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Detailed 

Message 

Code Reasons 

Solutions 

DISCHARGING

 7 Battery is being discharged 

normally. 

Program will continue when 
cycle has completed. 

HIGH CELL 

RESISTANCE

 

135 

Battery resistance has 
exceeded the OhmTest 
setpoint threshold  

Program is complete (see 

To 

edit the OhmTest Setpoint

, 

page 36). 

HIGH CELL 

RESISTANCE

 

136 

The battery resistance has 
exceeded the OhmTest 

setpoint threshold – this 
message is for BatteryShop  

Program is complete (see 

To 

edit the OhmTest Setpoint

, 

page 36). 

HOT BATTERY 

ON TRICKLE 

CHARGE

 

159 

Battery temperature has 
exceeded its maximum 

setting after service has 
ended and battery was on 

trickle charge. The trickle 
charge stops.  

Verify that the mAh rating of 
the battery matches the C-

code mAh setting. 
Reduce the Charge rate in the 
C-code. Reduce the trickle-

charge rate or the maximum 
standby voltage in the 

extended C-code.  
Lower the room temperature. 

HOT BATTERY

, 

LOW VOLTAGE

 

156 

Battery temperature went to 
its maximum setting in the 
initial charge cycle. Service 

terminates.  

Reduce the Charge rate in the 
C-code. Allow battery to cool 
before servicing the battery 

again.  
The internal cells may have 
shorted or the battery is old. 

Either monitor battery use or 
discard. 

 

 

137 

Summary of Contents for C7200

Page 1: ...C7400ER C Series Cadex Electronics Inc 22000 Fraserwood Way Richmond British Columbia Canada V6W 1J6 Tel 1 604 231 7777Fax 1 604 231 7755 Web www cadex com E mail info cadex com Manual P N 89 307 1016...

Page 2: ......

Page 3: ...to notify any person of such changes Please e mail service cadex com for suggestions or corrections Disclaimer While every effort is made to ensure that the information contained in this manual is ac...

Page 4: ...equipment not expressly approved by Cadex will void the approvals and void the user s authority to operate the equipment Disposal of Waste Electrical and Electronic Equipment WEEE in the European Unio...

Page 5: ...ause interference in which case the user is required to take whatever measures needed to correct the interference at their own expense EN55011 EN55022 Warning This is a Class A product according to EN...

Page 6: ...ratures Fast charging outside this temperature range may damage or reduce the life of the battery Allow cold batteries to warm up and hot batteries to cool before charging Do not attempt to charge non...

Page 7: ...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...

Page 8: ...g an unknown brand Not all brands contain intrinsic safety features that protect the cell when stressed During experiments place the test battery into a well ventilated fireproof container Cadex Elect...

Page 9: ...tteries only when they are removed and disconnected from their end use equipment Use the analyzer only as specified in the documentation Other uses may impair the protection provided by the unit Use o...

Page 10: ...leakage spills power fluctuations or power failure Damage caused by inadequate packaging for shipping or storage Product received without the appropriate model number serial number or safety markings...

Page 11: ...pport at E mail contact service cadex com Canada 1 604 231 7777 USA Toll Free 800 565 5228 Europe 49 0 911 240 332 0 If the analyzer is not covered by warranty the representative will provide the cont...

Page 12: ...rection Keys 5 Symbols 5 Abbreviations and Acronyms 6 Commonly Used Terms 7 Chapter 3 Operating Principles 10 Components 10 Front LCD Display Interface 13 Lights LEDs 15 Menu Structure 16 Battery Adap...

Page 13: ...8 Program 48 Target Capacity 49 Chemistry 49 Battery Voltage Volts 49 Battery Rating mAh 50 C code Setup Name 50 Scaled C code 51 C code Matrix 51 Locked C code 51 Extended C code Parameters 51 Charge...

Page 14: ...s 61 Managing C codes 61 Select a C code 61 Display a C code 61 Change Target Capacity or Program 62 Create or Edit a C code 62 Add or Edit the C code Setup Name 64 Reset Extended C code to the Defaul...

Page 15: ...atically Print Reports or Labels Auto Print 86 Automatic Report or Label printing 86 Manually Print Reports and Labels 87 Chapter 9 Events and Data Logs 89 Logging Events 89 Setting up the Event Log 8...

Page 16: ...Calibration Values for New Adapters 114 Chapter 13 Solving Problems and Getting Help 116 Troubleshooting 116 Manual Updates and Other References 120 Technical Support 121 Appendix A Messages and Warn...

Page 17: ...me and QuickSort o Ten advanced programs o Four user programmable programs Battery Adapters allow convenient interface to all battery types Over 1000 custom Battery Adapters are available and specialt...

Page 18: ...vices by connecting up to 120 Cadex analyzers to service up to 480 batteries simultaneously Provides easy access to a database of information for over 1000 battery models including C code settings Eve...

Page 19: ...s basic information about product features and connecting the Cadex analyzer to a computer Chapter 2 Getting Started goes through the items that are included with the analyzer and how the manual works...

Page 20: ...and graphing detailed voltage current temperature impedance analysis Chapter 10 Custom Programs describes how to create user defined programs for specialized or advanced applications Chapter 11 Servic...

Page 21: ...yzer Italics Emphasized words Bold Italic References to other sections in this manual Direction Keys Direction keys are represented in this manual as follows UP DOWN LEFT RIGHT Symbols Information tha...

Page 22: ...nd Lithium polymer battery chemistry Li ion Lithium ion battery chemistry Li Ph Lithium phosphate chemsitry Li polymer Lithium polymer battery chemistry This chemistry is treated in the same way as Li...

Page 23: ...how to service a specific battery type see Chapter 6 C codes Configuration Codes page 47 Cells Individual items within the battery Cycle One charge and discharge sequence even if the battery is only p...

Page 24: ...pacity Capacity remaining in the battery when it is inserted in an analyzer Resistance Also called internal resistance Opposition to current flow and dissipation of energy in the form of heat Self Dis...

Page 25: ...ion User Interface The front panel of the analyzer that provides information about the status of the analyzer and any batteries being serviced It consists of the LCD display the LED indicators and the...

Page 26: ...10 Chapter 3 Operating Principles Components Figure 1 Top and front panel of C7400 C C7400ER C Battery Analyzer...

Page 27: ...vice The C7200 C has two the C7400 C and C7400ER C has four PRINT key Prints labels and reports EDIT key Edits the C code battery parameters ESC key Used to exit menus cancel changes clear detailed di...

Page 28: ...3 Rear panel of Cadex battery analyzer USB Port Primary Input Fuse RS232 serial port Component Function On Off Power Switch Turns the analyzer On and Off IEC 320 AC Input Connect the unit to an AC ele...

Page 29: ...ral status of all stations This is the default view for the C7400 C and C7400ER C EMPTY NO ADAPT NO ADAPT EMPTY QuickSort PRIME Stations 1 and 4 adapter inserted no battery inserted Stations 2 3 no ad...

Page 30: ...the MENU key and select menu functions by pressing or to scroll through the menu and pressing ENTER when the desired function is displayed For example this message shows one option in the System Secu...

Page 31: ...ed Battery has passed the service Flashing Cold battery Service resumes when battery warms up code 12 FAIL red On Battery failed Flashing Hot battery Service resumes when battery cools code 13 All Fla...

Page 32: ...Menu Structure Figure 4 Menu hierarchy of the Cadex Analyzer see chapters 7 to 10 for details Cadex Electronics Inc C7000 C Series Battery Analyzers 16...

Page 33: ...ry shape There are over 1000 custom adapters available Universal Adapters are used when a custom adapter is not available Pins or alligator clips attach to the positive and negative terminals and incl...

Page 34: ...y service parameters called Configuration Codes or C codes in non volatile memory C codes will not be lost when adapters are removed and reinserted into any station on the analyzer or when the analyze...

Page 35: ...tion putting the front end in place first 2 Press down on the back panel with the label until the adapter snaps in place The LCD display for the station changes from NO ADAPT to EMPTY indicating that...

Page 36: ...bottom left in this case it is V1 00 and the security level in this case it has not been set This screen can also be cleared after 5 seconds by pressing the ESC key C7400 C C 2006 CADEX ELECTRONIICS I...

Page 37: ...ing Battery Service page 77 If the display continues to display an Empty message this means that the Cadex analyzer is not recognizing the battery There are a number of reasons this may happen Battery...

Page 38: ...C code especially the correct chemistry Failure to do so may damage the battery or cause fire or explosion 1 If the C code is correct press ENTER to confirm the settings 2 Press ENTER again to start t...

Page 39: ...e 123 3 To display details about an ongoing or completed battery service press the station key to see the detailed display Press to see any applicable warning codes For more information about message...

Page 40: ...atteries may create arcs that will degrade the performance of the analyzer Follow these instructions Press and release the Alt key and the station key that has the battery On the screen that appears p...

Page 41: ...basic programs are Auto Charge Prime and QuickSort for 16K Battery Adapters only These programs cannot be edited Each program performs functions for different purposes Program Does this Is used for t...

Page 42: ...reconditions NiCd and NiMH batteries that do not reach Target Capacity Li ion Li Ph and SLA batteries are not reconditioned only exercised Batteries in use are typically cycled every three months on A...

Page 43: ...acity is only obtained if there is a discharge Charge does not perform a diagnosis use the Auto or Prime program to fully diagnose a battery Results The global display alternates between current avera...

Page 44: ...il check the fault codes for details If the capacity is low the battery should be Primed again In some cases two or three Prime programs may be required to fully form a battery Duration Approximately...

Page 45: ...ay shows the battery condition as Good Low or Poor Detailed display also shows average battery or cell voltage analyzer charge or discharge current in mA OhmTest results battery temperature and durati...

Page 46: ...ife cycle For example take a sample of batteries to determine the Life Cycle of an entire batch of batteries Estimating performance time Discharge Only DCHOnly Discharges a battery to its end of disch...

Page 47: ...spectrum of batteries with various SoH Increasing QuickTest accuracy confidence grade for a given battery type QuickTest Tests battery SoH by comparing battery data to data from other batteries of th...

Page 48: ...ee cycles performed It also displays average battery or cell voltage analyzer charge or discharge current in mA OhmTest results battery temperature and duration of service Duration Approximately 30 ho...

Page 49: ...ntage of battery capacity achieved and OhmTest results for the first and last cycles run Look for the number of cycles a cycle is a charge followed by a discharge Batteries should provide the number o...

Page 50: ...vice Look for the green ready LED The battery capacity is measured during a discharge and if the battery is partially discharged the capacity may be lower than the target capacity This may give a Fail...

Page 51: ...han 80 or the target capacity If batteries fail check the fault codes for details If the capacity is low the battery should be Primed again In some cases two or three Prime programs may be required to...

Page 52: ...value is above the analyzer s OhmTest setpoint threshold the battery fails the OhmTest and should be replaced If the battery passes run the Auto or Prime program on the battery to determine whether t...

Page 53: ...e or discharge current in mA OhmTest results battery temperature and duration of service Duration Approximately 8 10 hours for a NiCd battery using default C codes To edit the Runtime settings 1 From...

Page 54: ...batteries with open protection circuits or with a very low voltage that the Cadex analyzer does not recognize it or gives a Shorted Code 121 message Sequence The battery is trickle charged for three...

Page 55: ...on how the analyzer is set up see To verify C code or enter Battery ID before battery service begins page 77 press ENTER again to accept the C code settings and start Boost 5 The program runs for 3 mi...

Page 56: ...tery temperature and duration of service The C code display screen shows a T in the upper right hand corner to indicate that a C code saved as a matrix has been stored for using with the QuickTest pro...

Page 57: ...ld be within the range of the actual battery capacity If not erase the battery matrix press FN and then press 2 and start over Once successful test other batteries with the same capacity if possible t...

Page 58: ...than 90 require additional time to bring their SoC to between 20 and 90 For most batteries this takes an additional 5 minutes but in some cases especially with high capacity batteries it may take long...

Page 59: ...m the capacity by servicing the batteries on the Prime program Note the final capacity and resistance readings Take the battery with the highest capacity ensure that it is 100 or greater and the highe...

Page 60: ...not exist for the C code i e no batteries of the same model have gone through the Q Learn or Learn programs a message appears stating that no QuickTest matrix has been found and that the Learn progra...

Page 61: ...tteries this takes about 5 minutes However with high capacity batteries it may take longer Custom 1 2 3 and 4 By default custom programs are blank when the Cadex analyzer is shipped from the factory s...

Page 62: ...conds 15 seconds 15 seconds Runtime Duration depends on settings Self Discharge 30 hours 60 hours 50 hours LifeCycle 1500 cycles NiCd 500 cycles NiMH 200 500 cycles 1000 cycles Discharge Only 1 hour 2...

Page 63: ...and will display NULL CODE when inserted into the analyzer Create a C code to clear the NULL CODE message see Managing C codes page 61 Each C code is divided into three parts Basic C codes include pro...

Page 64: ...s An adapter can save up to 10 C codes Each C code is unique and has the following characteristics Basic C code Parameters Basic C code parameters appear on the first detailed screen whenever a Batter...

Page 65: ...critical applications that require maximum energy reserve and high reliability Fewer batteries will pass 80 Recommended default setting that provides a balance between adequate energy reserve and long...

Page 66: ...25V cell see Voltage Display page 69 Some manufacturers may state the number of cells of their batteries To get the correct voltage multiply the number of cells by the chemistry type For example the v...

Page 67: ...nnot be edited but they can be deleted Extended C code Parameters In general extended C code parameters can be left on their default settings For servicing intrinsically safe I S batteries or Hawker S...

Page 68: ...bled In addition due to the very fine negative slope the current is cut in half twice towards the end of the charge cycle to ensure that the battery is fully charged this current is not reduced if the...

Page 69: ...Rate NiCd and NiMH only The Recondition Discharge Rate parameter refers to a slow gradual discharge applied during reconditioning after the battery reaches the end of discharge voltage During this pr...

Page 70: ...re sensing is disabled the analyzer automatically applies a rest period to allow NiMH batteries to cool down which lengthens the service time Negative Slope NiCd and NiMH only The Negative Slope measu...

Page 71: ...d Refer to the manufacturer specifications Li ion 3 00V cell A good number of Li ion batteries have 2 50V cell as the End Of Discharge setting Refer to the manufacturer specifications Li Ph 2 00V cell...

Page 72: ...ries that cannot accept a pulse charge some intrinsically safe batteries fall into this category Maximum Standby Voltage SLA and Li ion only The Maximum Standby Voltage is the level that SLA and Li io...

Page 73: ...d Li ion only The End of Charge parameter defines the rate of charge the analyzer uses to determine if the battery is fully charged When the charge current drops below the End of Charge setting while...

Page 74: ...1 00V cell End of Recognition 0 40V cell Charge Method Reverse Load 9 Default Extended C code for NiMH Batteries Parameter Default Setting Charge 1 00 C Trickle 2 Discharge 1 00 C Recondition 12 Temp...

Page 75: ...harge 1 75V cell Default Extended C code for Li ion Batteries Parameter Default Setting Charge 1 00 C Discharge 1 00 C Temperature Sensing 0 C 45 C Max Standby Voltage 4 05V cell Max Charge Voltage 4...

Page 76: ...following C code parameters as specified Parameter Setting Charge 0 10 C Discharge 0 10 C Charge Method DC charge End Of Discharge 0 96V cell Hawker SLA Batteries Before servicing Hawker SLA batterie...

Page 77: ...To set the user input required by the Cadex analyzer before battery service begins page 77 Select a C code 1 From the global display press the station key 2 Press or to scroll to the C code to select...

Page 78: ...ENTER 7 Press or to scroll to YES to accept changes and press ENTER 8 Press ESC twice to return to the global display Create or Edit a C code 1 From the global display press the station key 2 Use the...

Page 79: ...LTS of the battery to be serviced see Battery Voltage Volts page 49 10 Press to move to mAh 11 Press or or use the keypad to enter the battery capacity in milliampere hours mAh see Battery Rating page...

Page 80: ...elect characters for the setup name 5 Press or to move the cursor between character positions within the setup name There are ten positions available 6 Press ENTER 7 Press or to scroll to YES to accep...

Page 81: ...lobal display press the station key for the source adapter 3 Use the or key to scroll to the C code 4 Press FN and then press 3 5 Press the station key for the target adapter This can be the same as t...

Page 82: ...5 Press or to scroll to YES to accept changes and press ENTER 6 Press ESC twice to return to the global display Cadex Electronics Inc C7000 C Series Battery Analyzers 66...

Page 83: ...nd time information 5 Press or to move between fields year month day hour minute and second 6 Press or or use the number pad to enter the correct date and time information for each field 7 Press ENTER...

Page 84: ...e every time a key is pressed on the Cadex analyzer When various service events occur on the analyzer such as program completion an event alert is sounded To turn sounds ON or OFF 1 From the global di...

Page 85: ...ge for the battery On some NiCd and NiMH batteries manufacturers may rate their batteries based on 1 25V cell rather than 1 2V cell This can also be set on the analyzer see Battery Voltage Volts page...

Page 86: ...ll to OPTION CONTROLS and then press ENTER 3 Press or to scroll to SET SERVICE COUNTER and then press ENTER 4 Press or or use the number pad to enter the number of batteries to service before the anal...

Page 87: ...leared 1 From the global display press FN and then press 5 2 Press ESC to return to the global display Connecting to BatteryShop or a Printer The Cadex analyzer has a RS232 DB 9 pin female serial port...

Page 88: ...ous output A PC can be used to manually monitor battery data Use the cable supplied with BatteryShop to connect to the analyzer serial port or make one using the configuration shown in Typical Serial...

Page 89: ...ress ENTER 6 Press or to scroll to YES to accept changes and press ENTER 7 Press to scroll to SERIAL PORT SETTINGS and then press ENTER Skip this step if connecting to BatteryShop or the Dymo CoStar S...

Page 90: ...and 4 DTR together on the printer s DB 9 connector Other jumpers may be also required Check the printer manual for specific information Security The Cadex analyzer offers three security levels for pro...

Page 91: ...gram Settings Change Program Settings Option Controls Change Battery startup options Change Company name Change Sound control options Change Voltage display options Print Utilities Select battery serv...

Page 92: ...the global display press MENU 2 Press or to scroll to SYSTEM SECURITY and then press ENTER 3 Press or to scroll to CHANGE PASSWORD and then press ENTER 4 Enter the old password using the number pad an...

Page 93: ...ly The Cadex analyzer asks to verify C code settings only default The Cadex analyzer starts the program using the active C code without asking to enter the Battery ID or verify the C code To verify C...

Page 94: ...following programs QuickTest Q Learn Learn and Life Cycle OhmTest is included in these programs and the settings cannot be changed To turn Automatic OhmTest on or off 1 From the global display press M...

Page 95: ...e 148 TIME default CAPACITY 6 Press ENTER 7 Press or to scroll to YES to accept changes and press ENTER 8 Press ESC twice to return to the global display Termination Condition on dT dt The Termination...

Page 96: ...ndependent of setting Battery Adapter inserted in the station Program and target capacity settings programmed into the analyzer station will override the C codes programmed in the adapter Saving progr...

Page 97: ...ter Power Failure If there is a power failure the back up memory in the analyzer keeps service data for one hour If the power failure lasts less than an hour battery service resumes from where it left...

Page 98: ...is in service Alt Edit Enters unique names for C codes Recalibration Counter The analyzer can be programmed to notify when to calibrate the adapter after it has serviced a specified number of batterie...

Page 99: ...the C code description the cycles performed on the battery charge and discharge rates any applicable fault codes and final capacities For a sample battery service report see Figure 6 page 85 The Syste...

Page 100: ...bel This label contains a bar code representing either the battery ID number or the C code For samples of bar code and battery labels see Figure 7 page 86 Cadex Electronics Inc C7000 C Series Battery...

Page 101: ...Cycles 0 Elapsed Time 0 Days 6 Hours 40 Minutes BATTERY PARAMETERS Battery C Code 40 02 016 0505 505 3407 Program Auto Target Capacity 80 Battery Type 42 Lithium Ion Number of Cells 2 7 2V Battery Rat...

Page 102: ...rt or Label printing 1 Make sure the printer or a label printer is connected to the analyzer and it is working see Connecting to BatteryShop or a Printer page 71 2 From the global display press MENU 3...

Page 103: ...ing to BatteryShop or a Printer page 71 Tip Reports and labels can be printed through the menu under PRINT UTILITIES Print a battery service report 1 Perform the required service on the battery Do not...

Page 104: ...label with a battery ID bar code 1 Perform the required service on the battery Do not remove the battery from the adapter 2 Press PRINT 3 Press the station key of the station that contains the battery...

Page 105: ...26 BATTERY REMOVED 01 19 2000 10 25 0 2 18 PROCESS SUSPENDED 01 19 2000 10 25 0 2 188 SUSPENDED PROCESS ABORTED 01 19 2000 10 25 0 2 17 BATTERY REMOVED Figure 8 Sample event log Setting up the Event L...

Page 106: ...Event Log To print the event log 1 Make sure the printer or a label printer is connected to the analyzer and it is working see Connecting to BatteryShop or a Printer page 71 2 From the global display...

Page 107: ...inal program see Figure 9 page 92 Note When using BatteryShop the software s Data Monitor function is similar to the Data Log Two types of text strings are created when logging data The first is the e...

Page 108: ...gs not those of the computer Time This is the time the data string was created using the 24 hour clock and in the format hhmmss This string reflects the Cadex analyzer time settings not those of the c...

Page 109: ...slash characters separate the four elements Battery capacity In most cases this field displays the current or most recent battery capacity and the previous battery capacity both as percentages of the...

Page 110: ...event strings also contain a battery data field For example when an automatic OhmTest is run as part of a program the event string generated includes the OhmTest results in m Sample text strings Here...

Page 111: ...discharging process 7 terminal voltage is 1419 mV discharge current is 401mA and battery temperature is 35 C Current battery capacity is 85 previous capacity was 37 0 2 CDX01 01 25 2001 090500 250 5 1...

Page 112: ...log data to a computer 1 From the global display press MENU 2 Press or to scroll to SYSTEM SETUP and then press ENTER 3 Press or to scroll to SERIAL PORT DEVICE and then press ENTER 4 Press or to scr...

Page 113: ...its per second 9600 Data Bits 8 Parity None Stop Bits 1 Flow Control None 5 Click OK The HyperTerminal screen appears The bottom left hand corner of the screen should display the message Connected h m...

Page 114: ...perTerminal 2 Double click Cadex analyzer Connection or the name given to the connection when it was first set up HyperTerminal opens and starts displaying data sent from the Cadex analyzer 3 Click Tr...

Page 115: ...he text file to open in Microsoft Excel 6 Click Open Use Microsoft Excel functions to analyze graph or create a report of the data Note The data is not limited to spreadsheet programs Depending on wha...

Page 116: ...line Help for detailed instructions Custom programs can run virtually any sequence of service cycles They are stored in the analyzer to be globally used by any adapter A custom program consists of pha...

Page 117: ...battery for the specified time period in hhh mm ss format at the charge rate set in the extended C code Recondition Time for 000 00 00 Reconditions deep discharges the battery for the specified time p...

Page 118: ...h describes the action to be taken if the battery fails the test the condition is false IF Statements Choose from ten different test conditions or IF statements when setting tests for phases 1 through...

Page 119: ...Total Capacity 5 Selects the TRUE statement if the capacity during the last discharge cycle is greater than 5 otherwise selects the FALSE statement IF User Defined Timeout Selects the TRUE statement...

Page 120: ...hase Done REPEAT 0 times Repeats actions in the current phase the number of times specified Available settings 1 to 8 FOREVER The program continues forever See the IF Loop Count Max and IF Loop Count...

Page 121: ...isplay press MENU 2 Press or to scroll to PROGRAM SETTINGS and then press ENTER 3 Press or to scroll to CUSTOM PROGRAMS and then press ENTER 4 Press or to scroll to the program to create or edit for e...

Page 122: ...ove to Cycle 1 Press or to select the action to be performed There is only one cycle for Phase Done 1 After all the settings have been entered press ENTER 2 Enter a name for the program if desired Pre...

Page 123: ...t capacity complete the program Phase Done If the target capacity is not met apply the recondition cycle Phase 3 Phase 3 Recondition and charge the battery Phase 4 Discharge to find capacity after the...

Page 124: ...e Go to Phase 4 Phase 1 Cycle 1 Cycle 2 False Go to Phase 3 True Go to Done Test True False Phase 2 Cycle 1 Cycle 2 Test True False Phase 3 Cycle 1 Cycle 2 Test True False Phase 4 Cycle 1 Cycle 2 Test...

Page 125: ...hat the power cord is properly inserted and there is power available If the analyzer does not power up then primary input fuse may need to be replaced see Appendix D Parts and Accessories page 154 To...

Page 126: ...are available from Cadex Electronics Inc the Firmware Utility software comes with BatteryShop The current version of the firmware is always displayed in the lower left hand corner of the analyzer star...

Page 127: ...fe Cycle and custom programs Battery startup settings Key sound and alert sound USB port device Voltage display Service counter number of batteries serviced The setting for the serial port device chan...

Page 128: ...ttery Adapters 2 From the global display press MENU 3 Press or to scroll to SYSTEM SETUP and then press ENTER 4 Press or to scroll to CALIBRATE VOLTAGE and then press ENTER 5 Firmly insert the four vo...

Page 129: ...es or single cells operating at high charge or discharge currents OhmTest QuickSort and QuickTest results can also be affected in some cases dramatically To calibrate an adapter 1 Make sure that there...

Page 130: ...he new value If the new calibration is over 400m the new value is rejected Acceptable Calibration Values for New Adapters General calibration values are provided below to help gauge whether a calibrat...

Page 131: ...These ranges are only for new adapters shorted with gold plating Older adapters or those adapters shorted with different materials may have higher values 115...

Page 132: ...tartup under the Option Controls see To set user input page 77 Battery continually cycles without ending on QuickTest Battery Cells may be soft or in poor condition Verify battery condition using the...

Page 133: ...recognized when inserted in the analyzer Ensure that the adapter is firmly inserted into the analyzer Verify that the battery is correctly and firmly inserted into the adapter Ensure that the contacts...

Page 134: ...the analyzer is intermittent The battery may be intrinsically safe Change the charge method in the extended C code to DC Charge lower the charge and discharge rates reduce the end of discharge setting...

Page 135: ...a label at the back 16K adapters are needed for the QuickTest Q Learn and Learn programs Reports or labels are not printing Check the serial port setup for the serial printer see Connecting Other Devi...

Page 136: ...tached printer Analyzer does not respond to input and there is continuous beeping Incomplete boot or power failure during in boot up Remove the adapters and restart the analyzer No sounds are heard Tu...

Page 137: ...ights that are on or flashing What happened when the problem occurred Move the adapter and or battery between stations to isolate if it is a battery or adapter issue For questions related to batteries...

Page 138: ...Cadex Electronics Inc C7000 C Series Battery Analyzers 122...

Page 139: ...To view the detailed warning message press the appropriate station key in this case 2 and then press A display similar to this one appears Messages and warnings are listed in this appendix by code num...

Page 140: ...full Press the Esc key to clear the buffer and restart the analyzer Services may resume N A Not Applicable QuickTest or OhmTest has not yet been completed N R Not readable QuickTest could not determi...

Page 141: ...GE DISCHARGING 8 INSERT INSERT THE BATTERY 9 CHG WAIT CHARGE WAIT 10 EMPTY NO BATTERY 11 START START BATTERY PROCESS 12 COLD WAIT BATTERY TOO COLD 13 HOT WAIT BATTERY TOO HOT 14 OVERHEAT BATTERY OVER...

Page 142: ...OUT 115 FAIL 115 TARGET CAPACITY NOT MET in service 116 FAIL 116 TARGET CAPACITY NOT MET after service 118 ALERT 118 CHRGE CURRENT REDUCED 120 FAIL 120 OVER VOLTAGE 121 REVERSED BATTERY REVERSED 122 S...

Page 143: ...LIBRATION FAULT 171 FAULT SMART ADAPTER FAULT 172 FAULT SMART BATTERY FAULT 175 LOW SOC BATTERY UNDERCHARGED 176 HIGH SOC BATTERY OVERCHARGED 177 ALERT 177 BATTERY UNDERCHARGED 178 ALERT178 BATTERY OV...

Page 144: ...ssage 209 INV ADAPT ADAPTER DATA INVALID 210 BAD ADAPT BAD ADAPTER 211 NULL CODE NULL C CODE IN ADAPTER 214 C CODE U S C CODE UNUSABLE 250 None None battery being processed Cadex Electronics Inc C7000...

Page 145: ...If the message persists Press Esc ADAPTER NOT SET UP 208 Adapter is not programmed with a C code or the C code is invalid Delete and re enter the C code Contact Cadex to upgrade firmware ADAPTER REMOV...

Page 146: ...he battery may be faulty Try a different battery in the same station Single Cell NiCd or NiMH batteries may produce this error on the C7400ER C Service single cells on the C7200 C or C7400 C Check the...

Page 147: ...ischarge is repeated up to 5 times until SoC is below 90 If OhmTest is running the program is aborted Discharge the battery before running OhmTest again Turn off the automatic OhmTest If error continu...

Page 148: ...e initial charge cycle the voltage remains low Ensure battery leads are firmly connected to the battery Battery may be fully discharged Recharge battery in its original charger before placing it in th...

Page 149: ...r five minutes after which QuickTest restarts Charge is repeated up to 5 times until SoC is above 20 If OhmTest is running the program is aborted Partially charge the battery before running OhmTest ag...

Page 150: ...s so the negative slope is not well defined The program proceeds to the next cycle Wait until processing is complete because the Auto and Prime programs will attempt to correct this warning through se...

Page 151: ...is new or has been in storage use the Prime program CHARGE CYCLE COMPLETE 30 Charge cycle completed Program is going to the next step CHARGE TIMEOUT 144 Charge time has exceeded the expected value fo...

Page 152: ...n there is a bug in the custom program verify the custom program statements CYCLE RESUMED 32 Power resumed or the battery is re inserted into the adapter DCHG CYCLE COMPLETE 31 Discharge cycle complet...

Page 153: ...CKLE CHARGE 159 Battery temperature has exceeded its maximum setting after service has ended and battery was on trickle charge The trickle charge stops Verify that the mAh rating of the battery matche...

Page 154: ...ts Verify that correct contacts are used Verify that the battery is properly inserted Verify that the C code is correct for the battery Reduce the charge rate in extended C code Increase end of discha...

Page 155: ...could not be obtained in allotted time due to high battery capacity for set charge current incorrect voltage setting or shorted cells Verify C code settings and battery rating Replace battery if low...

Page 156: ...e The battery acted as if it was fully charged even though it isn t Increase the charge rate in the C code If the battery was in storage use Ext Prime If all fails discard the battery NULL C CODE IN A...

Page 157: ...gram is complete PROCESS RESUMING 25 Code 25 Battery service is continuing after a power interruption This message appears after the initial startup screen and remains until the analyzer determines th...

Page 158: ...ity or state of health is displayed Faults or warnings if any were corrected Remove battery and use as normal RECONDITION TIMEOUT 146 Recondition time has exceeded the expected value for the battery P...

Page 159: ...tes in 5 seconds and will continue to the next step of the program RESTING 19 Station is in a rest period as specified in the custom program The program will proceed to the next step when resting peri...

Page 160: ...the Max Standby Voltage SETTING UP CALIBRATION 22 Station is preparing for a calibration process If message persists remove the adapter Turn off the analyzer SMART ADAPTER FAULT 171 The analyzer has o...

Page 161: ...are chip in the analyzer may be loose Contact Cadex for instructions to reinsert firmware TARGET CAPACITY NOT MET 115 Battery capacity is below the target capacity The analyzer attempts to improve the...

Page 162: ...rade the adapter If the battery is NiCd or NiMH turn off the temperature sensing If the battery is known to be good or the adapter has two contacts in these adapters the negative contact is a thermist...

Page 163: ...utes and then charge again Battery is new Use the Prime program to prepare the battery for use Raise End of Charge SLA Li ion ad Li Ph to 0 10C Check that correct contacts are used UNABLE TO LEARN MAT...

Page 164: ...rrent constant voltage CC CV method for Li ion Li Ph and SLA batteries NiCd and NIMH batteries The C7x00 analyzer uses a constant current algorithm to charge NiCd and NiMH batteries A current and volt...

Page 165: ...tage plateau or temperature rise more than dT dt the current is reduced by half and the charge continues until the battery reaches full charge For NiMH batteries the current is often reduced by half t...

Page 166: ...hree stages during the charge Stage 1 the battery is charged at a constant current this current is the Charge Rate in the Extended C code until the battery reaches the Maximum Charge Voltage set in th...

Page 167: ...Charge has been reached In both cases of Optimization settings exceeding dT dt will fail a battery Stage 3 After the charge has completed the battery is maintained at a constant voltage level this is...

Page 168: ...ds the current scales down large batteries may go on waiting queue Line voltages 100 240VAC 50 60Hz 1 5A max 100 240VAC 50 60Hz 1 75A max 100 120 200 240VAC 50 60Hz 4A max Chemistries Lithium ion Lith...

Page 169: ...d on recommended monthly maintenance Each analyzer services two battery batches every 24h day and night run 20 days per month Physical Length Width Height Weight 12 1 312mm 9 4 240mm 3 5 90mm 7 1lb 3...

Page 170: ...n kit with instructions and calibration adapters 92 770 0212 Power Cord 6 68 723 1804 Cadex User s Manual 89 307 1013 C7200 C C7400 C Primary Fuse T2 0A 250 V 52 546 0200 C7400ER C Primary Fuse T5 0A...

Page 171: ...85 basic programs 25 See also programs Auto 25 26 Charge 25 27 Prime 26 27 Quicktest 26 31 batteries basic service 20 displaying number serviced 71 Gell SLA 61 Hawker SLA 51 60 136 inserting 20 intrin...

Page 172: ...arge rate 52 end of charge 57 end of discharge 54 negative slope 54 recondition discharge rate 53 temperature sensing 54 trickle charge rate 53 C Codes 18 copying 65 creating 62 deleting 65 displaying...

Page 173: ...display 123 detailed 14 lights LEDs 15 displaying C Codes 21 61 event log 90 firmware version 110 number of batteries serviced 71 done phase 104 editing Boost program 39 C Codes 62 64 custom programs...

Page 174: ...61 matrix Quicktest 44 copying 65 messages 92 123 modifying See also editing name C Code 50 negative slope 54 NULL code 20 128 OhmTest program 30 36 111 113 131 133 editing 36 OhmTest automatic 78 131...

Page 175: ...53 removing batteries 19 battery adapters 19 security 76 replacing primary input fuse 109 reports adapter setup 83 battery service 83 85 printing 87 system setup 83 resetting extended C Code parameter...

Page 176: ...See security system settings 67 automatic OhmTest 78 battery startup 77 calibration 112 charge optimization 79 sounds 68 voltage 69 system setup report 83 target capacity 8 49 80 107 133 145 changing...

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