accureg® 8000 - produktinfo.conrad.com
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1. sen s system elektrotechnik Battery testing andregeneration system for improving the start performance and capacity of 12V starter amp traction batteries accureg 8000 T Austrian Battery Research i tenn Laboratory GesmbH semw Important Read through this manual carefully before start up Always keep this manual ready to hand for later reference USER MANUAL As of 30 06 2008 Page 1 48 Dear customer We congratulate you on your purchase of the accureg 8000 battery testing and regeneration system for improving the start performance and capacity of 12 V starter and traction batteries In so doing you have chosen a system which contains a unique patented technology which performs both qualified tests and maximises the improvement in the state of your battery The system is therefore ideally suited for assessing the capacity and improvement in the properties of your battery You are able to make a professional decision e g at the start of the cold season about whether the battery used in your vehicle can and will meet the requirements for staring the vehicle s engine with sufficient reliability You therefore prevent potential loss of earnings restrictions on use breakdowns when using your vehicles by reliably determining the performance of your energy supply before it breaks down If a replacement is necessary you have sufficient time to purchase a replacement battery You can therefore replace t2. Select the function regeneration short test full test trickle charge cyclisation capacity test B Warning Before selecting the function you must select the battery type Starter battery type 1 closed or traction battery type 2 sealed see selecting services Enter characteristics capacity cold cranking amps Confirm entry data or edit entry Start process 0 N O Ol Upon completion of the selected function disconnect the battery and switch off the system CHAPTER 4 Working with the accureg 8000 4 1 Flow charts of the system functions see also page 46 49 in the manual Page 9 48 4 2 Description of the menu items navigation e Menu navigation for main menu_and submenu A Navigate up to respective menu level it is only possible to return to the higher menu in the first submenu item Y Navigate down to respective menu level Editing can be done with Edit Menu e Main menu Overview navigation with A Main menus 1 4 Main menu 1 Description Select the available test and regeneration functions Main menu 2 Description View of the latest test and regeneration parameters Main menu 3 Page 10 48 Description Select print function status indicated here OFF i e print function not activated Main menu 4 Description Select the available services such as operating hours indicator indicators for processes setting the time and date activating the printer se
3. A11 95 A1 96 A12 96 A13 98 A14 98 A15 00 A2 00 Test standard A16 01 EN 60335 2 29 96 A1 97 EN 55014 1 00 A1 01 A2 02 EN 55014 2 97 A1 01 EN 61000 3 2 00 EN 61000 3 3 95 A1 01 Prufbericht e Reference No 2003 ET PZW EX 1093 aus 01 2004 und Test report s T V Nr M EMV 04 114 aus 02 2004 Hiermit best tigt der T V sterreich dass das die oben angef hrte n Produkt e den Anforderungen der zutreffenden Pr fpunkte des oben angef hrten Pr fstandards entspricht entsprechen Der Antragsteller darf das nachstehend abgebildete Zeichen in Zusammenhang mit dem den oben angef hrte n Produkt en entsprechend dem daf r g ltigen Regulativ QVB P 001 99 verwenden Die Konformit t wurde anhand des der getesteten Muster s festgestellt Hereby the T V Austria confirms the conformity of the product s with all applicable test points of the test standard mentioned above The applicant is allowed to use the following label according to the adjustment factor QVB P 00 1 99 The conformity was asserted by the tested sample s 08 03 2004 08 03 2007 Dipl Ing K Mayerfi fer Datum der Ausstellung Ende der G ltigkeit der stv Leiter Date of issue End of validity Assistant head of division Auszugsweise Vervielf ltigung nur mit Genehmigung des T V sterreich gestattet The duplication of this document in parts is subject to the approval by TUY Austria T V sterreich pew cecs Seite 1 1 Tel 43 1 61
4. gt gt The Cyclisation function is designed for mobilising reversible capacities of traction batteries primarily sealed types AGM or gel batteries With the consecutive completion of several discharge and charge cycles passivated parts of the battery plates are reactivated and subsequently participate in the electrode reaction again The discharge charge process is performed as standard 5 times in total The user is asked afterwards whether specifying the improvement rate of the last cycle compared with the last but one cycle a further cyclisation sequence should be performed at the same time the user is asked whether to continue repeat the process a recommendation is displayed The process stops when the capacity increase rate is lower than a defined minimum increase rate 5 6 Capacity test function Test scope When the Capacity test function is called upon the following test routines are performed A Load test B Capacity test ad A Load test The test item test battery is subjected to a warm start test load test using the cold cranking amp value specified on the test item Based on the absolute position of the voltage value start value plateau value determined and the voltage drop over the test period a statement is generated on the cold start characteristics of the battery using the system s built in empirical database ad B Capacity test By using the specifications for the battery
5. in Cn_actual in of the new Capacity Upon successful completion of the regeneration process at this point the status message Battery OK is displayed or a short description of the fault which has occurred for a complete overview of possible battery faults see the appendix is displayed Description View of the latest test and regeneration parameters Page 18 48 4 8 Main menu 3 Printing Description Select print function status indicated here OFF i e print function not activated 4 9 Main menu 4 Selecting services Description Select the available services such as operating hours indicator indicators for processes setting the time and date activating the printer setting the language selecting the climate code selecting the driving profile setting the battery type The system provides the following services 4 5 1 Operating hours indicator List of the submenu items navigation with A YW Page 19 48 4 9 1 Operating hours indicator 4 1 Description Displays the number of operating hours completed 4 2 to 4 2 6 1 2 Indicators number of processes List of the submenu items navigation with A 4 2 Description Displays the number of processes The indicators of the functions performed by the system are supported by 4 2 1 to 4 2 6 Indicator levels Individual indicators all indicators can only be reset by authorised personnel entering the service code When you are in
6. in A the current which can be delivered under certain test conditions temperature time current strength by the battery When specifying cold cranking amp values the test process upon which they are based also has to be indicated e g 500 EN 340A DIN 440 A SAE etc Normally the specifications are made in EN a two stage test Page 31 48 The design and the layout of the poles also have a significant and decisive impact on the possibilities for using a starter battery dimensioning All of the relevant information is taken from the so called ETN number European Type Number which can be seen on the battery box of many products As well as the ETN the five digit DIN type number can also be specified Decoding the ETN The structure of the ETN consists of 9 numbers of respectively 3 groups with 3 numbers The first group of 3 numbers Group A codes the battery voltage and the nominal capacity the second group of 3 numbers Group B comprises the model and the third group of numbers Group C the cold cranking amps of the battery Structure of Group A Group A consists of 3 numbers which specify the battery voltage and the nominal capacity For 6V batteries the value of the nominal capacity is specified By definition numbers up to the maximum number of 499 are available i e 6V batteries with capacities between 1 and 499Ah can be coded with the ETN e g Group A 036 gt 6V 36Ah Batteries with a nominal voltage
7. measurement of the voltage of the battery and say nothing in practice about the current status of the battery b Rapid test including a back calculation on the internal values of the battery This is a widely used method for determining the status of the battery In most cases the battery is either charged by means of a constant charge over a period of a few seconds to minutes or charged by means of a defined number of charge impulses with a defined frequency Another common method of measurement in this category is by charging the test item with alternating signals with different frequencies The reaction of the battery to these signals is recorded and evaluated Page 35 48 In all cases based on the voltage current and complex resistance values determined during the charging an approximate calculation of the characteristic values of a battery capacity cold cranking amps and the state of charge SOC including even the state of health SOH is made c Full test determining the current capacity and the current cold cranking amps The right to perform a full test is in general retained by a specialist testing laboratory Here test items are tested for their specifications concerning capacity cold cranking amps on the basis of valid regulations standards Functional principle of the accureg 8000 The accureg 8000 is the first fully automated system for testing and improving the status of starter batteries based on lea
8. of 12V are coded with numbers from 500 i e the capacity value specified by the manufacturer is calculated from the text on the label by deducting the number 500 e g Group A 645 gt 12V 145Ah Structure of Group B The description of the structure of Group B is restricted to specifying the most important coded battery characteristics These are the dimensions length width height cell layout position and type of connection poles information on the design base hold down handles etc cover type information about water consumption etc Structure of Group C The 3 numbers for Group C correspond to one tenth of the cold cranking amps specified by the manufacturer e g 033 gt 310 A EN Operations and maintenance of a starter battery Before starting to use a Starter battery installation in a vehicle the energy store should be subjected to a complete charge at room temperature To do this commercial battery chargers can be used The maximum charge current should not exceed Cy 4 one quarter of the specified nominal capacity the voltage should in the process not exceed 16V After 24 hours the charging can be considered to be finished and the battery is ready for use When buying you have to take into account the size and type of the battery specified Under dimensioned batteries have a higher wear rate and accordingly fail earlier process There are conversion tables for current specifications for the individual test proces
9. s capacity nominal capacity according to the text on the label the current for a 10 hour charge of the battery K10 is calculated and the test item is charged over a period of 5 hours with this current Therefore 50 for testing with a setting for cold climate zones with a longer charge duration 60 of the capacity contained in the battery in real terms is taken capacity test If the terminal voltage of the battery falls during the testing period 5h below the lower voltage limit of 10 5V the discharge is aborted and the current capacity K20 is calculated based on the determined discharge capacity according to K10 If the terminal voltage of the test item is over the voltage value of 10 5V after the test period the remaining capacity is calculated by built in databases based on the voltage value before the discharge current U gt 10 5V was cut off By adding the value determined in the previous discharge after it has been converted to K20 the total capacity of the test item is determined Page 30 48 CHAPTER 6 Care and maintenance of the accureg 8000 6 1 Service The accureg 8000 does not require a regular service Services or repairs may only be carried out by the manufacturer or authorised specialists Failure to comply means you no longer have the right to claim warranty 6 2 Cleaning Clean the system with a dry cloth use a dampened cloth for more persistent dirt A Danger Always unplug before cleaning C
10. system Carefully keep this manual in a suitable place for later use Page 2 48 TABLE OF CONTENTS Page4 CHAPTER 1 SAFETY INFORMATION Page 5 Page 7 Page 10 Page 27 Page 31 Page Page Page Page Page 31 38 1 1 Notations 1 2 Safety information 1 3 Important safety instructions 1 4 System features CHAPTER 2 INSTALLATION OF THE SYSTEM 2 1 Delivery contents 2 2 Choice of set up location 2 3 Starting up the system CHAPTER 3 SHORT DESCRIPTION OF THE SYSTEM 3 1 Measures before start up 3 2 Guidelines for operation CHAPTER 4 WORKING WITH THE ACCUREG 4 1 Flow charts of the system functions 4 2 Description of the menu items navigation 4 3 Main menus 1 4 4 4 Main menu 1 Selecting the function 4 5 Submenus of main menu 1 1 1 1 1 4 4 6 Submenus of main menu 1 1 1 1 6 4 7 Main menu 2 Test records 4 8 Main menu 3 Printing 4 9 Main menu 4 Selecting services 4 9 1 Operating hours indicator 4 9 2 Indicators for processes and submenus 4 9 3 Setting the time and date 4 9 4 Activating the printer 4 9 5 Setting the language 4 9 6 Selecting the climate code 4 9 7 Selecting the driving profile 4 9 8 Setting the battery type CHAPTER 5 DESCRIPTION OF THE FUNCTIONS OF THE ACCUREG 5 1 Regeneration function 5 2 Short test function 5 3 Full test function 5 4 Trickle charging function 5 4 1 Trickle charging function with charge pause 5 5 Cyclisation fu
11. the submenu 4 2 1 and press the OK Start button the processes are displayed as follows Page 20 48 The numbers under the text Number Pos and Neg have the following meaning Number the number of times the respective function has be called upon process has been started Pos the number of successful without battery fault processes and Neg the number of negative battery failure with fault processes 4 9 2 Indicators for processes and submenus 4 2 1 422 4 2 3 Page 21 48 4 2 4 4 2 5 4 2 6 4 2 7 When this menu item has been called up you can reset all of the indicators Page 22 48 4 9 3 Setting the time and date 4 3 List of the submenu items navigation with A Description This service provides you with the opportunity to reset or change the system time date and time By pressing the button OK Start you go to the setting menu 4 3 1 Edit Menu The tens digit for Day s starts to flash By using the buttons A value here Then you press the button OK Start i been set o When you press Ec it Menu again the tens digit for the month starts to flash Proceed in the same way as described above by using the buttons Edit Menu and A order to select the correct values for the month the year and the time Page
12. the system s waste heat convection forced ventilation by ventilators and to make it easier to read the display and only use the system in a slanting position Ensure that the socket used to supply the power for the accureg 8000 has been installed professionally and has an appropriate earth connection 2 3 Starting up the system Connect the power cable Connecting the supplied power cable to the back of the system Page 6 48 The supplied power cable is to be connected to the back of the accureg 8000 system as illustrated above Switch on the system Switch on the system with the mains switch The system is switched on with the switch on the back of the system as illustrated above This step is acknowledged by the system with a bleep after which the system performs an internal self test LED status All of the LEDs red green and yellow briefly light up when switching on When the internal self test is being performed the green LED flashes In general there are three LED lights a red for errors a green indicates OK and a yellow light indicates in process The current software version and the time set are shown for approximately 3 seconds if necessary set the time see chapter 4 9 3 Setting the time and date CHAPTER 3 Short description of the a c c u r e g 8000 Short description of the system v accureg 8000 is a fully automated system for testing and improving the status of 12V
13. 0 91 6401 Technischer berwachungs Verein sterreich dl et n page 1 1 Fax 43 1610 91 6505 Elektrotechnik e mail et tuev or at A 1230 Wien Deutschstra e 10 http www tuev or at Page 42 48 Disposal of the accureg 8000 Batteries and accumulators do not belong in household waste In the interest of protecting the environment you as the end consumer are legally obliged in accordance with regulations concerning batteries and accumulators to return old and used batteries and accumulators You can hand in used batteries at the collection points of your local public waste management organisations or anywhere where batteries of the type concerned are sold The batteries are taken back at no cost to the consumer round cell battery has to be removed from the system It then has to be disposed professionally 0 Warning If the accureg 8000 regeneration system is scrapped the CHAPTER 10 Conversion table for transaction batteries Conversion table for transaction batteries The table shown below helps to determine the exact capacity data for your transaction battery This is requested when entering the data Please proceed as follows 1 Calculate based on the label on your battery whether the capacity Ah is specified according to K20 discharge capacity when discharging with a 20 hour current K10 K5 K3 or K2 5 If none of the K values mentioned apply please contact us For the entry into the accureg 8000 the K20 v
14. 23 48 4 9 4 Activating the printer 4 4 digit number starts to flash With the buttons A 7 you can select the correct numerical value for the activation code then press the button El nu again Now the second number of the code starts to flash which you can again set with the buttons A etc until you have entered all 6 numbers of your code The code is confirmed with the button OK Start 4 4 2 The activation code for the printer has now been successfully entered ES If the button Esc Stop is pressed in the menu Select function OK or ESC the status information appears on the display Page 24 48 By pressing the button OK Start sc Stop you return to the main menu 4 9 5 Setting the language 4 5 With the accureg systems it is possible for different users to make specific adjustments to the system settings including selecting the language in which they can operate the system German English and French can be selected The selection can be made in the following menu item You can select German English or French Page 25 48 4 9 6 Selecting the climate code 4 6 4 6 1 The climate code for your climate zone was set at the factory Please do not change anything without consulting our Hotline 4 9 7 Selecting the driving profile 4 7 4 7 1 Here you can choose between a short and a long distance vehicle when you regenerate a starter battery Page 26 48 4 9 8 Setting the battery
15. HAPTER 7 Information about starter batteries General The functional principle upon which a starter battery is based is over one hundred years old The lead acid battery still has a market share of almost 100 for starter batteries of vehicle combustion engines This circumstance is the result above all of the high efficiency of lead batteries in comparison with other technological solutions available Functional principle and characteristics of a starter battery The functional principle of a starter battery is based on the charging and discharging of an electrochemical system Charging adds energy to the system e g by the generator in a vehicle electrical system or by external battery chargers discharging takes energy away from the system e g by the starter or by the vehicle electrical system If a battery is left to itself clips open there is a constant inner discharge current self discharge which also consumes energy from the battery s system We have consciously not provided a detailed description of the electrical and chemical processes which take place during the charging and discharging of a battery We refer here to the numerous sources of information in the available technical literature The primary characteristics of a starter battery are the nominal voltage V normally 12V the nominal capacity the battery s capability to deliver a current over a defined time in Ah and the cold cranking current
16. alue is required If this is already available there must be no conversion 4 The following conversion factors are required Example calculation for K3 into K20 80Ah x 2 06 164 8 165 Ah Example calculation for K5 into K20 100Ah x 1 65 165 Ah Example calculation for K10 into K20 100Ah x 1 178 164 92 165 Ah Page 43 48 Specified value in 1 178 O gl Conversion table Conversion value in x u a Ts Page 44 48 others Chapter 11 Flow chart SHEET 1 se 1 1 1 1 1 OK start OK start lt gt gt Esc stop Esc stop 1 2 1 1 2 2 OK start OK start gt 4 gt dv lt gt Esc stop Esc stop 1 3 1 1 3 2 OK start OK start gt gt gt lt gt Esc stop i Esc stop 1 4 1 1 4 2 OK start OK start a gt Esc stop Eso stop 1 5 1 1 5 2 OK start OK start gt gt gt gt Esc stop Esc stop 1 6 1 1 6 2 Sheet 3 OKistart OK start gt gt 4 gt gt Esc stop ua SHEET 2 1 1 3 O start lt gt i esc stop gt gt Esc stop Esc stop 1 2 3 1 24 O start lt r esc stop gt lt gt gt Esc stop Esc stop 1 3 3 1 3 4 O start gt i r escistop gt gt gt Esc siop Esc stop 143 144 O start lt r esc stop gt gt lt gt Esc stop Esc stop 1 5 3 O start gt esc stop gt gt gt Esc stop Esc stop 1 6 3 O start gt t escisiop A 4 Esc sto
17. ct fault with battery check battery connection clips for clips contact Fan running System s internal temperature too Check whether the system s feet constantly high are open and the ventilation slots are covered ventilation slots must be kept free 8 2 Online help Provides help for using the system and describes the accureg 8000 and its fundamental operation as well as FAQ s At the internet address below you will also find the latest version of software for the system so that you can upgrade your system s software You can find the internet help at www system elektrotechnik de accureg htm 8 3 Overview of battery errors Battery errors are recognised automatically by the accureg 8000 and reported in coded form on the system s display LED status lf the battery fails during the regeneration process the red LED lights up The following battery errors can occur Battery error code 81 Capacity between 30 and 50 of Cn start voltage in last measurement before capacity test too low Battery error code 8 Capacity less than 30 of Cn Battery error code 5 Voltage drop in warm start test too high during the regeneration Page 38 48 Battery error code 6 Criterion for error indicator triggered during regeneration Battery error code 52 Voltage drop in warm start test too low after capacity test cell short circuit in capacity test Battery error code 53 Criterion for error indicator triggered at the end of th
18. d acid technology The following fundamental functional principles have been applied in the accureg 8000 Performance measurement based on the principle of fully testing the capacity and the cold cranking amps Optimised sparing desulphation process for lead acid batteries Time optimised test process to detect irreversible damage of batteries at the earliest possible time Use of the starter battery s characteristics to reveal whether a battery can continue to be used for its original purpose Description of the integrated processes A detailed description of the processes is provided in chapter 5 Description of the functions Here in particular the integrated functional principles regarding the latest state of the art technology and the innovative features of the accureg 8000 system are described in text form Test process The test modes short test full test aim to provide a quick initial measurement of the functionality of the battery The focus here is on producing immediate information on whether the battery to be tested is all right or what has happened to the battery if it is determined to be unsatisfactory for its original purpose voltage drop is too great under normal load The short test accordingly either shows that it is OK for use for its original purpose Battery all right or requests that it is regenerated Regenerate battery It cannot in the process provide any other information on any possible existi
19. designed to be used indoors The system must not be exposed to rain or spray water Warning Only the power cable supplied may be used to start up the system Always plug the power plug properly into the power socket Warning During set up care has to be taken that the system is set up out of the reach of children Caution If foreign bodies or fluids infiltrate the system there is a risk of damage Page 4 48 can be produced in the batteries Therefore please keep the battery well away from any flames and sparks and ensure that there is sufficient ventilation in the room Danger When using the accureg 8000 small quantities of explosive gases 1 3 Important safety instructions The system must be used strictly without any additional network systems such as vehicle electrical systems all poles disconnected If this condition is not established the battery can only be removed from the vehicle under very difficult conditions or with the use of a jump start pole inside the vehicle then to ensure the regeneration process is carried out properly with the accureg 8000 system it is recommended that the positive pole of the battery is disconnected as a minimum requirement Caution Before the battery is disconnected always finish the started or N completed operation regeneration short test full test and trickle charging of the accureg 8000 by pressing the Esc Stop button 1 4 System features The accur
20. e capacity test Battery error code 11 Voltage position of the battery in warm start test too low during the regeneration lt 8 0V Battery error code 12 Voltage position of the battery in warm start test too low after capacity test Battery error code 51 Voltage drop in warm start test too high in spite of previous over charging by the customer of the battery Battery error code 4 cell activation Cell activation unsuccessful high resistance battery Battery error code 5 activation charge Activation charge unsuccessful battery s energy absorption insufficient 8 4 Overview of various LED light statuses LED status All three LEDs red green and yellow briefly light up when switching on When the internal self test is being carried out the green LED flashes When the software version and the set time are displayed the green LED flashes Ifthe poles are reversed the red LED flashes In input mode function selection mode calling off services and printing all of the LEDs are off In the operating modes regeneration short test and full test etc the yellow LED flashes Upon completion of the processes short test full test etc all of the LEDs remain off with a regeneration recommendation When the battery fails during the regeneration process the red LED lights up In the trickle charge operating mode the green LED is continuously When cal
21. eg 8000 has a few features which form a complex system for testing and improving the actual condition of starter and traction batteries In chapters 5 and 7 you can find information about the system s functions and general information about batteries CHAPTER 2 Installation of the system 2 1 Delivery contents 1 battery testing and regeneration system for improving the start performance and capacity of 12 V starter and traction batteries 1 power cable 1 user manual Page 5 48 2 2 Choice of set up location Before setting up the accureg 8000 system choose a suitable set up location To do this please observe the following points To set up the system choose a stable tilt proof floor surface Position the system outside of the sphere of influence of equipment which either causes vibration e g compressors or the like or emit heat heaters heat sinks etc or emit to a greater degree electromagnetic radiation microwave ovens etc Also avoid set up locations where the accureg 8000 system could be exposed to rain or spray water The ventilation slots of the system are always to be kept free to prevent excessive temperature inside the system Make sure that the accureg 8000 system is not exposed to direct sunlight or is set up in particularly warm rooms The system must not be exposed to chemical substances risk of corrosion or vapours Open the system s feet to the improve the discharge of
22. electrical system in general can only make a small contribution towards preventing sulphation Rather the opposite effect occurs namely that strongly sulphated batteries are either declared as faulty when using commercial battery chargers systems or are overcharged due to too high a charge current and are broken in the process The patented process contained in the accureg 8000 system for desulphation breaking up of granular crystalline lead sulphate and reconverting it to active mass and electrolyte is essentially based on performing specific charge and discharge cycles The parameters which appear in the process and are constantly measured by the accureg 8000 system are used to calculate the current variables voltage current In this way the battery virtually dictates the tempo of its regeneration preventing the battery from being overcharged Options for electrically determining the status of a starter battery battery tests Rapid test voltage measurement a Rapid test including a back calculation on the internal values of the battery e g internal resistance b Full test determining the CURRENT capacity and the CURRENT cold cranking amps The measurement of the acid density of the electrolyte as far as the lid design allows this is determined chemically and can be drawn upon as a separate source of information see below a Rapid test voltage measurement Rapid test methods are based only on the
23. eration phase regeneration charging in stages with patented process v Test phase for batteries when the regeneration process is complete filter for batteries with too low capacity country specific filter for batteries with low start voltage Y Automatically changes to trickle charge Caution When performing the Regeneration function never change the poles of the battery clips during active operation When changing poles there is a risk of damage due to overloading the system If the display shows the text the battery can be disconnected from the system and used if urgently required At the start of the after charge phase the battery has already been completely desulphated and has already satisfied the required performance test It is though recommended to leave the battery connected to the system until the process has been finally completed and the following message appears on the display 1 1 6 5 2 Short test function gt gt If the Short test function is selected the system performs a short test to determine the start characteristics of the battery v Performs a cell short circuit test regeneration recommendation for batteries with suspected cell short circuit v Performs a start voltage test regeneration recommendation for batteries with reduced start voltage v Automatically changes to trickle charge if significant damage to the battery is identified Page 28 48 5 3 Full test
24. function gt gt When selecting the Full test function the connected battery is subjected to a comprehensive battery test v Tests the charge characteristics error message for batteries with insufficient charge characteristics v Monitoring function for deep discharge batteries activation of deep discharge batteries error message for batteries which can no longer be activated after a deep discharge v Performs a cell short circuit test regeneration recommendation for batteries with suspected cell short circuit v Performs a start voltage test regeneration recommendation for batteries with reduced start voltage v Automatically changes to trickle charge if significant damage to the battery is identified 5 4 Trickle charge function gt gt In trickle charge mode a very sparing likewise patented mode for performing a trickle charge is activated This mode is suitable for bridging short term breaks in battery use but can also be used ideally for permanent trickle charging because of the process implemented which takes into account the battery data 5 4 1 Trickle charging function with charge pause Activating the charge pause based on the charge current limit shortfall method By pressing the button W you obtain the status information on the current voltage and current value for the test item 1 4 4 When the button W is pressed the original display appears again Page 29 48 5 5 Cyclisation function
25. h vibration Thermal conditions at the point of installation electrolyte level layout dimensioning State of charge charging in cycles a good state of charge is beneficial If the discharge of considerable amounts of capacity beyond the starting of the vehicle cannot be avoided e g by additional consumers short distance journeys in particular during the cold season charging the battery to compensate for this has a positive effect Mechanical charging thermal conditions low mechanical charging and operating at around 25 C e g at the point of installation inside the vehicle in the car boot also have a positive effect Electrolyte level battery layout Regular checking of the electrolyte level for batteries where this is still possible and a good basic design of the battery to meet the requirements of the vehicle additional electrical consumers driving habits when retrofitting batteries are equally beneficial Page 34 48 Options for eliminating reversible deterioration in performance Sulphation can be described as the only sustainable and reversible deterioration in performance As a temporal reaction product granular crystalline lead sulphate is formed from microcrystalline lead sulphate through clusters The sulphation results in a considerable reduction in the start performance of a battery It can only be reduced to a limited extent by a commercial battery charger just as the generator in a vehicle
26. he battery in peace and without the pressure of an emergency situation due to the battery breaking down at an awkward time or possibly in an awkward place as well e g a very busy road The accureg 8000 system is therefore ideally suited for the ongoing quality control of your battery which you can do over a period of many years At the same time you mobilise with the accureg 8000 energy reserves which were contained in your battery but were immobilised deactivated after use over time in the vehicle by reducing the traceable damage of your battery Your battery is therefore restored to the best possible condition for its age Ultimately not only delays the accelerated process of irreversible damage which has already started but its lifespan and therefore its use in the vehicle are increased significantly You therefore save costs in any event On the one hand you use the battery until the end of its actual product life cycle and on the other hand you avoid the costs which would result from an unexpected breakdown of the battery during its use in the vehicle For simplicity the operating manual is divided into 3 main areas Brief information Operational manual Further information about battery technology processes statistics etc Bs We ask you to carefully read through all parts of the user manual This concerns in particular the safety information Read through the user manual before you perform any operation with the
27. isconnected from the accureg 8000 system It is though recommended to leave the battery connected to the system until the regeneration process has been finally completed as Phase Il of the full load cycle also continues with the desulphation of the battery Upon completion of the regeneration process the system automatically switches to trickle charging Trickle charging The trickle charging mode is reached either directly by selecting the trickle charging function or by automatically switching to this mode upon successful completion of a regeneration As well as the normal feeding of a reduced trickle charge current while keeping to a voltage limit of 13 8V the algorithm includes a new likewise patented switch off criterion current criterion This ensures that when a trickle charge or compensation charge is carried out the battery is actually fully charged switches off only when the load current falls below a certain value and on the other hand overloading is prevented capacity dependent specification of the load current voltage limit Page 37 48 CHAPTER 8 Help 8 1 What is when The following errors can be resolved as follows Error pattern Possible cause Corrective action Is not working No supply voltage Check whether the power cable plug is placed firmly in the socket Check the fuse in the mains switch Check battery Battery connected with poles Connect battery to correct poles connection poles reversed conta
28. ixed installation Details about test items batteries Capacity scope 10 240 Ah Cold cranking amps scope 70 1 400A EN 50 980 A DIN Internal resistance depending on type gt 1 mOhm Warning When using the accureg 8000 system to test or improve batteries whose characteristics are different to the values specified errors can occur in the assessment of the performance of the batteries In individual cases this can result in a negative assessment of the battery breakdown with battery error by the system Comparison table for cold start performance European standard EN 60095 1 DIN Deutsche Industrie Norm German Industry Standard 43539T 2 American standard IEC International Electrotechnical Commission 95 1 m mm sem em 280 170 300 195 Page 41 48 Declaration of conformity als T V sterreich Pr f berwachungs und Zertifizierungsstelle Er TUV Austria 5 testing inspection and certification bod m Pey f STERREICH sung Confirmation Nr beew0131 LI 2003 ET PZVV EX 1093 Produkt Akkuregenerierger t Haupttype accureg 7000 Product Maintype Antragsteller BECOM Burgenl ndische Elektronik und Kommunikations Gesellschaft m b H Applicant A 7442 Lockenhaus Hochstral3 Technikerstra e 1 Hersteller BECOM Technische Kenndaten 230V 50Hz 700mA Manufacturer Rating and characteristics Ausgangswerte 1 2VDC 5A Pr fstandard EN 60335 1 94
29. lead acid starter and traction batteries v accureg 8000 improves the state of batteries with optimised regeneration processes which maximise their upper performance limit and is especially adapted to meet the requirements of conventional starter batteries closed type fluid electrolyte and AGM or gel batteries Sealed type bound electrolyte v accureg 8000 has its own programme for improving the state of traction batteries closed and sealed type v accureg 8000 is also a fully fledged load test system for starter batteries v accureg 8000 is suitable for performing capacity tests in accordance with DIN EN 50342 Y When the Trickle charging function is selected accureg 8000 works as a trickle charging system and is suitable for continuous operation Page 7 48 v Please adhere to the operating manual of the system or follow the menu navigation shown on the display v Disconnecting the battery while the system is in use results in the selected process being interrupted and the system is returned to input mode or has to be re started The same also applies if there is a power failure 3 1 Measures before start up of the system Warning You must read the safety information and important safety instructions before you start using the system E Before connecting the battery check the following gt Check the electrolyte level of the battery If necessary fill up the electrolyte level with distilled
30. ling up the service or print functions all of the LEDs are switched to off Page 39 48 CHAPTER 9 Technical data Details about the system Nominal voltage Nominal frequency System s nominal current standby trickle charge max Power absorption standby trickle charge max Mains fuse in connector plug Rated output voltage Max rated output current Max load current test current Max power absorption from battery Environmental conditions for operation Environmental conditions for storage Details about the batteries 230V 50 Hz 0 25A 1 2A 30 VV 250 W 1x T 2A 250V 12 V DC 10 A DC 140 A 1 8 kW at 12 V 20 C to 30 C 20 C to 50 C 10 to 80 r F The accureg 8000 systems are suitable for testing assessing and improving by removing reversible battery faults the batteries listed below General specifications Battery types electrolytes Lattice technology Cell structure no restrictions Manufacturing process Models any Type of separator Nominal voltage of the battery 12V Number of cells 6 cells Page 40 48 Lead acid batteries with fluid or bound in gel or fleece no restrictions antimony hybrid calcium no restrictions casting process expanded metal process any jacketed non jacketed Details about application of the batteries Application areas of the batteries Starter batteries traction batteries batteries for f
31. m the battery when the engine is idle e g alarm system battery chargers for mobile phones etc then you should also charge the battery in particular during the cold season to compensate for this If you have a battery with accessible openings in the lid area plugs check the electrolyte level at the start and at the end of the warm season The fluid level should be well 0 5 1 cm above the plate of the battery Do not overfill the battery and keep where these exist to the manufacturer s specifications maximum level Ageing of a starter battery A battery is subject to natural ageing decline in the performance data from the time of its manufacture This decline in the performance data is comprised of 2 components a reversible deterioration in performance b irreversible deterioration in performance Concerning a reversible deterioration in performance mainly comprises discharging discharging by consumers or self discharging The sulphation forming of granular crystalline lead sulphate crystals fusion of microcrystalline lead sulphate crystals into larger structures which has appeared as a result of the discharge can also be reversed for the most part desulphation Concerning b irreversible deterioration in performance comprises primarily shedding loss of active mass from the plates and corrosion of the lattice Under certain circumstances the battery only reaches its maximum performance data af
32. nction 5 6 Capacity test function CHAPTER 6 CARE AND MAINTENANCE OF THE ACCUREG 6 1 Service 6 2 Cleaning CHAPTER 7 INFORMATION ABOUT STARTER BATTERIES CHAPTER 8 HELP 8 1 What is when 8 2 Online help 8 3 Battery errors 8 4 LED light statuses 40 CHAPTER 9 TECHNICAL DATA 44 CHAPTER 10 CONVERSION TABLE FOR TRANSACTION BATTERIES 46 CHAPTER 11 FLOW CHART Page 3 48 CHAPTER 1 Safety information 1 1 Notations In this manual the following notations are used PPP Tips Provide you vvith information or tips on hovv to best use your system Warning Important safety information Caution Indicates that non compliance with the suggested procedure can cause damage to your system or the battery which is being used Danger Indicates that there is danger for the user with non compliance 1 2 Safety information gt b gt b gt b BB Warning Read through this manual carefully before you set up your system Carefully keep this manual in an accessible place for later use Caution The accureg 8000 system many only be used for lead acid batteries with a nominal voltage of 12 V When connecting batteries with a nominal voltage other than 12V in particular with a higher nominal voltage and or other voltage sources electrical power supplies chargers etc there is a risk of damaging the system Non rechargeable batteries may not be connected to the accureg 8000 Caution accureg 8000 is
33. ng damage to the battery Before starting a regeneration the short test can be followed by a full test to shorten the process The full test also includes as well as the features of the short test a process to carry out an activation charge cell activation for deep discharge batteries with e g high resistance and tests the battery s ability to absorb energy The full test procedure can last up to 10 hours The information provided at the end of the process is though much more specific and enables the system to sort out batteries are actually unusable identifies irreversible faults Page 36 48 Description of the processes of the accureg 8000 when selecting the regeneration function The algorithm applied tests as a first step the battery s fundamental functional capability If this is not established whereby at the start a priori both reversible and irreversible loss of performance can be responsible for causing a detected deterioration activation processes are carried out by the accureg 8000 in the same way as described in the section for the full test In this phase batteries can already be recognised as irreversibly faulty and the appropriate test items can be declared faulty If all of the conditions for a successful regeneration eliminating the reversible faults of a battery this phase is started automatically by the system The regeneration phase passes through many stages whereby tests are constantly carried out by the acc
34. p gt Esc stop Page 45 48 SHEET 3 T OK start Okxstart Ok start Esc stop Esc stop Esc stop Ox stert Ox start OK start sta sto dl lt gt lt gt Esc stop esc stop Esc stop Esc stop Sheet 4 SHEET 4 3 1 edit menu ON OR start OR start gt gt gt gt gt on start Esc stop Esc stop OK start gt gt Esc stop Sheet 6 Sheet 5 Page 46 48 SHEET 5 4 3 1 OK start gt gt Esc stop 4 4 1 4 4 2 4 4 3 OR start OR start star OR start gt gt gt Esc stop Esc stop Esc stop 4 5 1 OK start gt gt Esc stop 4 6 1 OK start gt gt Esc stop 4 7 1 OK start gt gt gt Esc stop 4 8 1 OK start gt gt Esc stop Page 47 48 SHEET 6 4 2 1 1 OK start OK start gt gt Esc stop Esc stop 4 2 2 1 OK start gt gt Esc stop 4 2 3 1 OK start gt gt Esc stop 4 2 5 1 OK start gt gt Esc stop 4 2 5 1 OK start gt gt Esc stop 4 2 6 1 OK start gt gt Esc stop 4 2 7 1 OK start gt gt Esc stop Page 48 48
35. ses In the appendix to this operational manual a EN DIN conversion table is displayed Page 32 48 Install the starter battery in accordance with the requirements of the vehicle manufacturer Make sure the battery is assembled properly fastening via base hold down or anchor and the pole clips Always use in particular for short distance journeys during the cold season only as many electrical consumers in the vehicle electrical system rear window heating seat heating fan as absolutely necessary Turn off these consumers upon completion of the required activity de icing of the rear window etc The life of the battery is increased significantly if you perform a trickle charge at least once a year before the start of the cold season To do this connect a trickle charging system or charge the battery over a longer period e g 48 hours with a current of Cy 100 e g 60Ah charge current 0 6A and an upper voltage limit of 14 4V The specified loading time can also be staggered If an electrical consumer has been supplied by the battery for a longer period reducing the capacity by e g forgetting the light the stereo system repeated attempts to start without starting the engine etc you should subsequently charge the battery to compensate for this in the manner described above lf you have electrical consumers in the vehicle electrical system possibly installed retrospectively which also consume considerable energy fro
36. splay 1 1 3 C Stop the system again provides you with the opportunity to check or amend the values set by yourself By pressing once the cold cranking amp value which has been set appears by pressing again the capacity value which has been set By pressing the button Esc Stc If you want to start the selected process then press the button OK Start i The selected process is started automatically and on the display appears the text for the process selected 1 1 4 Page 13 48 4 6 Main menu 1 Test records 1 1 1 6 1 1 See chapter 5 1 Description of the regeneration function poles of the battery clips during active operation When changing poles there is a risk of damage due to overloading the system 1 2 See chapter 5 2 Description of the short test function 1 3 See chapter 5 3 Description of the full test function N Caution When performing the Regeneration function never change the 1 4 Page 14 48 See chapter 5 4 Description of the trickle charge function 1 5 See chapter 5 5 Description of the cyclisation function 1 6 See chapter 5 5 Description of the capacity test function ES You return to the main menu level vvith the button Esc Stop to return to the main menu from the first top submenu item It is only possible when selecting the short test function 1 2 4 when selecting the full test function Page 15 48 F
37. ter a certain period of use in the vehicle Page 33 48 Reversible and irreversible deterioration in performance normally occur together as part of the natural ageing process of a starter battery even with optimal maintenance the battery is subject to a certain minimum amount of damage due to being used in the vehicle Advanced reversible and irreversible deterioration in performance ultimately result in the failure of the energy store A significant reduction in performance can be seen when the battery is unable to start the vehicle reliably under certain conditions The battery related causes of this are State of charge too low voltage drop too high when starting drop of one or several cells due to cell short circuit cell short circuits Water consumption itself does not represent as such a deterioration in performance of the battery Deterioration in performance due to loss of electrolytes only occurs when the parts of the plates are no longer sufficiently washed with fluid or these are to be classified in the above list Parameters to change the ageing of a battery options to eliminate reversible deterioration in performance The ageing mechanism of a starter battery is based on complex and interrelated processes a description of which is beyond the scope of this manual Parameters to change the ageing process of a starter battery State of charge Charging in cycles with discharging Mechanical charging wit
38. ther the numerical value set corresponds with the nominal capacity of your battery and confirm your entry by pressing the button OK Start The system now jumps to the input mode for cold cranking amps where you enter in a similar way to the previous entry for the nominal capacity the rated cold cranking value in A according to EN Es With the cyclisation of a traction battery you only have to enter the battery capacity The capacity entered here needs to be the specification for K20 discharge capacity for discharges with 20 hour current If there is another specification K2 5 K3 K5 K10 on your battery please use the conversion table on page 44 45 When you have calculated the battery capacity enter the result 1 9 1 Confirm with OK Start The system then asks for the specifications for the cold cranking amps Page 12 48 Us The indicated value for the coldcrank amps are determined on the software and can be adopted Just confirm the process with OK till the cycling function starts Bs l the nominal values on your battery cannot be seen you have to estimate these based on the size and model of the battery or based upon what is known about its intended use Es You can also find in chapter 9 a conversion table which converts cold cranking amp values specified in A according to DIN into A values according to EN After confirming the cold cranking amp value entered the following message appears on the di
39. tting the language selecting the climate code selecting the driving profile setting the battery type 4 4 Main menu selecting the function Main menu 1 If you press OK St Start you go to the next submenu level vvith the follovving submenu items ha V navigation wit 4 5 Submenus of main menu 1 1 1 1 1 4 Instructions for entering the characteristics of the battery The characteristics of the battery are to be entered for all six built in system functions regeneration short test full test trickle charging cyclisation capacity test SOOO The characteristics are entered based on the example for activating the regeneration function illustrated below 1 1 Page 11 48 1 1 1 to 1 6 1 Select by pressing the button OK Start 1 1 1 The nominal value for battery capacity specified on the battery is to be entered The system suggests as standard the value 70 Ah You start to change the standard value to your battery s imprinted nominal value by pressing the button Edit Menu The first digit the hundreds digit then starts to flash and you can set the capacity to the nominal value of your battery with the buttons A V After correctly setting the hundreds digit you press Edit Menu again The tens digit starts to flash Set the tens digit to the correct value and then press Edit Menu again Now the units digit flashes and you can set the corresponding numerical value here Check whe
40. type A particularly important entry is the definition of the battery type to be regenerated Normal starter batteries in wet chemistry technology are according to the specifications of the standard DIN EN 503423 of the closed type Batteries in AGM technology or other recombination batteries are described as sealed When performing a regeneration you MUST WITHOUT FAIL select the battery type sealed to prevent damage to the battery 4 8 Important For traction batteries please select the setting 2 For starter batteries please select the setting 1 B You return to the main menu level with the button Esc Stop It is only possible to return to the main menu from the first top submenu item CHAPTER 5 Description of the functions of the accureg 8000 5 1 Regeneration function gt gt If the Regeneration function was selected the system automatically performs the following operations on the connected battery v Tests the charge characteristics v Performs a cell short circuit test an error message appears if the battery has a cell short circuit v Monitoring function for deep discharge batteries activation of deep discharge batteries error message for batteries which can no longer be activated after a deep discharge v Identification of state of charge process ended when the battery is fully charged automatically changes to trickle charge mode Page 27 48 v Pre charge phase v Regen
41. ull test active U 12 5V 0 1A I Please wait Trickle charge active U 12 4 V 0 0 A Cyclisation active Number of cycles 0 U 14 8 VI 1 0A When you select the cyclisation function for a traction battery please make sure that you have made the right selection under select the battery type 1 6 4 Capacity test active U 11 2VI 3 0A 4 7 Main menu 2 Test records 2 Test record regeneration Date 00 00 08 Time 00 00 CET Page 16 48 By selecting this menu item the results of the previously performed regeneration process can be shown The test results can be printed out 2 1 On the display the values for the capacity nominal capacity entered by the user and the cold cranking amps testing current according to the standard DIN EN 50342 are shown On the display the load voltage values results of load tests are shown at the start of the regeneration process input test U1 10s is the voltage for 10s load U2 40s the voltage value for 40s load with the testing current The 50 REGENERATION display shows the load test result values when the regeneration process is approx 50 complete Page 17 48 The load voltage final test display shows the load voltage test result values at the end of the regeneration process Upon successful completion of the regeneration process at this point the rated battery K20 is displayed in Ah Cn_actual absolute and
42. ureg 8000 to provide information on the current status of the battery and the regeneration process This is done by e g load tests load current 10 of the battery s preset cold start test current which are evaluated based on defined criteria absolute position of the discharge voltage level voltage progress during discharge Monitoring whether the time permitted for completing the individual regeneration stages is kept to guarantees on the one hand that the total process is carried out within the specified time max 5 days On the other hand further information on the state of the battery and the progress of the regeneration is fed to the algorithm The time optimised process for reducing reversible faults in particular the granular crystalline lead sulphate layers is completed as soon as the increase in the battery s performance values falls below a certain limit Following the phase to reduce the reversible faults the accureg 8000 automatically switches to Capacity testing mode i e a discharge in accordance with K20 takes place to determine the current capacity Then the battery is re charged with a subsequent further load test to check for any possible damage which may have occurred to the test item during the discharge in the capacity test If a fault is found this is shown accordingly If everything is OK the battery is subject to a further full load cycle After the first phase of the full load cycle the battery can if needed be d
43. water Visually check the battery for mechanical damage cracks in the battery box and the like gt Clean the pole of the battery Use a wire brush or steel wool do to this It is advised that you do not use commercial pole cleaners which are based on scraping clean the top layer of the pole as these erode the pole too much during cleaning gt If the contact surfaces of the clips of the accureg 8000 become dirty due to corrosion or excessive deposits of grease and dirt these are also to be cleaned with a wire brush or steel wool You can now connect the battery test item The display Selecting the function forward Ok start back esc stop This provides you with the opportunity to select the desired function see chapter 4 B Before selecting the function please select the battery type see chapter 4 9 8 LED status In input mode both LEDs are off Page 8 48 ES If the poles of the battery are reversed the and an error message appears on the screen poles are the wrong way round LED status lf the poles are reversed the red LED flashes If this error message appears please reverse the poles The red LED stops flashing and the system returns to input mode 3 2 Guidelines for operation of the accureg 8000 system 1 Switch on the system Connect the battery take care to connect the poles correctly See above Select the battery type Traction battery or starter battery FR W N
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