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Servicing Batteries with Bar Code

This applies when the analyzer is equipped with the OP-72 option board which supports

a bar code reader.

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

Print

Utilities for detailed procedures.)

Place the labels onto the battery.

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

Scan the Battery ID.

Scan the C-Code.

When the READY (green) light flashes, insert the battery and press ENTER to

start service.

Note that the active C-Code displayed is

C11, a read-only position in the

adapter reserved for bar code entries.

C7000 & 7000ER Battery Analyzer V3.5

Содержание C7000

Страница 1: ...C7000 C7000ER Battery Analyzer User s Manual...

Страница 2: ...This page is blank...

Страница 3: ...lyzers are independent of the date stored in the analyzer Therefore all functions and the performance of the C7000 and C7000ER Battery Analyzers are not affected by dates during and after the year 200...

Страница 4: ...ms 6 Commonly Used Terms 7 3 Operating Principles 8 Components 8 Option Boards 9 Components 9 Battery Adapters 10 Special Handling Tip for Smart Cable Adapters 11 User Interface 12 Display 12 Menu 14...

Страница 5: ...ments 37 Phase Done 38 Example 38 Creating or Modifying a Custom Program 40 8 System Security 41 Password Requirement 41 Setting Security 42 Changing Password and Removing Security 42 9 System Setup 4...

Страница 6: ...el C7000 1 C7000 2 C7000 9 69 Extended Range Model C7000ER 70 Replacing Backup Battery with OP 70 or OP 72 only 71 IEC320 Power Cord 72 14 Specifications 73 Hardware 73 Firmware 74 15 Getting Help Pro...

Страница 7: ...mmercially available battery models The battery adapter contains the battery configuration code also know as C Code which automatically sets the analyzer to the correct parameters for serving the batt...

Страница 8: ...Battery Adapters Improved NiMH charge algorithm Reorganized programs separated Basic and Specialty Programs 4 additional Custom Programs Improved user interface 3 4 Support for BatteryShop General upd...

Страница 9: ...ction also serves as a general system reboot Connecting to BatteryShop BatteryShop is a powerful Windows based battery management tool that allows automation of the C7000 and C7000ER functions to incr...

Страница 10: ...printer to print reports Label Printer to print labels The DYMO LabelWriter SE300 is recommended For more information on label printers contact Cadex or DYMO CoStar Bar Code Scanner to scan bar coded...

Страница 11: ...ion that is necessary to operate the analyzer Conventions 2 Getting Started e c a f e p y T g n i n a e M c i l a t I d e z i s a h p m e e r a t a h t s d r o W d l o B s s e r p o t s y e K u n e m...

Страница 12: ...5 Abbreviation Name or Term AWG American Wire Gauge A U S wire size standard BMS Battery Maintenance System LCD Liquid Crystal Display Referred to as Display LED Light Emitting Diode Referred to as Li...

Страница 13: ...ery discharged at 0 5C would provide 500mA for two hours Intrinsically Safe I S Battery with built in safety protection circuitry These batteries are primarily used in explosive environments Reconditi...

Страница 14: ...hen pressed with the 0 key after a firmware upgrade or as a general system reboot ENTER Key Save settings and start servicing Menu Key Access menu Numeric Keypad Enter numeric parameter settings LED I...

Страница 15: ...hased Components Parallel Printer Port connects to a parallel printer Refer to System Setup on how to set up the parallel port device settings Battery Backup RAM retains test data on power interruptio...

Страница 16: ...000ER Battery AnalyzerV3 5 Adapter Type Description Custom Adapters Accommodate any specific battery shape There are over 600 Custom Adapters available Dual station Custom Adapters Designed to handle...

Страница 17: ...battery to be serviced Refer to C Codes for more information For Li Ion batteries of greater than 7 2V 2 cells a custom designed adapter is strongly recommended Cadex continuously designs adapters fo...

Страница 18: ...ell Voltage Resistance Program Duration hh mm Temperature S1 CHARGING S1 CHARGING S1 CHARGING S1 CHARGING 1 35V Cell 1006mA 233m 1 35V Cell 1006mA 233m 1 35V Cell 1006mA 233m 1 35V Cell 1006mA 233m 32...

Страница 19: ...following if System Security is selected See Menu for the overview of the functions Operating Principles 3 SYSTEM SECURITY 17 53 10 SYSTEM SECURITY 17 53 10 SYSTEM SECURITY 17 53 10 SYSTEM SECURITY 17...

Страница 20: ...bel Bar Code Label System Setup Report Auto Print View Event Log Print Event Log Clear Event Log Events to Log ENTER S2 S1 S2 S1 S2 S1 S1 S2 to scroll ENTER to select Esc to exit Menu ENTER ENTER ENTE...

Страница 21: ...station using the menu Refer to Calibrating Station Press To Fn 5 View number of batteries serviced Fn 7 View firmware version Fn 8 Calibrate adapter station 15 To Press Select a value Scroll through...

Страница 22: ...Green on Service in progress flashing Cold battery Service resumes when battery warms up Code 12 FAIL Red on Battery failed flashing Hot battery Service resumes when battery cools down Code 13 All fl...

Страница 23: ...odes by pressing the ENTER key Refer to Battery Configuration C Codes for details on C Codes If the active C Code indicated by the is correct proceed to step 7 to start service Basic Battery Service S...

Страница 24: ...Press ENTER and select Yes Now you can proceed to step 7 to start service Refer to Battery Configuration C Codes to add or edit C Codes Warning Always use the correct C Code especially the correct che...

Страница 25: ...EADY NO ADAPT NO ADAPT NO ADAPT READY NO ADAPT NO ADAPT NO ADAPT READY NO ADAPT NO ADAPT NO ADAPT READY NO ADAPT NO ADAPT NO ADAPT 620mA 620mA 620mA 620mA 19 Status Current Voltage mV DISCHARGE NO ADA...

Страница 26: ...s for detailed procedures 2 Place the labels onto the battery 3 With the Battery Adapter inserted select the station by pressing the station key 4 Scan the Battery ID 5 Scan the C Code 6 When the READ...

Страница 27: ...Use Auto Exercises batteries to maintain optimum performance If the Target Capacity cannot be reached recondition is applied Restore batteries affected by memory Routine battery maintenance Identify m...

Страница 28: ...definable wait period If the second reading is lower by 30 or more the battery is failed Identify high self discharge on batteries that otherwise may have good capacity readings Life Cycling Continuou...

Страница 29: ...high reliability Fewer batteries will pass 80 Recommended default setting which provides a balance between adequate energy reserve and long service life 70 Recommended for less stringent applications...

Страница 30: ...Code for which you want to select the program and or set the Target Capacity 2 Press Prog 3 Select the desired program depending on which program list you are in If you are in the Basic Program list...

Страница 31: ...Life Cycling Cycle time and load current in Runtime Custom Programs refer to Custom Programs 1 Select Program Settings on the menu Refer to Menu 2 Select the program to edit 3 Press Prog then edit th...

Страница 32: ...LA Li Ion Auto 2 5 10 hours 20 40 hours 6 20 hours Charge 1 5 hours 10 hours 4 hours Prime 5 10 hours 40 80 hours 12 25 hours OhmTest 5 seconds 5 seconds 5 seconds Runtime Self Discharge 30 hours 60 h...

Страница 33: ...how to create a C Code A C Code is divided into 2 parts Basic C Code that includes chemistry voltage and capacity Extended C Code that consists of Charge Discharge C rates Trickle Charge rate recondit...

Страница 34: ...ncrements of 1 Recondition Discharge Rate NiCd and NiMH only A slow and gradual discharge after the battery reaches the End of Discharge voltage During this process the crystalline build up memory on...

Страница 35: ...recombination of gases Available settings DC Charge No Rev Load Rev Load 5 12 Max Standby Voltage SLA and Li Ion only Maintains the battery at full charge state after service is complete Available set...

Страница 36: ...hange the settings Advance or go back using the and keys Then press ENTER and select Yes Scroll to the C Code with the and keys then press Fn 0 and select Yes Scroll to an empty C Code with the and ke...

Страница 37: ...cted by this change since these voltages are definitions only Some manufacturers may state the number of cells of their batteries To get the correct voltage multiply the number of cells by the chemist...

Страница 38: ...ty Offset 0 Temperature Sensing Disabled adapters without temperature sensor 0 45o C NiCd NiMH SLA 5 45o C Li Ion Negative slope 32mV Cell NiCd 16mV Cell NiMH End of Discharge 1 00V Cell NiCd NiMH 1 7...

Страница 39: ...ograms run virtually any sequence of service cycles They are stored in the analyzer and can be assigned to any C Codes in the adapters A Custom Program consists of 6 phases Phase 1 5 and Phase Done Ea...

Страница 40: ...period in hhh mm ss format The Charge rate is set in the Extended C Code Recondition Time Recondition for 000 00 00 Recondition Deep discharge the battery for the specified time period in hhh mm ss fo...

Страница 41: ...low the Target Capacity go to the True statement Otherwise the False statement is selected IF 5 Capacity Increase If the improvement in capacity during the last two discharge cycles is less than 5 for...

Страница 42: ...is fully charged discharged or reconditioned go to the True statement Otherwise the False statement is selected For Trickle Charge and Rest the program will proceed to the True statement only IF Loop...

Страница 43: ...ctions in the current phase by the number of times specified Available settings 1 8 and Forever If Forever is selected the cycle repeats for 255 times Refer to IF Loop Count Max and the IF Loop Count...

Страница 44: ...ally performs discharge charge every 30 days 180 days for SLA Trickle Charge Trickle charge the battery according to the Trickle Charge Rate in the Extended C Code Phase Action Phase 1 Discharge for 1...

Страница 45: ...1 Cycle 2 Test True False Cycle 1 Cycle 2 Test True False Phase 1 Phase Done Phase 2 Phase 3 Phase 5 Phase 4 Discharge Charge Discharge True Goto Phase 2 Skip Skip TC Met Done True Goto Done Recond C...

Страница 46: ...program name then press ENTER You can enter up to 9 characters numbers Otherwise press Esc to skip 4 Enter the program settings Use the and keys to scroll through the phases and cycles or select the s...

Страница 47: ...Off Level 1 Low Level 2 High C Code Not required Edit C Code Edit C Code Set Default C Code Security Not required Set Security Change Password Remove Security Set Security Change Password Remove Secur...

Страница 48: ...elect the security level using the and keys Then select Yes to accept changes Changing Password and Removing Security Select Change Password or Remove Security on the menu To change the password for L...

Страница 49: ...am settings Refer to Editing Program Settings Company Name Set up the company name for printing on Battery Labels and Battery Service Reports You can enter up 20 characters numbers Default CADEX ELECT...

Страница 50: ...brating Voltage You need a calibration kit P N 92 770 0210 This kit can be purchased from Cadex or through your Cadex Representative The C7000 calibration kit consists of 4 calibration adapters P N 07...

Страница 51: ...e Battery Adapters could cause inaccurate capacity readings especially on low voltage batteries or single cells Recalibrate adapters when they are moved from one station to another 1 Make sure that th...

Страница 52: ...CTS RTS XON XOFF CTS RTS Data Bits 7 8 8 Stop Bits 1 2 1 Parity NONE ODD EVEN NONE DB 9 to DB 25 DB 9 DB 25 RD 2 2 TD TD 3 3 RD CTS 8 4 RTS RTS 7 5 CTS SG 5 7 SG Note If connecting to a serial printe...

Страница 53: ...e parallel port is a DB25 connector available only to analyzers with the OP 70 or OP 72 option boards System Setup 9 47 Option Description Disabled No output is provided to the serial port Printer Pri...

Страница 54: ...ating and cell voltage Also describes the C Code cycles performed Charge Discharge rates any applicable fault codes and final capacities Battery Label Contains company name date test result with any f...

Страница 55: ...pany CADEX ELECTRONICS Date 01 19 2000 Time 16 47 11 BATTERY STATUS Battery STATION 2 Battery ID 1234567890 Current Cycle PROCESS COMPLETE Cycle Capacities 30 82 98 Battery Resistance 122m Cell Voltag...

Страница 56: ...vent log Clear Event Log Clear all events in the event log Events to Log Specify events to record or ignore Event Log 50 C7000 7000ER Battery Analyzer V3 5 DATE TIME STN CODE DESCRIPTION 01 18 2000 14...

Страница 57: ...to log select Yes to activate or No to de activate Use the and keys to toggle between the events Then select Yes to accept changes 51 Log Event Description Errors Problems that stop the service Warni...

Страница 58: ...view the Detail message press the Station key When you get a message or warning you can look into the possible reason s and solution s by detail or code number Code FAIL 120 EMPTY NO ADAPT NO ADAPT FA...

Страница 59: ...ssage persists press Esc B Bad adapter FAIL 210 Adapter is not recognized by the analyzer Remove and re insert the adapter Clean the gold contacts on the underside of the adapter Reset the Extended C...

Страница 60: ...OVED Code 17 Battery is removed when the program completed This message appears instantaneously when the battery is removed Battery removed REMOVED Code 26 A 5 second delay after the battery is remove...

Страница 61: ...it until processing is complete since the Auto and Prime programs will attempt to correct this warning If corrected code 192 Cell mismatch corrected will appear The negative slope in Extended C Code m...

Страница 62: ...is complete An appropriate WAIT code may appear until the battery has cooled before the next process begins The Charge rate in the Extended C Code may have to be lowered Observe battery performance Th...

Страница 63: ...s old Either monitor battery use or discard For non OEM battery turn off temperature sensing I Insert the battery INSERT Insert battery into the station Intermittent battery FAIL 129 Battery connectio...

Страница 64: ...pacity for set charge current incorrect voltage setting or shorted cells Check C Code settings and battery rating Replace battery if low voltage remains N N A m OhmTest has not been performed yet so n...

Страница 65: ...ide the analyzer Process completed FINISHED Battery service completed Process suspended INTERRUPT Battery is removed during service Re insert battery within 5 seconds to resume service Program fault d...

Страница 66: ...adapter is not enabled S Setting up calibration CAL WAIT Station is preparing for a calibration process Shorted or reversed SHORT REV Battery voltage is too low on insertion Battery may be connected...

Страница 67: ...have the same firmware version number Press Alt 0 to reset the system Suspended Process Aborted INTERRUPT Battery is removed during service for more than 5 seconds Program terminated For non OEM batt...

Страница 68: ...charge TRKL CHRG The reconditioning process completed and the battery is being recharged The program has specified a trickle charge Trickle charge overheat FAIL 159 The temperature on the battery has...

Страница 69: ...INSERT THE BATTERY INSERT 009 CHARGE WAIT CHG WAIT 010 NO BATTERY EMPTY 011 START BATTERY PROCESSING START 012 BATTERY TOO COLD COLD WAIT 013 BATTERY TOO HOT HOT WAIT 014 BATTERY OVER TEMP OVERHEAT 0...

Страница 70: ...TTERY SHORTED FAIL 122 123 LOW VOLTAGE TIMEOUT 1 FAIL 123 124 LOW VOLTAGE TIMEOUT 2 FAIL 124 125 NO SLOPE TIMEOUT ZONE 1 FAIL 125 126 LOW VOLTAGE NEGATIVE SLOPE FAIL 126 127 LOW VOLTAGE TIMEOUT 3 FAIL...

Страница 71: ...BORTED INTERRUPT 192 CELL MISMATCH CORRECTED READY 195 CAP IMPROVED TO TARGET READY 200 POWER ON POWER ON 201 ADAPTER INSERTED ADAPT IN 202 ADAPTER REMOVED ADAPT OUT 207 TEMPERATURE HOLD COOLING SYS T...

Страница 72: ...nded wrist and or foot band be used when dismantling the analyzer If a wrist or foot band is not available firmly grasp the metal edge of the RS 232 Serial Port before touching any components Repeat o...

Страница 73: ...release tab outward with a fingernail or small screwdriver 4 If the primary input fuse needs to be replaced remove the fuse from the fuse drawer and replace the fuse 5 Push the release tab back to th...

Страница 74: ...o turn the fuse holder clockwise until it is released Then pull the holder 4 If the primary input fuse needs to be replaced remove the fuse from the holder and replace the fuse 5 Insert the fuse drawe...

Страница 75: ...lug power cord 2 Unscrew the 3 screws located on the rear The cover will still be attached to the analyzer by a grounding strap Put the cover to one side 3 Remove the open fuse from the holder taking...

Страница 76: ...discharge 2 Unscrew the 2 screws located on the rear to remove the top cover Disconnect the wire on the power supply circuit board that is attached to the power assembly filter 3 Remove the open fuse...

Страница 77: ...1 Remove all batteries and adapters turn the analyzer off and unplug power cord 2 Unscrew the 3 screws located on the rear of the C7000 2 screws on the C7000ER to remove the top cover The cover will...

Страница 78: ...cords for connection to any standard line voltage source If you need a special power cord for your particular wall socket obtain an approved cord fitted with an IEC320 socket at one end and the appro...

Страница 79: ...9lb with option board 6 4kg 14 1lb 5 7kg 12 6lb Accuracy Voltage 1 at max rated voltage Current 2 5 at 1A Throughput 4 batteries every 4 8 hours up to 160 batteries per month based on 2 batches per da...

Страница 80: ...0mAh 24 975mAh 100mAh 24 975mAh 100mAh 24 975mAh 100mAh 24 975mAh Charge Method Reverse Load Constant voltage with current limit Display Format Capacity Percentage of nominal rating Voltage Volts Cell...

Страница 81: ...rect Make sure that the power cord is firmly inserted in the back connector Check the input fuses 2 The fan turns off and on even when no battery is being analyzed This is normal 3 Password is not acc...

Страница 82: ...e pin configurations 7 Battery service does not start Ensure that the adapter is firmly inserted into the analyzer Check that the battery is correctly and firmly inserted into the adapter Make sure th...

Страница 83: ...tent results Calibrate the station Set the charge method in the Extended C Code to DC Charge due to low terminal voltage Single cells are discharging and or charging too quickly Lower the Discharge ra...

Страница 84: ...that are on or flashing What happened and what you were doing when the problem occurred For questions related to batteries or adapters Battery Model Number Adapter Number C Code being used Display me...

Страница 85: ...t 8 00 am 4 30pm Pacific Time GMT 08 00 Monday through Friday Technical Support Phone 1 604 231 7777 Toll Free 1 800 565 5228 US and Canada only Fax 1 604 231 7755 Email service cadex com Mail Cadex E...

Страница 86: ...cause interference in which case the user at his own expense will be required to take whatever measures required to correct the interference EN55022 Warning This is a Class A product according to EN55...

Страница 87: ...age to the battery Allow cold batteries to warm up and hot batteries to cool before charging Use only a grounded AC outlet to power the analyzer Do not attempt to charge non rechargeable batteries suc...

Страница 88: ...ir the protection provided by the unit Use only a grounded AC outlet to power the analyzer Before attempting any internal service remove all batteries from the battery stations turn the analyzer off a...

Страница 89: ...ct Cadex Technical Support If the service representative has determined that your product needs to be returned for service or replacement the representative will fax or provide a Return Authorization...

Страница 90: ...27 active 17 20 48 Basic 27 Extended 27 28 32 managing 30 viewing 17 30 calibrations 15 44 45 commands 15 commonly used terms 7 components 8 Custom Programs 33 creating or modifying 40 D display 12 13...

Страница 91: ...e 81 security 41 removing 42 setting 42 serial cable pin configurations 46 47 serial ports 11 46 device settings 47 settings 46 service duration 26 service procedures 17 19 batteries with bar code 20...

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