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C8000 Battery Testing System
User Manual (V2.x)
Cadex® Electronics Inc.
22000 Fraserwood Way
Richmond, British Columbia
Canada V6W 1J6
Phone: 1-604-231-7777
FAX: 1-604-231-7755
Web: www.cadex.com
E-mail: info@cadex.com
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Trademark
Cadex® and BatteryLab® are registered trademarks of Cadex Electronics Inc. All other
trademarks or registered trademarks mentioned herein are the property of their
respective owners.
Copyright Notice
Copyright © 2010 by Cadex Electronics Inc. All rights reserved. No part of this
publication nor the software and/or 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) for suggestions or corrections.
Disclaimer
While every effort is made to ensure that the information contained in this manual and
Online Help is accurate and up-to-date, Cadex Electronics Inc. does not warrant or
guarantee the accuracy of the contents of this manual and Online Help. Further, Cadex
makes no warranties, either expressed or implied, as to the merchantability or fitness for
a particular purpose of the C8000 Battery Testing System and/or its documentation.
In no event will Cadex or its officers or employees are 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
C8000 Battery Testing System and/or its documentation.
Document Number: PSMAN0056 Rev 3
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C8000 Battery Testing System User Manual
Contents
Contents .......................................................................................................................................... i
1 Safety and Warranty ............................................................................................................ 1
1.1 Cautions and Warnings ................................................................................................... 1
1.1.1 Use of Equipment ....................................................................................................... 1
1.1.2 Modification of Equipment ......................................................................................... 1
1.1.3 Hazard Symbols .......................................................................................................... 2
1.1.4 Disposal of Waste Electrical and Electronic Equipment (WEEE) in the European
Union…................................................................................................................................... 3
1.1.5 Radio Interference ....................................................................................................... 3
1.1.6 Explosion Hazard ........................................................................................................ 4
1.1.7 Charge and Discharge Lithium-ion (Li-ion) Batteries ................................................ 5
1.1.8 Shock Hazard .............................................................................................................. 6
1.2 Warranty and Service ...................................................................................................... 7
1.2.1 Warranty Service ........................................................................................................ 7
1.2.2 Non Warranty Repairs ................................................................................................ 8
1.3 Back Up and Restore Calibration Data ........................................................................... 8
1.3.1 Back Up Calibration Data ........................................................................................... 8
1.3.2 Restore Calibration Data ............................................................................................. 8
2 Battery Tester ...................................................................................................................... 10
2.1 Getting Started with the Battery Tester ........................................................................ 10
2.1.1 The C8000 Battery Tester User Manual ................................................................... 10
2.1.1.1 Topics You Need to Know ............................................................................... 10
2.1.2 What is in the Box..................................................................................................... 11
2.1.3 Optional C8000 Accessories ..................................................................................... 12
2.1.3.1 C8000 Adapter Unit .......................................................................................... 12
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2.1.3.2 RigidArmTM Universal Battery Adapter ........................................................... 12
2.1.3.3 SnapLockTM Universal Battery Adapter (4-wire versions only) ....................... 13
2.1.3.4 Load Capture Unit (LCU) ................................................................................. 13
2.1.3.5 C8000 Rack Mounting Bracket Set .................................................................. 13
2.1.4 Front Panel ................................................................................................................ 14
2.1.4.1 LCD Settings ..................................................................................................... 14
2.1.4.2 Channel Key Buttons ........................................................................................ 14
2.1.4.3 Arrow and ENTER Buttons .............................................................................. 15
2.1.4.4 Navigating the LCD Display ............................................................................ 15
2.1.4.5 Numeric Keypad ............................................................................................... 15
2.1.4.6 Battery Port Connections .................................................................................. 16
2.1.5 Back Panel ................................................................................................................ 17
2.1.5.1 AC Input............................................................................................................ 17
2.1.5.2 Ethernet Port ..................................................................................................... 17
2.1.5.3 Serial Ports and USB Port ................................................................................. 17
2.1.5.4 Cooling Fans ..................................................................................................... 18
2.2 Cadex C8000 Adapter Unit ........................................................................................... 18
2.2.1 Cadex C8000 Adapter Unit ....................................................................................... 18
2.2.2 Connect the C8000 Adapter Unit to the C8000. ....................................................... 19
2.3 Cables ............................................................................................................................ 20
2.3.1 Power Port Cable ...................................................................................................... 20
2.3.2 Connect the Power Port Cable to the C8000 ............................................................ 20
2.3.3 Auxiliary data cables (for I/O ports) ......................................................................... 23
2.4 C8000 Specifications .................................................................................................... 26
2.4.1 C8000 System Techincal Specifications ................................................................... 26
2.4.2 Auxillary Port Absolute Maximum Ratings ............................................................. 28
2.4.3 Auxillary Port Operating Ratings ............................................................................. 29
2.5 Configure the C8000 ..................................................................................................... 30
2.5.1 Set Up the C8000 ...................................................................................................... 30
2.6 User Maintenance for the C8000 .................................................................................. 30
2.6.1 User Maintenance Warnings ..................................................................................... 30
2.6.2 Clean the C8000 ........................................................................................................ 31
2.6.3 Replace the Fuse ....................................................................................................... 31
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2.6.4 Replace the Backup Battery ...................................................................................... 32
2.7 The Battery Tester Application ..................................................................................... 35
2.7.1 Execute a Program on a Battery ................................................................................ 36
2.7.1.1 Execute a Program without BatteryLab ............................................................ 36
2.7.1.2 Suspend and Resume a Running Program ........................................................ 39
2.7.1.3 Abort a Running Program ................................................................................. 39
2.7.1.4 View Auxiliary Port Information ...................................................................... 40
2.7.1.5 Jump to a Specific Program Step ...................................................................... 41
2.7.1.6 View SM-Bus Information ............................................................................... 42
2.7.1.7 Select a Program to Run ................................................................................... 43
2.7.2 Test Results ............................................................................................................... 45
2.7.2.1 View Test Results ............................................................................................. 45
2.7.2.2 Print Test Results .............................................................................................. 46
2.7.2.3 Delete a Test Result .......................................................................................... 46
2.7.2.4 Delete All Test Results ..................................................................................... 47
2.7.3 Battery Profiles ......................................................................................................... 48
2.7.3.1 View and Edit a Battery Profile ........................................................................ 49
2.7.3.2 Delete a Battery Profile ..................................................................................... 51
2.8 C-Codes......................................................................................................................... 52
2.8.1 Add, Edit, and Delete C-Codes ................................................................................. 52
2.8.1.1 Create a C-Code ................................................................................................ 53
2.8.1.2 View and Edit a C-Code ................................................................................... 53
2.8.1.3 Delete a C-Code ................................................................................................ 56
2.8.2 Import a C-Code ....................................................................................................... 57
2.8.3 Export a C-Code ....................................................................................................... 58
2.9 Programs ....................................................................................................................... 59
2.9.1 View a Custom Program ........................................................................................... 59
2.9.2 Delete a Custom Program ......................................................................................... 60
2.10 Waveforms .................................................................................................................... 61
2.10.1 View Information about a Waveform ................................................................... 61
2.10.2 Delete a Waveform ............................................................................................... 62
2.11 Specify System Options ................................................................................................ 63
2.11.1 Set the Clock ......................................................................................................... 63
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2.11.2 User Information ................................................................................................... 64
2.11.3 LCD Settings ......................................................................................................... 65
2.11.4 Serial Ports ............................................................................................................ 65
2.11.5 Specify the TCP/IP Address on the C8000 ........................................................... 66
2.11.6 Maintenance .......................................................................................................... 67
2.11.7 Options .................................................................................................................. 67
2.11.8 Security ................................................................................................................. 69
2.11.9 System Information ............................................................................................... 70
2.11.10 Factory Defaults .................................................................................................... 72
2.12 External Devices ........................................................................................................... 73
2.12.1.1 Programmable DC Electronic Loads ............................................................ 73
2.12.1.2 Thermal Chambers ........................................................................................ 73
3 Cadex BatteryLab ............................................................................................................... 74
3.1 System Setup ................................................................................................................. 74
3.1.1 System Requirements................................................................................................ 74
3.1.2 Set Windows Explorer and My Computer to Display File Extensions. ................... 75
3.1.3 Create a Database for BatteryLab ............................................................................. 75
3.1.4 Back Up the Data Files on the PC ............................................................................ 76
3.1.5 Install and Uninstall BatteryLab ............................................................................... 76
3.1.5.1 Install BatteryLab.............................................................................................. 77
3.1.5.2 Uninstall BatteryLab ......................................................................................... 80
3.1.6 Software Updates ...................................................................................................... 81
3.1.6.1 Software Version .............................................................................................. 81
3.1.6.2 Update BatteryLab Software ............................................................................. 81
3.1.7 BatteryLab Security Information .............................................................................. 82
3.1.8 Set Up BatteryLab..................................................................................................... 82
3.1.8.1 Connect the C8000 to the Network ................................................................... 83
3.1.8.2 Set Up the C8000 to Use BatteryLab ................................................................ 83
3.1.8.3 Choose IP Addresses for the Local Network .................................................... 83
3.1.8.4 Find the IP Address for Your PC ...................................................................... 84
3.1.8.5 TCP/IP Settings ................................................................................................. 84
3.1.8.6 Network Cable .................................................................................................. 85
3.1.9 Firewalls .................................................................................................................... 85
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3.1.9.1 Ports .................................................................................................................. 86
3.1.9.2 Other Firewall Software or Hardware............................................................... 86
3.1.10 Selecting a TCP/IP Address for the C8000........................................................... 86
3.1.10.1 Before Entering the Settings ......................................................................... 86
3.1.10.2 Ping the Network to Check for Available IP address ................................... 88
3.1.10.3 Add IP Addresses for C8000s on the PC ...................................................... 88
3.1.10.4 Disable an IP address .................................................................................... 90
3.1.11 Start the BatteryLab Program ............................................................................... 90
3.1.11.1 The Menu Bar ............................................................................................... 90
3.1.12 Set the Clock on the C8000 .................................................................................. 92
3.1.13 Set Security Setting on the C8000 ........................................................................ 93
3.1.14 Set the Password to Configure C8000 Functions ................................................. 94
3.1.15 C8000 Settings ...................................................................................................... 94
3.1.16 Alert Window........................................................................................................ 96
3.1.17 Exit BatteryLab ..................................................................................................... 97
3.2 Configure BatteryLab ................................................................................................... 98
3.2.1 Results Panel ............................................................................................................. 98
3.2.2 Event Logging ......................................................................................................... 101
3.2.3 Report Template Options ........................................................................................ 102
3.2.4 Graph Options ......................................................................................................... 102
3.3 View Battery Status in Real-Time .............................................................................. 104
3.4 Test Batteries with BatteryLab ................................................................................... 108
3.4.1 View the Status of a Test in BatteryLab ................................................................. 110
3.4.1.1 Background Color of Tests Running .............................................................. 110
3.4.2 Cancel or Suspend a Test in BatteryLab ................................................................. 111
3.4.2.1 Cancel a Test ................................................................................................... 111
3.4.2.2 Suspend a Test ................................................................................................ 111
3.4.2.3 Resume a Suspended Test ............................................................................... 111
3.4.2.4 Simulate a Battery Removal ........................................................................... 111
3.4.3 Retrieve Test Results from the C8000 .................................................................... 111
3.5 Test Status ................................................................................................................... 112
3.6 View Test Results in BatteryLab ................................................................................ 113
3.6.1 Import Test Results ................................................................................................. 114
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3.6.2 Print a Search List ................................................................................................... 114
3.6.3 View and Print Test Details .................................................................................... 115
3.6.3.1 Edit a Test Result Record ............................................................................... 116
3.6.3.2 Delete a Battery Test Record .......................................................................... 117
3.6.3.3 Print Test Result Document ............................................................................ 117
3.6.3.4 View Details.................................................................................................... 118
3.6.3.5 View Program Steps ....................................................................................... 118
3.6.3.6 View a Battery Test Graph ............................................................................. 119
3.6.3.7 View C-Code Information .............................................................................. 119
3.6.3.8 Custom Waveform .......................................................................................... 120
3.6.3.9 Playback a Waveform ..................................................................................... 120
3.6.3.10 Load Capture Waveform............................................................................. 121
3.6.3.11 View Termination Data............................................................................... 121
3.6.3.12 Cycle Graph ................................................................................................ 122
3.6.3.13 Print Results ................................................................................................ 123
3.6.3.14 Print a Battery Test Graph .......................................................................... 123
3.6.3.15 Export Test Record Results to a File .......................................................... 123
3.6.3.16 Export Graph Data To a File ....................................................................... 124
3.6.3.17 Export Termination Data to a File .............................................................. 125
3.7 Reports ........................................................................................................................ 125
3.7.1 Print Battery Test Reports ....................................................................................... 125
3.7.2 Add, Edit, and Delete Report Templates ................................................................ 125
3.7.2.1 Add a Report Template: .................................................................................. 125
3.7.2.2 Edit a Report Template: .................................................................................. 127
3.7.2.3 Set the Default Report Template..................................................................... 128
3.7.2.4 Delete a Report Template ............................................................................... 129
3.7.2.5 Copy a Report Template ................................................................................. 130
3.7.2.6 Set Up Your Printer ........................................................................................ 132
3.8 Battery ID Database .................................................................................................... 134
3.8.1 Add a Battery ID ..................................................................................................... 134
3.8.2 Edit a Battery ID ..................................................................................................... 135
3.8.3 Delete a Battery ID ................................................................................................. 136
3.8.4 Copy a Battery ID ................................................................................................... 138
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3.8.5 Import a Battery ID ................................................................................................. 139
3.8.6 Export a Battery ID ................................................................................................. 143
3.8.7 Search for a Battery ID ........................................................................................... 147
3.8.8 Sort Battery IDs ...................................................................................................... 147
3.9 C-Code ........................................................................................................................ 147
3.9.1 Add a C-Code ......................................................................................................... 147
3.9.2 Add a SM-BUS (Smart Battery) C-Code................................................................ 148
3.9.3 Edit a C-Code .......................................................................................................... 152
3.9.4 Delete a C-Code ...................................................................................................... 153
3.9.5 Copy a C-Code ........................................................................................................ 155
3.9.6 Import a C-Code ..................................................................................................... 156
3.9.7 Export a C-Code ..................................................................................................... 160
3.9.8 Search for a C-Code ................................................................................................ 164
3.9.9 Sort the C-Codes ..................................................................................................... 164
3.10 Programs ..................................................................................................................... 164
3.10.1 Factory Default Programs ................................................................................... 165
3.10.2 A Custom-Program Example .............................................................................. 171
3.10.3 A Custom-Program with Thermal Chamber Example........................................ 175
3.10.4 Add a Program .................................................................................................... 183
3.10.4.1 Add a Step to a Program ............................................................................. 184
3.10.4.2 Remove a Step from a Program .................................................................. 193
3.10.4.3 Copy a Step in a Program ........................................................................... 193
3.10.4.4 Save the Custom Program ........................................................................... 193
3.10.5 Add Folders ......................................................................................................... 194
3.10.6 Edit a Program .................................................................................................... 195
3.10.7 Delete a Program................................................................................................. 196
3.10.8 Copy a Program .................................................................................................. 199
3.10.9 Organize Programs in Folders ............................................................................ 202
3.10.10 Import a Program ................................................................................................ 203
3.10.11 Export a Program ................................................................................................ 207
3.10.12 Search for a Program .......................................................................................... 210
3.10.13 Sort Programs and Folders .................................................................................. 210
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3.11 Load Capture ............................................................................................................... 211
3.11.1 Load Capture Programs Database ....................................................................... 215
3.11.2 Add a Load Capture Program ............................................................................. 215
3.11.3 Edit a Load Capture Program ............................................................................. 216
3.11.4 Delete a Load Capture Program .......................................................................... 218
3.11.5 Copy a Load Capture Program ........................................................................... 219
3.11.6 Import a Load Capture Program ......................................................................... 221
3.11.7 Export a Load Capture Program ......................................................................... 222
3.11.8 Search for a Load Capture Program.................................................................... 224
3.11.9 Sort the Load Capture Programs ......................................................................... 224
3.12 Waveforms .................................................................................................................. 224
3.12.1 Sample Custom Waveform ................................................................................. 224
3.12.2 Add a Waveform ................................................................................................. 228
3.12.2.1 Add a Step to a Waveform .......................................................................... 230
3.12.2.2 Remove a Step from a Waveform ............................................................... 230
3.12.2.3 Copy a Step to Another Step in a Waveform .............................................. 230
3.12.2.4 Move the Order of Steps in a Waveform .................................................... 231
3.12.3 Organize Waveforms in Folders ......................................................................... 231
3.12.4 Edit a Waveform ................................................................................................. 233
3.12.5 Delete a Waveform ............................................................................................. 234
3.12.6 Copy a Waveform ............................................................................................... 235
3.12.7 Import a Waveform ............................................................................................. 237
3.12.8 Export a Waveform ............................................................................................. 240
3.12.9 Search for a Waveform ....................................................................................... 244
3.12.10 Sort the Waveforms ............................................................................................ 244
3.13 Sequences .................................................................................................................... 244
3.13.1 Add a Program Sequence .................................................................................... 245
3.13.2 Edit a Program Sequence .................................................................................... 246
3.13.3 Delete a Program Sequence ................................................................................ 248
3.13.4 Copy a Program Sequence .................................................................................. 249
3.13.5 Import a Program Sequence ................................................................................ 251
3.13.6 Export a Program Sequence ................................................................................ 255
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3.13.7 Search for a Program Sequence .......................................................................... 259
3.13.8 Sort Program Sequences ..................................................................................... 259
3.14 System Updates ........................................................................................................... 260
3.14.1 Firmware Information ......................................................................................... 260
3.14.1.1 Update the Firmware on the C8000s .......................................................... 260
3.14.1.2 Update the Calibration Data........................................................................ 262
3.15 Troubleshooting .......................................................................................................... 263
3.15.1.1 Communication Issues ................................................................................ 263
3.15.1.2 Frozen Keyboard and LCD Display ........................................................... 263
3.15.1.3 Check IP Addresses .................................................................................... 263
3.15.1.4 DAO Error .................................................................................................. 263
3.15.1.5 Corrupt Database ........................................................................................ 264
3.15.1.6 Folder Access Permissions ......................................................................... 264
3.15.1.7 Set Access Permissions in Windows XP .................................................... 264
3.15.1.8 Error Writing to the Log File ...................................................................... 265
4 C-Code Parameters ........................................................................................................... 266
5 Status Messages ................................................................................................................. 273
5.1 Status Messages Listed by Code ................................................................................. 273
5.2 Status Messages Listed by Detailed Message ............................................................. 278
6 Glossary of Terms ............................................................................................................. 281
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C8000 Battery Testing System User Manual
1 Safety and Warranty
1.1 Cautions and Warnings
1.1.1 Use of Equipment
The C8000 Battery Testing System is designed with adequate safeguards to
protect you 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.
1.1.2 Modification of Equipment
CE, FCC, Safety Agency, and other approvals apply only to the C8000 Battery
Testing System in the factory-authorized configuration. Changes or modification
to the equipment not expressly approved by Cadex will void the approvals and
void your authority to operate the equipment.
Safety and Warranty 1
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C8000 Battery Testing System User Manual
1.1.3 Hazard Symbols
The following symbols are used to warn of potential hazards:
Warning or Danger
Information that, if ignored, can result in serious injury or death.
Caution
Information that, if ignored, can result in damage to the C8000 Battery Testing
System, battery adapters, or the battery.
Potential Electrical Shock Hazard
Potential Explosion Hazard
2 Safety and Warranty
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C8000 Battery Testing System User Manual
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 to drop off waste equipment
for disposal, please contact your local municipal office,
waste disposal service, or wherever you purchased the
product.
1.1.4 Disposal of Waste Electrical and Electronic Equipment (WEEE)
in the European Union
1.1.5 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 you must take whatever
measures needed to correct the interference, at your 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 you must, at your expense, take adequate corrective
Safety and Warranty 3
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.
Caution
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C8000 Battery Testing System User Manual
The equipment may be affected by interference from other devices. If the
equipment is running abnormally, please ensure that the equipment is moved
away from any source of radio interference.
1.1.6 Explosion Hazard
Warning
Batteries can burst if treated improperly. Follow
these precautions at all times:
Do
Clean battery contacts before servicing. To clean battery
contacts, use a lint-free cotton swab dipped in 100%
isopropyl alcohol.
Do Not
Press the battery firmly into the adapter.
Observe battery temperature, which is displayed on the
C8000 Status screen. Internal battery temperature must be
between 5°C (41°F) and 50°C (122°F) during testing. Stop
service if the battery's internal temperature exceeds 50°C.
Allow cold batteries to warm up and hot batteries to cool
before charging. The temperatures cited here are the
battery temperatures, not the ambient temperatures. Fast
charging outside this temperature range may damage or
reduce the life of the battery.
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 channel to another. Failing
to follow the guidelines in this manual could result in
venting with flame, explosion, fire and personal injury. An
electrical short to any point outside the channel bypasses
the current regulation loop and may blow a fuse or cause
permanent component damage.
4 Safety and Warranty
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C8000 Battery Testing System User Manual
Do not exceed the battery manufacturer’s recommended
charge current and voltage limits for batteries.
Do not remove the battery from the adapter while the test
is running. To minimize arcing, stop or cancel battery
service before removing the battery from the adapter.
1.1.7 Charge and Discharge 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.
Warning
Please follow these 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.
Explosion Hazard
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.
Safety and Warranty 5
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C8000 Battery Testing System User Manual
1.1.8 Shock Hazard
Warning
The C8000 Battery Testing System contains highvoltage circuits, and can pose a shock hazard
when the upper cover is removed. Do not attempt
to perform any service procedures on the tester
other than replacement of the external fuse or
internal backup battery.
Shock Danger
To reduce the risk of electrical shock hazard, service batteries only when
they are removed and disconnected from their end-use equipment.
Use the tester 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 tester.
Before attempting any internal service, remove all batteries from the battery
channels, turn the C8000 Battery Testing System 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.
Replace the internal backup battery only with the same type of battery.
Observe the correct polarity when installing the backup battery. Discard the
used battery according to the battery manufacturer’s instructions.
6 Safety and Warranty
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C8000 Battery Testing System User Manual
1.2 Warranty and Service
Cadex Electronics Inc. warrants your C8000 Battery Testing Unit against
defective materials and workmanship for a period of two (2) years from the
original purchase date.
The warranty does not cover:
Damage caused by abusive operation, negligence, accident, or improper
installation.
Damage caused by an attempted repair not authorized by Cadex.
Cosmetic damage caused by normal wear and tear.
Damage from external causes such as leakage spills, power fluctuations,
power failures, or inadequate shipping.
Product received without the appropriate model number, serial number, or
safety markings.
Products used for rental purposes.
1.2.1 Warranty Service
Before sending the unit for service, contact Cadex Technical Support. If your
product requires warranty service, the representative will provide a Material
Return Authorization Form or Material Return Authorization (MRA) and the
location of the nearest service center.
Ship the product to the service center with freight, insurance, and customs
duties prepaid. The MRA must be included to obtain warranty service.
Ensure that each unit 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.
Safety and Warranty 7
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C8000 Battery Testing System User Manual
1.2.2 Non Warranty Repairs
Before sending the unit in for service, contact Cadex Technical Support at 1-800565-5228 or 1-604-231-7777. 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.
Cadex Electronics Inc. and Cadex authorized service centers require a Purchase
Order or written authorization to precede with repairs.
1.3 Back Up and Restore Calibration Data
It is possible to manually back up the calibration data for each
C8000 using the System Update window. This calibration data
includes the settings used on the unit, such as the IP address and
mask. Back up of the calibration data from the PC to removable
media (writeable CD, DVD, or magnetic tape) is recommended.
1.3.1 Back Up Calibration Data
If required, following the instructions below can perform a
manual backup of the calibration data. Note: By default the
calibration data is stored in the following location; C:\Documents
and Settings\All Users\Application Data\Cadex Batlab\DB\
Calibration
1. From the Tools menu, click System Update.
2. Select the check box for each C8000 to back up calibration
data for.
3. Under the Calibration tab, click Backup Calibration Data.
4. Click OK.
1.3.2 Restore Calibration Data
BatteryLab copies (restores) backed up calibration data from the
database.
To restore calibration data:
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1. From the Tools menu, click System Update.
2. Select the check box for each C8000 to restore calibration
data for.
3. Under the Calibration tab, click Restore Calibration Data
to restore previously backed up data.
4. Click OK.
Important
Each new C8000 has been calibrated at the factory,
and has its factory calibration data stored on the
C8000. This calibration data is essential to providing
accurate testing of batteries.
On receipt of each new C8000, configure the unit with
a static IP address, the network mask address, and the
PC Host IP address. Then run BatteryLab and
configure BatteryLab to allow connection from the new
C8000. Choose Connect to allow BatteryLab to
automatically backup the calibration data for the new
C8000.
This calibration data is essential to providing accurate
testing of batteries. After installing and configuring
Cadex BatteryLab to communicate with the C8000, use
BatteryLab to back up the calibration data to the
computer.
Each new C8000 should be connected to the PC for
BatteryLab to automatically back up the calibration
data.
If, for any reason, the calibration data on the C8000
gets corrupted, the calibration data can be restored
from the backup copy. Otherwise, the C8000 must be
shipped to a Cadex Service Centre for re-calibration.
The shipping and service cost is not covered by the
warranty.
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2 Battery Tester
2.1 Getting Started with the Battery Tester
2.1.1 The C8000 Battery Tester User Manual
Welcome to the Cadex C8000 Battery Tester User Manual. This
manual provides instructions to configure the C8000 and to test
batteries. Up to four batteries can be tested at any time using one
of several testing programs.
2.1.1.1 Topics You Need to Know
To properly use the C8000, review the following sections of this
manual:
Cautions and Warnings
Configure the C8000
Test Batteries
View Test Results
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Caution!
The C8000 has been calibrated at the factory and has
its factory calibration data stored on it. The calibration
data is automatically backed up to a file in the
\Batlab\DB folder (or the folder indicated in the About
window) when a C8000 connects to Cadex BatteryLab.
If for any reason, the calibration data on the C8000
gets corrupted, restore the calibration data from the
backup copy provided by Cadex Electronics.
For more information, see 1.3 Back Up and Restore Calibration Data.
2.1.2 What is in the Box
The C8000 box contains:
(1) C8000 Battery Testing System (Part #11-308-0000)
(4) 1.8m (6’) Power port cables (for battery ports)
Power Port Cable (Part #17-670-0058)
Alligator Clips:
Part #62-634-0002 (Red 2mm)
Part #62-634-0003 (Black 2mm)
Part #62-634-0010 (Red 4.4mm)
Part #62-634-0011 (Black 4.4mm)
Specifications:
o Voltage: 0~48V
o Current: 0~10A
o Wattage: 0~100W
(4) 1.8m (6’) Auxiliary data cables (for I/O ports) (Part#17-
670-0059)
(1) C8000 DUAL POWER PORT CABLE (Part# 17-070-
1008)
Specifications:
o Voltage: 0~48V
o Current: 0~20A
o Wattage: 0~200W
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(3) Power cords
(1) North American power cord (Part #68-723-1815)
(1) British power cord (Part #68-723-1806)
(1) European power cord (Part #68-723-1805)
(1) 3m (10’) Ethernet cable
(The supplied Ethernet cable is only required for
communication between BatteryLab and the
C8000.) (Part #68-931-0010)
(1) BatteryLab PC software on CD-ROM (Part #84-100-
0010)
Before configuring the C8000 Battery Tester, become familiar with
the Front Panel, Back Panel and Components of the Battery
Adapter sections of this manual. When ready, see section 2.5
Configure the C8000 to continue.
Caution
The case of the C8000 has air vents to allow cooling
airflow. Do not cover, block, or obstruct the air-vents.
2.1.3 Optional C8000 Accessories
2.1.3.1 C8000 Adapter Unit
Desktop converter unit that provides cross platform compatibility
with SnapLockTM and RigidArmTM Battery Adapters (4-wire
version only). Battery applications include Cellular phones, 2-way
radios and other custom applications.
Specifications:
Supports all RigidArm and SnapLock 4-wire series adapters.
2.1.3.2 RigidArmTM Universal Battery Adapter
RigidArmTM allows for easy connection to cellular batteries of any
size. Spring-loaded arms lock in position to allow quick and
accurate setup for repetitive testing. A retractable floor holds
batteries vertically or horizontally; adjustable magnetic battery
guides are included. Requires C8000 Adapter Unit.
Specifications:
Voltage: 18V
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Current: 3A
2.1.3.3 SnapLockTM Universal Battery Adapter (4-wire versions only)
SnapLock
easy hook up. The adapter contains C-Codes that can be used to
configure the C8000 and other Cadex platforms to the correct
setting. Specialty adapters available on request. Requires C8000
Adapter Unit.
Specifications:
Voltage: 18V
Current: 3A
TM
gives a precise connection to the battery allowing for
2.1.3.4 Load Capture Unit (LCU)
LCU captures and stores load signatures (in BatteryLab) of any
device up to 100A in real-time. Capture a power tool load
signature (or any other electronic device) by drilling through a
steel beam. Then apply a repeatable load signature to any battery
to determine; performance characteristics, battery life, time of use,
etc. Other applications for the LCU include spinning up a hard
drive on a laptop or accelerating an electric motor.
Specifications:
Buss-bar Current:
o 0-10A (2% of Full Scale, Ripple: 20mA)
o 0-100A (2% of Full Scale, Ripple: 50mA)
External Current Clamp:
o 0-400A (1% of Full Scale, Ripple: 500mA)
Voltage Input Terminals:
o 500mV~48V (2% of Scale, Ripple: 20mV)
Capture Frequency:
o DC to 250Hz
Thermal Couple:
o Supports K-type –
±2°C plus Thermal Couple accuracy
2.1.3.5 C8000 Rack Mounting Bracket Set
For 19” 3U mounting type rack. (PN# 92-470-0054)
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Display and Controls
2.1.4 Front Panel
2.1.4.1 LCD Settings
The LCD screen displays the fields that you need to fill in prior to
executing a test and also displays test status and results. Use the
keypad and arrow buttons to enter information into the fields on
the screen.
2.1.4.2 Channel Key Buttons
There are four channel key buttons below the LCD screen. The
functions of these buttons vary depending on the window
displayed on the LCD. The function (if any) of each button is
displayed on the screen, just above the button.
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Use the arrow buttons to move from
field to field.
Use the ENTER button to accept the
information entered into the fields
Use the Numeric Keypad to enter
numbers in the selected field.
To exit from a field without saving
changes, press the ESC key.
2.1.4.3 Arrow and ENTER Buttons
Note: The Menu and Print buttons are not used. The Edit button
activates the onscreen keypad when an editable field is selected on
the C8000.
2.1.4.4 Navigating the LCD Display
2.1.4.5 Numeric Keypad
Use the , and arrow keys to move from one field to
another.
Press the Edit key to activate the selected remark field for
edits.
Use the and keys to scroll through the alphabet.
Press
ENTER to select the letter
Use the numeric keypad to enter numbers in the selected
field.
Press ENTER to save the data you have entered in the field
and move to the next field.
Press OK to save the data you entered in the screen.
.
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Each Battery Port is used to plug
a Power Port Cable and I/O Port
is used for secondary
measurements and control. A
C8000 Adapter Unit use both
ports for the SnapLock
TM
/Rigidarm
TM
series adapters For
more information about the
SnapLock Adapter, see 2.1.3.3
SnapLockTM Universal Battery
Adapter (4-wire versions only).
If the plastic button on a circuit
breaker pops out, the breaker has
tripped. Determine and correct
the condition that caused the
breaker to trip.
Allow the breaker to cool for 15
minutes before pushing in the
button to reset the breaker.
2.1.4.6 Battery Port Connections
There are four port connections, to attach up to four battery
adapters.
Each channel has a battery port, an auxiliary input/output, and a
circuit breaker.
A battery adapter may not always be available.
In most cases, the channel cable will terminate with
positive/negative wires and have a magnetic temperature probe
to attach to the battery.
If the breaker button does not stay in when you push it, allow
more time for the breaker to cool. (The breaker does not
automatically reset.)
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2.1.5 Back Panel
2.1.5.1 AC Input
The AC Input connects the C8000 to an AC electrical power source
with the provided power cord. The power entry uses standard
IEC320 socket on the back panel. A fuse protects the C8000 from
AC overload.
2.1.5.2 Ethernet Port
The Ethernet port is used to connect the C8000 to the network or
the host computer. The Ethernet Port (on the back panel) has two
LEDs to indicate communication between the C8000 and a
computer.
Use this port with the TCP/IP Settings menu. For more
information, see 3.1.8.5 TCP/IP Settings.
2.1.5.3 Serial Ports and USB Port
The first Serial Port (DB9 Female I/O sockets) on the C8000 is
reserved. The intended uses of the remaining Serial Ports are for
Cadex-approved External Loads (Serial Port 2) and Thermal
Chamber (Serial Port 3) controls.
Pinout Serial Ports (2) and (3)
1 – Not Used
2 – RX (Receive signal)
3- TX (Transmit signal)
4- DTR (Digital Terminal Ready) 5V
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5 – GND (Ground)
6 – Not Used
7 – RTS (Request To Send)
8 – CTS (Clear To Send)
9 – Not Used
USB functionality is not enabled.
2.1.5.4 Cooling Fans
The thermostatically controlled fans operate automatically to keep
the inside of the C8000 at optimum temperature. Keep all case
vents and fan openings clear to ensure free airflow through the
C8000.
2.2 Cadex C8000 Adapter Unit
2.2.1 Cadex C8000 Adapter Unit
The Cadex C8000 Adapter Unit allows C7x00 adapter to be used
with the C8000.
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2.2.2 Connect the C8000 Adapter Unit to the C8000.
1. Align the notch on the battery connector cable plug with the
notch on the battery connector and push in the cable.
2. Push the battery connector plug in while turning the ring on
the battery connector clockwise until the lock is engaged.
See 2.3.2 Connect the Power Port Cable to the C8000 for
instructions on how to connect the Power Port Cable.
3. Push the DB25 female connector in to corresponding
Auxiliary connector of the C8000 channel and tighten the
connector hand screws.
To remove the battery connector cable from the C8000, turn the
ring on the connector plug counter-clockwise and then pull the
cable plug out of the connector.
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2.3 Cables
2.3.1 Power Port Cable
The Power Port Cable conducts electric power between a
connected battery and the C8000. The Power Port Cable is used
only for power transfer, voltage measurement and temperature
reads – all other functions operate via the Auxiliary Input/Output
(I/O) cable.
To achieve better accuracy, the C8000 utilizes a four-wire design,
where the two main wires provide a path for charge and
discharge currents while the other two paths measure the voltage
as close to the battery as possible.
2.3.2 Connect the Power Port Cable to the C8000
a. To connect a Power port cable or Dual power port cable.
i. On the C8000 front panel, choose your desired battery channel.
Note: The Dual power port cable can be connected to channels 1 & 2
and/or 3 & 4.
ii. Align the notch with the tab on the power port cable connector (see
connector end diagrams).
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Figure 1 – Power port cable connector end-view
Figure 2 – Dual power port cable connector end-view
iii. Push the battery connector plug into the desired battery channel outlet
(on the C8000), then rotate the locking wheel to secure the connector to
the battery channel outlet.
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Figure 3 – Channel 1 outlet (on C8000)
iv. The Power port cable is now ready to connect to a battery.
To remove the battery connector cable from the C8000, turn the
ring on the connector plug counter-clockwise and then pull the
cable plug out of the connector.
The following diagram shows how the Drive and Sense lines of
the cable should be connected for normal operation.
The cable has six leads as follows:
Two drive lines with heavy gauge wire to supply the
charge and discharge current
Two sense lines to measure the voltage on the battery
terminals. Warning: Sense lines should be connected to the
battery terminals and correctly installed - otherwise,
incorrect operation may occur.
The sense plugs can be plugged into the drive plug molded
body for single connection to the battery.
Two for the magnetic temperature sensor. The magnetic
temperature probe should be attached to the casing of the
battery.
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2.3.3 Auxiliary data cables (for I/O ports)
The Auxiliary data cables (for I/O ports) enables the C8000 to
interface with third-party devices, the Cadex
SnapLock/RigidArm series (when using the C8000 Adapter Unit),
and SM-Bus batteries.
Custom programs can be configured to control and respond to
states of the configurable lines.
The connector provides the following interfaces:
SM-Bus
Four configurable Digital Inputs or Outputs (Program
Configurable) (Pull-up Required)
Two Analog outputs (Program Configurable)
Four Differential Analog inputs with selectable ranges
(Program Configurable).
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Note: Once theC8000 Adapter Unit is connected, the input/output
ports become reserved.
The following diagrams show the pin and electrical specifications
of interfaces for the Auxiliary Input/Output Connector.
Auxiliary data cables (for I/O ports) Pinout Diagram
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Pin #
Function
Wire Color
1
Digital I/O 1
White
2
Digital I/O 2
Yellow
3
Digital I/O 3
Orange
4
Digital I/O 4
Pink
5
Analog Out 1
Gray
6
Analog Out 2
Brown
7
Ground
Black
8
+5VDC
Red
9
SMBC
Purple/white
10
SMB D I/O
Brown/white
11
SMB DO
Black/white
12
Reserved
Yellow/black
13
Reserved
Pink/black
14
Ground
Green
15
Temperature (T+)
Blue
16
Pressure (P+)
Purple
17
Differential Analog Input 1 Positive (+)
Red/white
18
Differential Analog Input 1 Negative (-)
Red/black
19
Differential Analog Input 2 Positive (+)
Orange/white
20
Differential Analog Input 2 Negative (-)
Orange/black
21
Differential Analog Input 3 Positive (+)
Green/white
22
Differential Analog Input 3 Negative (-)
Green/black
23
Differential Analog Input 4 Positive (+)
Blue/white
24
Differential Analog Input 4 Negative (-)
Gray/black
25
Ground
Light green
Shell
Earth
Drain
Auxiliary data cables (for I/O ports) Wiring Chart
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Channels
4 Independent Channels each including:
1 Battery Port + 1 I/O Port
Physical
Dimensions
480mm x 380mm x 140mm (18.9” x 15.0” x 5.5”)
Weight
15.5 kg (34 lb)
Mounting Options
Desktop or 19” (483mm) 3U Rack-mount
Display
5.7” (145mm) QVGA 320x240 graphics with
backlight
Battery Ports (front panel)
4 Ports each including:
Battery Positive (+)
Battery Negative (-)
Sense Positive (+)
Sense Negative (-)
Thermistor Input
Thermistor Ground
Auxillary Ports (I/O) (front panel)
4 x DB25 Type each including:
4 Differential Analog Inputs: 0-5V, 0-10V, or
0-15V
4 Digital Inputs: 0-5V
2 General Purpose Analog Outputs: 0-5V
SMBus Enabled: 5 Possible Termination
Signals
Active Data Ports (back panel)
Ethernet 10/100MB for connection to PC
Designated Serial Port for External Load
Designated Serial Port for Environmental
Chamber
Environment
Operating Temperature
5ºC-35ºC (40ºF-95ºF)
Storage Temperature
-20ºC-70ºC (-4ºF-160ºF)
2.4 C8000 Specifications
2.4.1 C8000 System Techincal Specifications
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Battery Compatibilty
Chemistries
All Standard Battery Types
Lead Acid
Ni-based: NiMH, NiCd
Li-based: Li-ion, Li-Phosphate
Capacity Range
50mAh to 1000Ah
Electrical
Input Power
100-240 VAC
50-60 Hz
Battery Voltage Range
Nominal 1.2V-36V (max 45V) supports serial
connection of:
Up to 10 Li-ion cells (3.6V/cell)
Up to 18 Lead Acid cells (2.0V/cell)
Up to 30 Nickel-based cells (1.2V/cell)
Maximum Charge Power
100W per channel = 400W total
Maximum Discharge Power
80W per channel = 320W total
Dual Power Port cable may be to increase the
maximum Power Rate to 160W per channel pair
External Load may be used to increase
Discharge Rate up to 2400W
Maximum Charge/Discharge
Current
30mA to 10A set in 1mA increments
Dual Power Port cable may be to increase the
maximum Discharge Rate to 20A per channel
pair
External Load may be used to increase
Discharge Rate up to 240A
Output Frequency
Square 2 kHz (500 microseconds)
C8000 Accuracy
Voltage = 0.1% full scale
Current = 0.25% full scale
Other Specifications
Power Management
Current automatically scaled down if power
limits are exceeded – message indicates scaled
test
Charge Methods
Charge methods are dependent upon chemistry:
Li-ion + Lead Acid = constant current/
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constant voltage
Nickel-based = constant current (DC
charge) with optional Reverse Load Charge
method
Discharge Methods
Constant current
Constant power
Data Acquisition
System Sample Rate
500 microseconds
Termination Data (last 500
samples) Capture Rate
2~200 milliseconds
Capture/Display Rate (non-
termination)
1~60 seconds
Certification
Safety
CSA, UL, CE
Environmental
RoHS, WEEE
Voltage Setting
Maximum Rating
Voltage at Digital I/O 1-4:
-0.1 to +6V
Voltage at SMBC, SMBD or
SMBDIO:
-0.1 to +5.5V
Voltage at Analog Output 1-2:
-0.1 to +6V
Voltage at T+ or P+:
-0.1 to +5V
Voltage at Differential Analog
Input 1-4 (either input, relative
to ground):
-50 to +50V
Voltage at Differential Analog
±50V
2.4.2 Auxillary Port Absolute Maximum Ratings
When using the Auxiliary Input/Output Connector, the voltage
settings for the pins must not exceed the absolute maximum
ratings – otherwise the C8000 may become damaged. The absolute
maximum ratings for the Auxiliary Input/Output Connector are
as follows:
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Input 1-4 (differential):
Current at Digital I/O 1-3:
-20mA (open collector / sinking
only)
Current at Digital I/O 4:
-100mA (open collector /
sinking only)
Current at Analog Out 1-2:
±5mA
Current at +5VDC:
+100mA
Voltage Setting
Operating Rating
Voltage at Digital I/O 1-4:
0 to +5V (A Pull-up is required)
(open collector)
Voltage at SMBC, SMBD or
SMBDIO:
0 to +5V
Voltage at Analog Output 1-2:
0 to +5V (±1mA)
Voltage at T+ or P+:
0 to +3.3V
Voltage at Differential Analog
Input 1-4 (either input, relative
to ground):
0 to +48V
Voltage at Differential Analog
Input 1-4 (differential, + relative
to -):
0 to +15.5V
Impedance of Analog Input + to
-
~1.1MOhm
Impedance of Analog Input + to
gnd
~100kOhm
Impedance of Analog Input - to
gnd
~1MOhm
2.4.3 Auxillary Port Operating Ratings
When using the Auxiliary Input/Output Connector, the operating
ratings must be set according to the following settings:
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2.5 Configure the C8000
2.5.1 Set Up the C8000
To set up and configure the C8000 perform the following steps:
1. Plug in the power cord and ensure the battery adapter cords
are properly connected to the C8000.
2. Switch ON the C8000 set the clock and enters user information.
For instructions, see 2.11.1 Set the Clock and 2.11.2 User
Information.
3. If required, use LCD Settings to adjust the contrast of the LCD
display. See 2.11.3 LCD Settings for more information.
2.6 User Maintenance for the C8000
2.6.1 User Maintenance Warnings
Warning
There are no internal user-serviceable parts in the
C8000 other than the internal backup battery.
Except for changing the battery, unauthorized
disassembly and/or repair of the C8000 by anyone
other than an authorized Cadex Service Center may
cause a risk of injury or death and will void the
warranty.
For more information, see 1.1 Cautions and Warnings.
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2.6.2 Clean the C8000
Caution
Before cleaning, turn off the power and unplug the AC
power cord.
Do not allow any liquids to enter the case under any
circumstances.
Clean the C8000 only with a damp cloth moistened
with mild soap and water. Allow to thoroughly dry.
For more information, see 1.1 Cautions and Warnings.
2.6.3
Replace the Fuse
If the C8000 does not power up, make sure that the power cord is
properly inserted and that power is available.
If the C8000 still does not power up, the main (AC input) fuse may
need to be replaced.
Replace fuses only with fuses of the same type and rating:
Fuse 5x20mm T8A 250V, Cadex part number 52-546-0800.
Caution
Before replacing the fuse, unplug the power cord and
allow the C8000 to cool for at least one minute.
The C8000 contains capacitors that could retain a
charge after the AC power is disconnected.
For more information, see 1.1 Cautions and Warnings.
To replace the main fuse:
1. Remove all batteries and adapters, turn off the C8000, and
unplug the power cord from the AC Input.
Wait at least one minute before continuing.
2. Using a flathead screwdriver, position the screwdriver at
the top of the fuse cover (beneath the AC Input) and pry
open the fuse cover.
3. Carefully pull out the fuse.
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4. If the filament inside the glass tube is broken, replace the
fuse. Be aware that the filament can sometimes appear
intact even when it is broken.
5. With the fuse inserted, push the fuse cover back into place.
6. Connect the power cord and turn ON the C8000.
2.6.4 Replace the Backup Battery
Caution!
Test results may be lost when the backup battery is
removed. Backup the calibration data to the PC hard
disk. Retrieve test results stored on the C8000 to the
BatteryLab database. To download the test results to
BatteryLab, select Retrieve Results from the File menu
on the Test Results window. For more information,
see 3.6 View Test Results in BatteryLab.
The C8000 uses a 3-volt lithium coin battery (type CR2032 or
equivalent, Cadex part number 45-206-0001) to preserve settings
while the C8000 is turned OFF. With normal use of the C8000,
you will seldom need to replace the backup battery.
You will need the following items to replace the battery:
A #2 Phillips screwdriver.
A new 3-volt lithium battery.
A wrist strap or other device to eliminate electrostatic discharge.
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Wait at least one minute before continuing.
Do not attempt to open the C8000 while it is
plugged into an electrical outlet or any
peripheral device. Severe electrical shock to
the service person and/or damage to the
C8000 could result!
Do not use pliers or tweezers with bare
metal tips. They will short the battery and
could cause it to explode.
Caution! Electrostatic Sensitive Device
Do not open the C8000 or touch any part of its internal
components if you are not grounded.
Do not attempt to open the C8000 while it is plugged
into an electrical outlet or any peripheral device.
Severe electrical shock to the operator and/or damage
to the C8000 could result!
For more information, see 1.1 Cautions and Warnings.
To replace the backup battery in the C8000:
1. Remove all batteries and adapters, turn off the C8000 and
unplug the power cord and I/O port cords.
2. Use a Phillips screwdriver to remove the following screws:
Two screws on the right side.
Two screws on the back panel.
Two screws on the left side.
One screw on the top.
3. Remove the top cover by sliding it back slightly and then lifting.
The backup battery is located at the back of the C8000, in
front of the expansion slot and between two fans.
4. Move the upper clip of the battery holder out of the way.
5. Using your fingers or insulated pliers or tweezers, gently
pull the old battery out of the holder. Be very careful not to
damage the battery.
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Ensure correct battery polarity.
Insert the new battery in the holder, with the positive terminal
facing toward the fan until the clip slips in place.
1. Replace the cover, making sure that no interior wires or
cables are caught or pinched between the cover and the
C8000 case.
2. Replace the seven cover screws.
3. Plug in the power cord and cables.
4. Turn ON the C8000. The settings may have returned to
factory defaults, in which case you will need to reprogram
settings.
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2.7 The Battery Tester Application
Customizing features not available in standalone:
1. Waveform creation (Waveform revision information only)
2. Custom Programs (Version/Comment/ “I/O” port
configuration only) List feature only.
3. No Graphing or Detail information for Test Results.
(Summary of information only).
4. No Load Capture capabilities.
When you power on the C8000 without any batteries
connected, the Main screen appears: When connected to
BatteryLab, the C8000 displays the Unit # that corresponds
to BatteryLab’s windows.
The Main screen displays six menu items: 2.7.2 Test Results, 2.7.3
Battery Profiles, 2.8 C-Codes, 2.9 Programs, 2.10 Waveforms, and
2.11 Specify System Options.
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The date appears in the top left corner of the Main screen while
the time appears in the top right corner. When the caption says
C8000 – Unit 3, it means the C8000 is connected to BatteryLab. If
the caption says Cadex C8000, it means the C8000 is in standalone
mode. The bottom portion of the Main screen shows the channel
status on the first line and the channel voltages on the second line.
2.7.1 Execute a Program on a Battery
2.7.1.1 Execute a Program without BatteryLab
To execute a program (test) on a battery in standalone mode
without using BatteryLab:
1. Connect the battery.
2. Select a battery ID or C-Code from the StartUp screen.
Note: If the StartUp screen is minimized, the channel
status indicates “Startup”. Press the Channel button to
maximize the screen.
3. Select a program from the list of available programs on the
C8000. The list of available programs includes all Default
programs and any custom programs that have been
transferred to the C8000.
4. The test starts.
If a test is currently running, press the corresponding Channel
button to view current status on the Channel screen. The Channel
screen displays the status of this channel. From the Channel
screen you can suspend a program (2.7.1.2), resume a suspended
program (2.7.1.2), abort a program (2.7.1.3), jump to another step
in a multi-step program (2.7.1.5), and view auxiliary input and
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Field
Description
Battery ID
The battery’s identification. This field is
blank of a Battery ID has not been added to
BatteryLab.
Program
The name of the program that is being run.
Cycles
Indicates the number of charge and
discharge cycles that have been run during
any given program.
Test Results
Indicates the file name to which the current
program’s results will be saved to, during
operation. On completion of a program,
indicates the file to which the results have
been saved. Note: BatLab will generate an
impendent TEST ID and will incorporate the
data from the C8000 test result file.)
C-Code
The battery parameters being applied by the
C8000.
Step
The step number for the action currently
executing within the program.
Volts
Across the battery terminals. The current
Voltage across battery sense terminal lines.
(Screen is updated once per second.)
Amps
Charge or discharge current. (Screen is
output port information (2.7.1.4)
The following table describes the fields shown in the Channel
screen.
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updated once per second.)
Temp
Displays the current temperature at all
times. If a thermistor is not attached,
displays N/A. (Screen is updated once per
second.)
Capacity
A percentage value showing the battery’s
latest measured capacity. (Note: Only after a
Discharge Cycle has been run); otherwise
this displays N/A.
M-Ohms
The resistance of the battery measured in
milliohms. Displays the latest resistance
measurement otherwise N/A when
resistance measurement is not selected.
Elapsed
The time since starting the program on this
battery. Test times vary depending on the
program chosen and the condition of the
battery.
1. From the Main screen, press the Channel button for the
C8000 to test. The Channel screen appears.
2. The Channel screen shows the status of this channel,
providing a test is currently running.
3. To view additional information, press MORE. A second
Channel screen appears.
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2.7.1.2 Suspend and Resume a Running Program
While a program is running, it can be temporarily suspended.
Later, the program can be resumed.
1. From the Channel screen, click Suspend. The program is
immediately interrupted.
2. Press Resume to restart the program.
2.7.1.3 Abort a Running Program
To terminate a running program:
1. From the Channel screen, press ABORT. The Confirm
Action screen appears.
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2. Press OK. The Aborted screen appears.
2.7.1.4 View Auxiliary Port Information
While a program is active, the current program configuration can
be viewed.
1. From the Channel screen, press MORE. A second Channel
screen appears.
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2. Press AuxPorts. The Auxiliary Ports screen appears.
3. Press BACK twice to return to the Channel screen.
2.7.1.5 Jump to a Specific Program Step
A program may contain one or more action steps. The “JUMP”
command allows the ability to move immediately from the
current action step to any of the other action steps, within the
active program - for example, Charge, Discharge, Rest, and so on.
The Jump function moves to a specific step in the program.
1. From the Channel screen, press MORE. A second Channel
screen appears.
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2. Press JUMP. The Jump screen appears.
3. The Current Step field shows the current step that the
program is in. Enter the step number to move to in the
Jump To field and press OK. The C8000 will resume
program operation at the selected step.
2.7.1.6 View SM-Bus Information
Before using any SM-Bus battery functions, ensure the SM-Bus
lines from the I/O port are connected to the battery. Note: The
temperature reading for SM-Bus batteries will still use the
Cadex thermistor that is attached to the Power Port Cable.
All SM-Bus c-codes, both factory and custom, will contain only
the actions to be executed, when the status/alarm bit is
received.
A factory SM-Bus c-code is available with the following
parameters. (Note: To change any of the status/alarm bit
actions, create a new SM-Bus code.)
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A
Fully Charged
Finished
B
Terminate Charge Alarm
Finished
C
Overcharged Alarm
Finished
D
Fully Discharged
Finished
E
Terminate Discharge Alarm
Finished
F
Over-Temperature Alarm
Two retries
A
Finished
The C8000 will end the
current step as a success.
B
Fail
The C8000 will end the
current step as a failure.
C
Ignore
The C8000 will ignore this
flag and continue the current
step.
D
# Retries
# indicates a value between 1
and 10. This option is
available for OverTemperature Alarm bit only.
The setting will indicate to the
unit the number of SM-Bus
samples with the overtemperature alarm bit set
before the C8000 will
terminate the step as a fail.
(Note: SM-Bus is sampled at
15-second intervals.)
The following are definitions for available actions on the
status/alarm bits:
2.7.1.7 Select a Program to Run
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Select a program with which to test the connected battery.
(Note: All programs require battery parameters to be
established by selecting either a Battery ID or a C-Code.
Pressing C-Code “Edit” button, for either Battery ID or C-code
can modify the battery parameters).
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1. Select the program by battery ID or C-Code.
2. In the Program field, press ENTER. The Select Program
screen appears.
3. Select the program to run and press ENTER. Note: When
scrolling through the list of programs, all factory programs
are indented. All custom programs have the
creation/modification date of the program at the bottom of
the screen.
4. Press START. The program begins.
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2.7.2 Test Results
2.7.2.1 View Test Results
1. From the C8000 Main screen, select Test Results. The Test
Results screen shows the results sorted by battery ID,
followed by the sequential number if the test was started
using a battery ID or Cx (where x is the channel number,
followed by the sequential number).
The date shown is the date the test result file was created
for the currently selected test result. Click the and
buttons to view the previous and next list of test
results.
2. Use the arrow keys to select the test result to view and
press ENTER. The Results screen appears.
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Field
Description
ID
The battery’s identification.
Date
The date the test was performed.
Program
The program run during the test.
Result
Indicates whether the battery completed
or failed the test.
Capacity
The battery capacity, if available.
m-ohms
Show the battery’s results of impedance
in milli-Ohms.
Chrg Cycles
The number of charge cycles performed
during the test.
Dchg Cycles
The number of discharge cycles
performed during the test.
Duration
The time it took to complete the test.
Status Codes
Displays the last five status codes,
regardless if test completed or failed.
Failed Step
Displays the step number where the test
failed.
Step Name
Displays the name of the step where the
test failed.
The following table describes the fields that appear in the
Results screen.
2.7.2.2 Print Test Results
2.7.2.3 Delete a Test Result
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When finished viewing the results, press CANCEL.
Use BatteryLab to print test results. For more information, see
3.6.3 View and Print Test Details.
Delete a specific test result if it is no longer needed:
1. From the Main screen, select Test Results. The Test
Results screen shows the results sorted by battery serial
number.
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2. Select the test result to delete.
3. Press DELETE. The Confirm Action screen appears.
4. Press OK to delete the test result.
2.7.2.4 Delete All Test Results
To delete all test results:
1. From the Main screen, select Test Results. The Test Results
screen shows the results sorted by battery serial number.
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2. Press, "DELETE ALL." The Confirm Action screen appears.
3. Press OK to delete all test results.
2.7.3 Battery Profiles
To add, edit, and delete battery profiles in the C8000:
From the Main menu, select Batteries. The Battery Profiles screen
appears.
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2.7.3.1 View and Edit a Battery Profile
To view a battery profile, select the profile in the Battery Profiles
screen and press ENTER. The Battery Profiles screen appears.
Edit the information for the battery profile, as required, and press
OK to save the changes.
When adding or editing a battery profile, select the c-code by
scrolling to the C-Code field. Press ENTER to view a list of
available c-codes in the C-Codes screen.
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Select the c-code for the battery profile and press ENTER.
For a description of the fields, see 2.8.1.2 View and Edit a C-Code.
Edit the details of the battery c-code as required and press OK to
save the changes. Press CANCEL to discard any changes just
made to the c-code.
To view the next page of information for this c-code, press PAGE
2. The Page 2 screen appears.
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Edit the details of the battery c-code as required. (For instructions
on editing a c-code, see 2.8.1.2 View and Edit a C-Code.) Press
BACK to return to the Page 1 screen.
2.7.3.2 Delete a Battery Profile
To delete a battery profile:
From the Main screen, select Batteries and press ENTER. The
Battery Profiles screen appears.
Select the battery profile to delete and press DELETE. The
Confirm Action screen appears.
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Press OK to delete the battery profile. Note: The referenced CCode is not deleted.
2.8 C-Codes
To create, view, and edit c-codes, and to import or export c-codes
to and from the C8000: (Note: The Import and Export functions
apply only to SnapLock/RigidArm Adapters when using the
C8000 Adapter Unit.)
From the Main screen, select C-Codes and press ENTER. The C-
Code Options screen appears.
2.8.1 Add, Edit, and Delete C-Codes
To manage c-codes, select View/Edit from the C-Code Options
screen. The C-Codes screen lists the c-codes in the C8000.
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2.8.1.1 Create a C-Code
To create a c-code, select View/Edit in the C-Code Options screen
and press NEW.
Enter the c-code identification. To select the chemistry, use the
Enter key or the arrow keys. Press NEXT.
Enter the cells and rating and press ENTER.
Press Next and the battery c-code information appears. Make any
required changes and press OK to save the changes. See section
2.8.1.2 View and Edit a C-Code for detailed information on the
displayed fields.
2.8.1.2 View and Edit a C-Code
To view a c-code’s information, select the c-code in the C-Codes
screen and press ENTER. The Battery C-Code screen appears.
(Note: This screen may differ slightly, depending on the selected
chemistry.)
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Field
Description
C-Code ID
A unique identification name for the CCode.
Chemistry
Selects the desired chemistry (Options:
SLA/NiCD/NiMH/Li/LiPH/Primary)
Cells
Enter the number of cells. Number of
cells supported by Battery chemistry:
NiCD and NiMH up to 30 cells in
series (36 Volts nominal).
SLA batteries up to 18 cells in
series (36 Volts nominal).
Li-ion batteries up to 10 cells in
series (36 Volts nominal).
LiPH batteries up to 10 cells in
series (32 Volts nominal).
Primary batteries up to 30 cells in
series (36 Volts nominal.
Discharge only).
Rating
The capacity rating of the cell(s) or
battery pack. Supported Range 0.050-100
(values are stated in Milli-amperage
hour (mAh)).
Chrg Rate
The rate of charge current to be applied.
(Unit (A))
Edit the details as required and press OK to save the changes.
See Section 4 C-Code Parameters for system limitations during
C-code Creation.
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Dchg Rate
The rate of discharge current to be
applied (Unit (A))
End Dchg
The end-of-discharge voltage (Unit (VV))
Rapid Chrg
The required voltage level for the battery
before a full charge current (as per Chrg
Rate) is applied. Otherwise, charge
current is equal to CTP (LiPh/SLA) or
trickle rate (NiCD/NiMH) (Unit (V))
Temp Low
Minimal temperature reading of battery
for a current o be applied (Unit (°C))
Temp High
Minimal temperature reading f battery
for a current to be applied Unit (°C))
Target
The minimal capacity value required to
determine a Pass/Fail condition. Value is
stated in percentage of the total rating
field (Unit (%))
m-Ohms
The minimal resistance/impedance
value is required to determine a
Pass/Fail condition. (Unit (m-ohm))
Range” 1-1000
Trickle Rate
The current rate of charge/discharge
when a trickle current is required (Unit
(A)) (NiCD/NiMH only)
Record Rate
The rate of discharge during a
recondition action step (Unit (AA))
(NiCD/NiMH only)
End Record
The end-of-recondition voltage during a
recondition action step (Unit (V))
(NiCD/NiMH only)
Neg Slope
The negative slope value to determine
End-of-Charge for NiCD/NiMH
batteries only (Unit (mV))
dT/min
The rate of temperature battery
temperature increase over a one minute
period (Unit (°C)) (NiCD/NiMH only)
Rev Load
Percentage of reverse current to be
applied (Unit (%)) (NiCD/NiMH only)
Standby (V)
The rated nominal or standby voltage of
the battery (Unit (VV))
Max Chrg (V)
The maximum voltage of a battery for
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Constant Voltage charge (Unit (V))
(SLA/LiPH only)
CTP
End of Charge point for a battery charge
(Unit (A)) (SLA/Li/LiPH only)
Min Voltage
The minimal voltage the C8 allows
before terminating action (Unit (VV))
Max Voltage
The maximum voltage the C8 allows
before terminating action (Unit (VV)
Chrg Timeout
The maximum length of time that a
Charge current can be applied before
terminating (Unit (C-minutes))
Dchrg Timeout
The maximum length of time that a
Discharge current can be applied before
terminating (Unit (C-minutes))
Max Chrg Curr
The maximum allowable Charge current
allowed to be applied to the battery
before terminating (Unit (AA))
Max Dchrg Curr
The maximum allowable discharge
current allowed to be applied to the
battery before terminating (Unit (AA))
Max Temp
The maximum allowable temperature
allowed before terminating (Unit (°C))
2.8.1.3 Delete a C-Code
To delete a c-code, select the c-code to delete and press DELETE.
The Confirm Action screen appears.
Press OK to delete the c-code.
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2.8.2 Import a C-Code
To import a c-code from a SnapLock/RigidArm Adapter to the
C8000 (an adapter unit is required), select C7 Import from the C-
Code Options screen and press ENTER. The Import C-Codes
screen appears.
Select the channel to import the c-codes from. The Import C-
Codes screen appears, showing which c-codes (1-10) were
extracted from the SnapLock/RigidArm Adapter.
Next, select the c-codes to import. To select a c-code for import,
select the c-code by its corresponding numeric value (0 through 9).
The selected c-code is highlighted. This name is used to store the
c-code on the SnapLock/RigidArm Adapter.
When finished selecting the c-codes to import, press SAVE. The ccodes are imported from the SnapLock/RigidArm Adapter to the
C8000. The imported c-code name is renamed with a prefix of
Cxxx.
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2.8.3 Export a C-Code
To export a c-code from the C8000 to a SnapLock/RigidArm
Adapter (a C8000 Adapter Unit is required), select SnapLock
Adapter Export from the C-Code Options screen and press
ENTER. Select the c-code to export and press ENTER. The Export
C-Codes screen appears.
Select the channel to export the c-codes to. The Export C-Codes
screen shows which c-codes were extracted from the C8000.
The numbered (1 through 10) fields list all c-codes contained
within the SnapLock/RigidArm Adapter. In the C-Code field,
press Enter to retrieve a list of c-codes currently on the C8000 and
select one. The name of the c-code you just selected appears in the
Export Name field – you can rename this c-code before you export
it, if needed. The Setup # field tells the C8000 the memory location
on the SnapLock/RigidArm Adapter to save to.
Next, select the c-code to export. To select a c-code for export,
select the memory location for the C8000 c-code to be exported to.
The selected c-code is highlighted. When finished selecting the c-
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code to export, press SAVE. The c-codes are exported from the
C8000 to the SnapLock/RigidArm Adapter.
1. Select a channel.
2. Select the C8000 C-Code to export.
3. Edit the Export name, if needed.
4. Select the location to export the C8000 C-Code to.
5. Save the C-Code.
2.9 Programs
The C8000 includes factory default programs. See 3.10.1 Factory
Default Programs for information on the default programs.
From the Main screen, select Programs. The Custom Programs
screen appears.
2.9.1 View a Custom Program
View the details of a custom program.
1. From the Main screen, select Programs. The Custom Programs
screen appears.
2. Select the program to view and press ENTER. The Program
Details screen appears. The Version field displays the program
version that was entered when the custom program was
created in BatteryLab, otherwise this field displays V0.00. The
Waveform field displays the custom waveform, if it is associated
with the program; otherwise this field is blank. The Comment 1
and Comment 2 fields displays any comments for the program
that were entered when the custom program was created (the #
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indicates the part number). The Digital I/O, Analog Output #,
and Analog In # fields display the settings for the port as
programmed.
3. When finished viewing the information about the custom
program, press CANCEL to return to the Custom Programs
screen.
2.9.2 Delete a Custom Program
Custom programs can be deleted only if the security setting is set
to Disabled. For more information on security settings, see 2.11.8
Security.
1. From the Main screen, select Custom Programs and press
ENTER. The Custom Programs screen appears.
2. Select the custom program to delete.
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3. Press DELETE. The Confirm Action screen appears.
4. Press OK.
2.10 Waveforms
To view information about a waveform or delete one or more
waveforms:
From the Main screen, select Waveforms. The Custom
Waveforms screen appears.
The Custom Waveforms screen lists all custom waveforms stored
in the C8000.
2.10.1 View Information about a Waveform
To view information about a waveform:
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Select the waveform and press ENTER. The screen shows the
version, the waveform, and comments about the selected
waveform. Note: if a version number is not entered when the
waveform is created, V0.00 is displayed.
When finished viewing the waveform’s information, press
CANCEL to return to the Custom Waveforms screen.
2.10.2 Delete a Waveform
To delete a waveform, select the waveform to delete and press
DELETE. The Confirm Action screen appears.
Press OK to delete the waveform(s).
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2.11 Specify System Options
To specify system options on the C8000:
From the Main screen, select System. The System Options screen
appears.
The System Options screen shows 10 menu items: Set Clock, User
Information, LCD Contrast, Serial Ports, TCP/IP Settings,
Maintenance, Options, Security, System Information, and Factory
Defaults.
2.11.1 Set the Clock
To set the time and date on the C8000:
1. From the Main screen, select System and press
ENTER. The System Options screen appears.
2. Select Set Clock and press ENTER. The System Time
screen appears.
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3. Using the numeric keypad, enter the time (in 24-hour
format) and the date (year/month/day).
4. Press OK.
2.11.2 User Information
To enter user information:
1. From the Main screen, select System and press ENTER.
2. Select User Information and press ENTER. The User
3. To activate the onscreen keyboard, press Edit. Using the
The System Options screen appears.
Information screen appears.
arrow buttons to select alphabetic characters and the
numeric keypad to enter numbers, enter the name of the
company in the Company field.
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4. Enter the company’s address in the Address 1, Address 2,
and Address 3 fields.
5. Press OK.
For instructions to enter alphabetic characters see 2.1.4.4
Navigating the LCD Display.
2.11.3 LCD Settings
To set the contrast of the C8000’s LCD screen:
1. From the Main screen, select System and press ENTER.
The System Options screen appears.
2. Select LCD Contrast and press ENTER. The Set LCD
Contrast screen appears.
3. Use the and buttons to adjust the contrast.
4. Press OK.
2.11.4 Serial Ports
To set the serial ports for the C8000:
1. From the Main screen, select System and press ENTER.
The System Options screen appears.
2. Select Serial Ports and press ENTER. The Serial Ports
screen appears.
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3. Use the and keys to select the bits per second, data
bits, and parity for each port. Use the and keys to
move to the previous or next field.
4. Press OK.
5. Restart the C8000 after modifications.
2.11.5 Specify the TCP/IP Address on the C8000
Note that the TCP/IP addresses must be static IP addresses. For
more information, see 3.1.10 Selecting a TCP/IP Address for the
C8000.
1. From the Main screen, select System and press ENTER.
The System Options screen appears.
2. Select TCP/IP Settings and press ENTER. The TCP/IP
Settings screen appears.
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3. In the TCP/IP Settings screen, press to select Enabled
and press ENTER.
4. Enter the following information:
Address: This is the IP address for the C8000 from your
network administrator.
Mask: This is the network mask obtained from your network
administrator.
5. Press OK two times and let the C8000 reboot.
Note: Ensure that the IP Address is unique on the network system and
the IP Address assigned to the C8000 has been removed from the DCHP
server assignment list.
2.11.6 Maintenance
Test results for each battery test are saved on the C8000 and are
automatically deleted after the specified number of days.
1. From the Main screen, select System and press
ENTER. The System Options screen appears.
2. From the System Options screen, select Maintenance
and press ENTER. The File Maintenance screen
appears.
3. Enter the number of days to keep test results. To
prevent results from being deleted automatically, enter
(0) zero - the default is 30 days.
4. Press OK.
2.11.7 Options
If the Save Termination Data option is enabled, the C8000 can
capture the last 500 Voltage and Current readings for each
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channel. You can specify the capture rate (5-100 readings per
second).
If the Save Results Data option is enabled, the C8000 saves test
results for each completed test. This is open default to ON.
If a power failure occurs while a test is executing, and the power is
restored within the specified timeout, the interrupted test will be
resumed. To disable this feature, set the Resume Hours value to 0
(default value). To enable this feature, set the Resume Hours field
to any other value.
1. From the Main screen, select System and press
ENTER. The System Options screen appears.
2. From the System Options screen, select Options and
press ENTER. The System Options screen appears.
3. To save termination data, select Yes.
4. To save results data, select Yes.
5. Enter the number of hours before an interrupted test
will be resumed.
6. Enter the number of minutes before the screen saver is
activated (the default value of 0 will disable this
option).
7. To enable SnapLock/RigidArm Adapter auto import,
select Yes (the default is No).
8. Enter the Low RDD in kilobytes. The default value of 0
means only a console error message is displayed when
space reaches zero bytes.
9. Press OK.
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2.11.8 Security
When security is enabled on the C8000, you (or another operator)
cannot delete test results or alter c-codes stored in the unit. Note
that the password is a numeric password only; alphabetic and
alphanumeric characters are not valid in the password.
When security is on (enabled) and the password is entered to
disable the security, the security will automatically enable after a
reboot or after 10 minutes of no activity. To deactivate the security
permanently, disable the security temporarily and enter a new
password of “0000”.
1. From the Main screen, select System and press
ENTER. The System Options screen appears.
2. From the System Options screen, select Security and
press ENTER. The Security screen appears.
3. In the Enter Password field, enter your password.
4. In the Confirm Password field, enter your password a
second time.
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Field
Description
Unit Number
The unit number assigned by
BatteryLab. N/A indicates in standalone
mode.
Firmware
Version
The version of firmware installed.
DSP Version
Both versions of the DSP firmware
installed on the C8000.
5. Press OK.
A valid password can be changed in BatteryLab. To receive
additional help with passwords, contact Cadex Electronics Inc. or
an authorized service center. To disable the password, enter a
value of “0000”.
2.11.9 System Information
To view the C8000’s system information:
System information includes the unit number, the version of
firmware that is installed, both DSP versions, the LCD version,
both PIC versions, the RDD free space, and whether security is
enabled or disabled. The units MAC and serial number are also
shown.
Each C8000 contains three microprocessors – one Coldfire
processor and two Digital Signal processors (DSP). The System
Information screen reports the versions of both DSP firmware
installed in the C8000.
The System Information screen displays the version of firmware
programmed into the C8000’s Liquid Crystal Display (LCD).
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LCD Version
The version of the Liquid Crystal
Display.
PIC Version
Both versions of the PIC installed on the
C8000.
RDD FreeSpace
The amount of free memory remaining
in the C8000, shown in bytes.
Security
Enables or disables the C8000’s security
feature.
MAC
The MAC version.
Serial No
The C8000’s serial number.
Power on time
The last time the C8000 was turned on
The security password enables or disables the C8000’s security
feature. The default password is 0000 and security features are
disabled by default. If a security password is specified, security
will be enabled. For more information on setting security
passwords, see 2.11.8 Security.
1. From the Main screen, select System and press ENTER.
The System Options screen appears.
2. From the System Options screen, select System
Information and press ENTER. The System Information
screen appears.
3. Press CANCEL when finished viewing the system
information.
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2.11.10 Factory Defaults
Use this option to restore the C8000 back to its factory default
settings. Warning: Restoring factory defaults erases all saved
data, customized programs, waveforms, and c-codes. This data
should be backed up before proceeding to restore factory
defaults.
1. From the Main screen, select System and press
ENTER. The System Options screen appears.
2. From the System Options screen, select Factory
Defaults and press ENTER. The Factory Defaults
screen appears.
3. Press OK to reset the C8000 to factory defaults.
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2.12 External Devices
The C8000 system supports the following third-party devices VIA
the serial ports.
2.12.1.1 Programmable DC Electronic Loads
All programmable loads are supported on Serial Port Three only.
Connect an electronic load
Configure the external load to communicate with the following settings;
BAUD: 384000 (Recommended), Data bits: 8, Parity: N, Stop Bits: 1
Connect a 9-pin Serial Cable to the C8000 and DC load.
Reboot the C8000.
Note:
1) Ensure that all waveforms used in conjunction with an electronic load are within
the capabilities of the DC load.
2) Some DC loads have only a TTL output. Contact the manufacturer of the DC
load for a TTL to Serial convertor.
Supported DC Electronic Loads
BK Precision 8510 - BK Precision 8514 - BK Precision 8518 - BK Precision 8520
BK Precision DC Electronic Load Limits;
The programming of the DC Load will take between 10~90 seconds to complete. All waveforms
will be programmed at the start of the EXTERNAL LOAD steps.
Minimal pulse width supported by the BK DC Loads is 1ms.
2.12.1.2 Thermal Chambers
All programmable Thermal Chambers are supported on Serial Port Two only.
Connect to a Thermal Chamber
Configure the Thermal Chamber to communicate with the following settings;
BAUD: 19200 (Recommended), Data bits: 8, Parity: N, Stop Bits: 1
Connect a 9-pin Serial Cable to the C8000 and DC load..
Reboot the C8000.
Note: Ensure that all program steps and commands used in conjunction, with the thermal
chambers, are within the capabilities of the thermal chamber units.
Supported Thermal Chambers
Thermotron 2800 - Thermotron 3800- Thermotron 8800- TestEquity Watlow F4
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3 Cadex BatteryLab
3.1 System Setup
Welcome to Cadex BatteryLab – the PC software that provides a
visual interface to start, monitor, and control custom battery tests
on up to eight Cadex C8000 Battery Testers simultaneously. The
software provides interfaces to create or edit password-protected
c-codes, battery IDs, waveforms, and custom programs to test
batteries. Tests can be viewed in real-time via the results panel or
program listing and monitored on multi-variable graphs. (Note:
Real-time is defined as the rate of data acquisition. By default, all
data is acquired at a rate of 60 seconds. Programs can be defined
to acquire data at a rate of 1 second. Only status code changes are
acquired immediately.)
Customizable reports can be generated from historical results
retrieved from the database. Test data can also be exported to tab
delimited files for further analysis.
3.1.1 System Requirements
To use BatteryLab, a dedicated Windows - based personal
computer (PC) system is needed with the following features:
1GHz Processor (minimum).
Windows XP with Service Pack 2, with at least 512MB
RAM and 10 GB of free hard drive space.
An Ethernet Port for primary communication between the
PC and C8000.
A 100-BASE-T Ethernet network switch or hub with
sufficient free ports, to connect the hub to the local
network, a port for the Host PC, and one for each Cadex
C8000 Battery Tester. A switch or hub is not required if the
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PC and C8000 are connected directly and are not required
to be connected to the local network.
An SVGA color monitor with 1024 x 768 or better
resolution, and 16-bit color minimum.
A writable CD or DVD drive, for installing software and
creating backups.
A keyboard and mouse.
A printer.
Correct operation of Cadex BatteryLab requires that a printer
driver be installed. Windows comes with an extensive database of
printer drivers. Alternatively, commercial software, such as
Adobe Acrobat PDF Writer, can be installed as the default printer
driver.
3.1.2 Set Windows Explorer and My Computer to Display File
Extensions.
A file extension describes a file type. A filename and its extension
are separated by a period ".", for example “Setup.exe”. The
extension .exe indicates an executable program file.
To set Windows Explorer and My Computer to display file
extensions in the lists of files:
1. Open Windows Explorer (explorer.exe) or My Computer.
2. From the Tools menu, click Folder Options.
3. Click the View tab.
4. Clear the Hide extensions of known file types check box.
5. Click OK.
3.1.3 Create a Database for BatteryLab
To create a database for BatteryLab:
1. Exit BatteryLab.
2. Backup the following two folders to backup media (Note:
Installation Location can be viewed on the About window):
\(Installation Location)\DB
\(Installation Location)\Export
3. Delete all files in the folder \(Installation Location)\DB
except the newc8000.mdb file. If the newc8000.mdb file is
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accidentally deleted, retrieve a copy of this file from the
backup media and save it to the \(Installation Location)\DB
folder.
4. Copy the newc8000.mdb file in the same directory and then
rename this second copy to c8000.mdb.This way, you can
repeat this function multiple times, if required.
5. Start BatteryLab.
3.1.4 Back Up the Data Files on the PC
All hard disk drives eventually fail, with the loss of all saved data.
Hard drive files can also be destroyed or corrupted by: an AC
power surge, a computer virus (that slips through antiviral
software), failure of electronic parts in the computer, or by human
error.
Caution
Back up BatteryLab data files regularly onto separate
media, such as writable DVD, or CD, or magnetic tape.
It is possible to reinstall software, but the data files on your
computer (including test records and calibration data for your
C8000s) can be restored only if a backup copy exists.
Scheduled data backups are recommended on a weekly basis
using Windows Backup, which is accessed from the Start menu:
Start > Programs > Accessories > System Tools > Backup.
Windows Backup is described in Windows Help, which you
access from the Start menu. Use the Help Index to find topics
under "Backup".
Using Windows Backup, schedule a periodic backup of the batlab
folder located, by default, under C:/Program Files.
Discuss backup procedure and frequency of backups with your
System Administrator.
3.1.5 Install and Uninstall BatteryLab
Before installing Cadex BatteryLab, ensure your computer meets
the 3.1.1 System Requirements to run the software. BatteryLab and
its database can be installed in the default folder locations or
different locations, as needed. Note: If BatteryLab is already
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installed, the Upgrade window appears – BatteryLab’s database is
automatically preserved during the upgrade.
3.1.5.1 Install BatteryLab
1. Insert the installation CD into the CD drive.
2. Browse your CD drive in Windows Explorer and double-
click Setup.exe. If BatteryLab is already installed on the
computer, the Upgrade Prompt window appears. Click
Upgrade to continue.
The Welcome Dialog window appears.
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3. Click Next. The License window appears.
4. Read the license agreement and click I Agree. The Choose
Program Location window appears.
5. BatteryLab is installed in the C:\Program Files\Batlab folder
by default. To install BatteryLab in a different location,
click Browse. The Select Destination Directory window
appears. Select the location and click OK. If BatteryLab is
already installed in that location, the Install window
appears. Click Yes to overwrite the existing copy of
BatteryLab.
6. Click Next. The Choose Data Location window appears.
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BatteryLab's database is installed in the C:\..\Application
Data\Cadex\Batlab folder by default. To install
BatteryLab's database in a different location, click Browse.
The Select Destination Directory window appears. Select
the location and click OK. Click Yes to overwrite the
existing copy of BatteryLab's database.
7. Click Next. The Start Installation window appears.
8. Click Next. The Installing window appears, showing the
files being installed.
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9. The Installation Complete window appears. Click Finish.
3.1.5.2 Uninstall BatteryLab
1. In Control Panel, click Add Remove Programs.
2. Select Cadex BatteryLab and click Remove.
3. You can select either Automatic or Custom. If you select
Custom, select All followed by Next on each successive
dialog box until the software uninstall is complete.
If you choose Automatic, the uninstall process will retain
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shared system components that were installed by the
installer during setup.
Uninstalling removes all BatteryLab information, including the
test results database.
3.1.6 Software Updates
3.1.6.1 Software Version
To see what version of BatteryLab is installed on the computer,
select About from the Help menu. The build number and the
location of the database files appears in the About window.
4. Follow the steps through the uninstall wizard.
3.1.6.2 Update BatteryLab Software
When a new version of BatteryLab becomes available, registered
users can download it from the Cadex website.
The download is a compressed executable file (with file extension
.EXE).
Running the downloaded executable will run Setup and install a
new version of the software.
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Important
If the computer or network uses a firewall, it may
be necessary to reconfigure firewall access to the
new version of BatteryLab.
3.1.7 BatteryLab Security Information
Cadex BatteryLab security serves to secure the software and
connected battery analyzers to preserve settings configured by
operators who administer the Battery Testing System. Report
templates, configuration settings, battery ID databases, c-code
databases, programs databases, and waveform database are
secured, preventing inadvertent changes by operators.
Password Setting
You must have a password to disable BatteryLab security. Note
that creating a password does not automatically enable security in
BatteryLab and connected analyzers. To enable and disable
security, see 2.11.8 Security.
To select a password, select Password Setting from the Database
menu. You must specify a four-digit number, re-type the fourdigit number, and then click OK.
Security Setting
Security setting in BatteryLab is either enabled or disabled. To
enable or disable security setting, select Security Setting from the
Database menu. You must specify a four-digit number, re-type
the four-digit number, and then click OK. You can then enable or
disable security setting. For more information, see 3.1.13 Set
Security Setting on the C8000.
3.1.8 Set Up BatteryLab
Before starting to test batteries with BatteryLab, set up the
following items:
The cables connecting each C8000 to the network.
The “Host” IP Address of the PC where BatteryLab is
installed and the IP Address for each C8000 connected to
the local network.
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3.1.8.1 Connect the C8000 to the Network
To use BatteryLab with C8000, each C8000 must be connected to
the network and be assigned a static IP Address and a network
mask.
The static IP addresses for each C8000 must be unique and belong
to the same network. For more information on assigning an IP
address to a C8000, see 3.1.10.3 Add IP Addresses for C8000s on the
PC
Note that the TCP/IP addresses must be static IP addresses. A
Network Administrator can supply static IP addresses for each
device that is to be connected to the local network.
3.1.8.2 Set Up the C8000 to Use BatteryLab
The procedure for setting up the network connections is:
Acquire a unique IP Address from your network
Administrator.
On each C8000, enter a unique IP address and the
(network) mask.
Launch BatteryLab, on the host PC, to enter the IP
address for every C8000 that the host PC will
communicate with. See 3.1.10.3 Add IP Addresses for
C8000s on the PC for information on entering the IP
addresses into BatteryLab.
Once the IP address information is entered, connect the C8000
directly to the PC or to a hub/switch connected to the network.
Use the Ethernet cable provided. On the C8000 side, the Ethernet
cable connects to the Ethernet port at the back of the C8000.
3.1.8.3 Choose IP Addresses for the Local Network
An IP address is a set of four numbers that identifies a single
computer or device on a TCP/IP network. Each of the four
numbers can range from 1 to 254.
1. Click Start and choose Run.
2. In the Run dialog box, type cmd and click OK.
The Command Prompt window appears.
3. Type ipconfig /all in the command prompt window
(cmd.exe) and press ENTER.
4. Make a note of the PC IP Address that is shown in the
Command Prompt window under Ethernet adapter
Local Area Connection.
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5. Close the Command Prompt window.
The IP address for each C8000 will likely have the same numbers
for the first three parts of the PC IP Address and a different
number, in the range 1-254, as the final part of the IP address. The
final number for a C8000 cannot be the same as the final number
in the IP Address of the PC or the final number in the IP Address
of any other device on the Local Area Network.
3.1.8.4 Find the IP Address for Your PC
To find the IP address for your PC:
1. Choose Start > Programs > Accessories > Command
Prompt.
The Command Prompt window appears.
2. Type ipconfig and press Enter.
The IP Address and Subnet Mask for your computer are
displayed.
3.1.8.5 TCP/IP Settings
3. Make a written note of these numbers and then close the
Command Prompt window.
Use the Cadex C8000 standalone or connected to a TCP/IP
network and use with Cadex BatteryLab PC software.
In the standalone option, information is specified manually into
the C8000 to start tests and test results are accessible via the C8000
display. However, because of hardware memory limits, not all
customizable features will be available and the test results must be
deleted periodically to make memory available for new test
results. A message appears if RDD space is low (space can be
configured in Systems > Options). (Default: 250 Kbytes)
In the networked option, Cadex BatteryLab software can be used
to start tests, store test result histories, and print test reports.
Cadex BatteryLab is also required to update the firmware on the
C8000. This documentation refers to the computer on which
BatteryLab runs as the “host” PC.
The C8000 must be assigned an IP address with a network mask
that matches the network mask of the host computer to
communicate and update firmware with Cadex BatteryLab.
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3.1.8.6 Network Cable
A network connection between the computer and C8000 can occur
using a hub or switch or directly using the network cable
provided.
The host PC’s IP address must connect the C8000 to the PC
directly via the provided cable.
3.1.9 Firewalls
All operating systems from Microsoft windows XP Service pack 2
and newer will by default have a Firewall installed and active or a
third party application may have been installed, regardless of the
operating system. For BatteryLab to communication with the
C8000 a rule will be required to be configured and granted or
allowed communications to the network.
On the initial execution of the BatteryLab application, the majority
of firewall applications will recognize the communication attempt
and will prompt the user for permission. Always “ALLOW” or
“GRANT” full communication permissions to the BatteryLab
application.
Depending on the firewall application the application may be
expressed as BATLAB.exe.
If the firewall application does not prompt for permission or
BatteryLab has been denied access to the network, refer to the
documentation for that firewall for instructions to open the
required ports.
See 3.1.9.1 Ports for a list of the required ports, which must be
“allowed”.
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3.1.9.1 Ports
The following ports on the PC firewall must be “allowed”.
TCP port 51935 must remain open.
The required ports are open by default in Windows 2000.
3.1.9.2 Other Firewall Software or Hardware
For other firewall software or hardware,
3.1.10 Selecting a TCP/IP Address for the C8000
3.1.10.1 Before Entering the Settings
Ask the Network Administrator for:
A static IP Address for each C8000
The network mask
If the C8000 will be used stand-alone without BatteryLab, then ignore all
references to TCP/IP settings for BatteryLab. The TCP/IP Settings on
the C8000 are disabled by default.
An IP address is a set of four numbers that identifies a single
computer or device uniquely on a TCP/IP network. Each of the
four numbers can range from 0 to 255. If a Network administrator
is unavailable, follow the instructions below on a computer to
determine a unique IP address for each C8000, other proceed to
step 2:
Note: If the network system uses dynamic IP address assignment,
ensure that any IP addresses assigned, to a C8000, are exempted from the
Dynamic IP Address range of the server/router.
1. Determine a unique IP address for each C8000 to be
connected to the local network.
Ping the network for each IP address (from the PC) to
determine that the IP address is not already in use on the
local network. If an IP address is “in use”, determine
another unique IP address. To ping an IP address, see
3.1.10.2 Ping the Network to Check for Available IP address
2. To enter a unique IP address for each C8000, follow the steps
in the section 2.11.5 Specify the TCP/IP Address on the C8000.
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IP Address
This is the Internet Protocol (IP) address for
the PC on the local network.
An IP address is a 32-bit number that is
notated by using four numbers from 0
through 255, separated by periods
Subnet Mask
This number identifies the network segment
on which the PC is located.
A subnet mask is a 32-bit number that is
notated by using four numbers from 0
through 255, separated by periods.
Typically, default subnet mask numbers use
either 0 or 255 as values (such as
255.255.255.0), but other number values can
appear.
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3.1.10.2 Ping the Network to Check for Available IP address
To “Ping” an IP address on the network, enter the keyword
“ping” followed by a space followed by the IP address into the
Command Prompt window and press Enter on the keyboard. If
the Command Prompt window is not visible, choose Run from
the Start menu and type "cmd" in the Run dialog and click OK.
The Command Prompt (cmd.exe) window appears.
Example: “ping 192.168.4.3”
If a device on the local network uses the IP address, the ping
response will return a message indicating that the IP address is in
use and cannot be assigned to a C8000:
Reply from 192.168.4.3: bytes=32 time<10ms TTL=128
Reply from 192.168.4.3: bytes=32 time<10ms TTL=128
Reply from 192.168.4.3: bytes=32 time<10ms TTL=128
Reply from 192.168.4.3: bytes=32 time<10ms TTL=128
Note: Should the computer receive a reply when the
C8000 has not been programmed with an IP Address,
select another IP Address.
If there is no device on the local network currently using this
address, the ping request will not return a reply indicating that
the IP address is available and can be assigned to one C8000:
Request timed out.
Request timed out.
Request timed out.
Request timed out.
Note: Different versions of the Windows operating system may
reply differently.
3.1.10.3 Add IP Addresses for C8000s on the PC
BatteryLab can be set up to communicate with up to eight C8000
Battery Testers, each of which can test up to four batteries
simultaneously.
All the C8000s must be switched ON and connected to the
network. When there is only one network port available, connect
a switch or hub to the network first and then connect the C8000s
and PC to this switch or hub.
Assign a static IP address to each connected C8000. Also, specify
the network mask into each C8000. For more information, see
3.1.8.1 Connect the C8000 to the Network.
To add IP addresses for the C8000 units:
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