Features...............................................................................................................1
Connecting to Cadex BatteryShop™................................................................................2
Chapter 2 Getting Started.......................................................................................1
Contents of the Box ..........................................................................................................1
Using this Manual .............................................................................................................1
Conventions ......................................................................................................................3
Direction Keys ...............................................................................................................3
Symbols.........................................................................................................................3
Abbreviations and Acronyms.........................................................................................4
Commonly Used Terms.................................................................................................5
Chapter 3
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
x Cadex Electronics Inc.
Battery Service Programs...................................................................22
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
Cadex C7000 Series Battery Analyzers xi
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
xii Cadex Electronics Inc.
Events and Data Logs .........................................................................92
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
Cadex C7000 Series Battery Analyzers xiii
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
xiv Cadex Electronics Inc.
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.
Cadex C7000 Series Battery Analyzer 1
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).
2 Cadex Electronics Inc.
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
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.
2 Cadex Electronics Inc.
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.
Cadex C7000 Series Battery Analyzers 3
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
4 Cadex Electronics Inc.
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
TM
QuickTest
Cadex C7000 Series Battery Analyzers 5
. A matrix is stored with a C-Code.
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
6 Cadex Electronics Inc.
about the status of the analyzer and any batteries being
serviced: It consists of the LCD display, the LED
indicators and the input keys.
Chapter 3 Operating Principles
Components
Figure 1: Top and front panel of C7400 & C7400ER battery analyzer
Cadex C7000 Series Battery Analyzer 7
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.
MENU
key To access a list of options to set up the analyzer.
Numeric keypad To enter passwords or numeric values in a C-Code..
8 Cadex Electronics Inc.
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
TM
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
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.
10 Cadex Electronics Inc.
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
2
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
MENU
the
provides access to various functions of the analyzer when
key is pressed (see Menu Structure, page 13).
Cadex C7000 Series Battery Analyzers 11
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.
Menu Structure
The menu-driven interface allows access to the various functions of the analyzer.
See sections on individual functions for details and instructions.
MENU
System
Security
System
Setup
Program
Settings
Option
Controls
Print Utilities
ENTER
ENTER
ENTER
ENTER
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.
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
•
14 Cadex Electronics Inc.
Loading...