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4200-001 Rev 5.0

1. we are then left to getting data in the best ways possible The second best time to obtain a set of data is shortly after capacities have been determined on the same model cells of the same age Lastly try obtaining data on the same model cells of any age Over time data to the end life or 80 capacity level will be accumulated CAUTION Internal resistance data taken without the benefit of correlated known capacities is often referred to as as found comparative values This as found data could be used to set a baseline but be very cautious It is not unusual to find an entire string of cells of uniform internal resistances and normal appearance on float but with failing capacities In this situation we highly recommend at least a crude service load test be performed to lend some credence to the internal resistance measurements THE COURSE OF ACTION If you do not have end life or 80 baselines developed from significant samples of the same cells age etc you should use the following rough rules of thumb based upon Cellcorder user reports and in house experience If the internal resistance is 20 50 above the 100 baseline then the cell be load tested the sooner the better if it s towards the high end at 50 or above the baseline the cell be replaced Surprisingly the IEEE ANSI VRLA P 1188 proposed standard is more liberal in this matter It recommends that from 25 to about 43 the cell
2. as many as four yearly per battery string if the P 1188 guidelines are followed To quickly identify these type files and manage them with minimum errors through DOS or through Windows File Manager a file naming system can be important Try to include in the filenames eight characters as many descriptors as possible to reflect the data s date location and battery Thus filename 941 WPB1A DAT would describe the first test data in 1994 for location WPB s battery 1 string A 46 Whether you use numbers or characters the important thing is to make the filename as recognizable as possible while avoiding duplicate filenames This helps immensely in finding files and to avoid overwriting deleting or copying wrong files especially when using operating systems before version MSDOS 6 SAFEGUARDING THE CELLCORDER By far the most common cause of damage to the Cellcorder is from grossly excessive input voltages particularly when taking UPS cell readings AWARENESS is the most important factor in avoiding these kind of problems Before any testing begins take five minutes to survey the battery bank to make sure that e cells are not misnumbered e the intertier cable routing is unmistakable e the main battery terminals and other spanable high voltage points are identified and temporarily covered Also before making a measurement that includes a cable routed through a tray to another tier use a voltmeter to identify
3. GOVERNMENT LICENSEE If you are acquiring the software on behalf of any unit or agency of the United States Government the provisions of Section 3 apply to are incorporated in and are made a part of this Software License Agreement GENERAL This Software License Agreement will be governed by the laws of the State of Florida except for that body of law dealing with conflicts of law Should you have any questions concerning this Software License Agreement or if you desire to contact Alb rcorp for any reason please contact Alb rcorp 3103 No Andrews Ave Ext Pompano Beach FL 33064 email alber alber com 3 GOVERNMENT PROVISIONS The Government acknowledges the representations of the Alb rcorp software as Restricted Computer Software as the term is defined in Clause 52 227 19 of the Federal Acquisition Regulations FAR and is Commercial Computer Software as that term is defined in Clause 52 227 7013 a 1 of the Department of Defense Federal Acquisition Regulation Supplement DFARS The Government agrees that i if the software is supplied to the Department of Defense DOD the software is classified as Commercial Computer Software and the Government is acquiring only restricted rights in the software and its documentation as that term is defined in Clause 252 227 7013 c 1 of the DFARS and ii if the software is supplied to any unit or agency of the United States Government other than DOD the Government s rights
4. rcorp be liable for the cost of retrieving or replacing lost or corrupted data Albercorp s sole and exclusive liability for any and all losses and damages arising out of any cause whatsoever shall in no event exceed the purchase price of the software product purchased NO LIABILITY FOR CONSEQUENTIAL DAMAGES ALBERCORP SHALL NOT IN ANY CASE BE LIABLE FOR ANY DAMAGES INCLUDING SPECIAL INCIDENTAL INDIRECT EXEMPLARY COLLATERAL OR CONSEQUENTIAL ARISING FROM BREACH OF WARRANTY BREACH OF CONTRACT NEGLIGENCE OR UNDER ANY OTHER LEGAL THEORY ARISING FROM THE WARRANTY HEREIN STATED OR THE PURCHASE OF PRODUCT INCLUDING WITHOUT LIMITATION LOSS OF PROFITS USE OR GOODWILL Some states and countries do not allow the exclusion or limitation of incidental or consequential damages therefore the above exclusion or limitation may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary state to state and country to country 2 SOFTWARE LICENSE AGREEMENT THIS IS A LEGAL AGREEMENT PLEASE READ BEFORE INSTALLING SOFTWARE Any use of this media other than to review this Software License Agreement constitutes your acceptance of and agreement with the terms of this Software License Agreement with respect to the Alb rcorp Software If you do not accept and agree to these terms you must return the full product with proof of purchase to Alb rcorp within thirty 30 days for a full refund Instal
5. Cellcorder 3 8 4 1 A D Reference Adjustment 1 2 3 Open the top cover by removing four screws on the bottom of the Cellcorder Attach a voltmeter to TP3 GND and TP6 A D REF Adjust RV2 until the meter reads 2 0480 volts 0 0001 volts 3 8 4 2 2V Cell Calibration 1 2 3 4 Using the two voltage leads connect the Cellcorder across the same 2V source used in the Cell Readings section From the Calibration menu select option 1 2V Cell Measure the voltage using the HP voltmeter Press the Cellcorder UP and DOWN arrow keys until the reading on the Cellcorder matches the input level the HP DMM reading 31 5 6 NOTE Rapidly pressing the arrow keys changes the value displayed by large increments If a small change is needed press the arrow keys for about a second Select the Multimeter mode and verify the reading matches the input level If the reading is off by more than 0 1 return to the Calibration menu and readjust the calibration value with the arrow keys After readjustment return to the Multimeter mode and repeat this step Record the calibrated value displayed in the Multimeter mode on the Calibration Log under Cell 2V After Calibration 3 8 4 3 6V Cell Calibration 1 2 3 4 5 6 Using the two voltage leads connect the Cellcorder across the same 6V source used in the Cell Readings section From the Calibration menu select option 2 6V Cell Measure the voltage
6. Cellcorder press the ON key The ON key operates as an ON OFF key After the display shows the firmware revision level the Main Menu appears At the Main Menu select option 3 Setup then select 3 Memory Configs A warning message appears CAUTION Do not change memory configuration after data has been taken or the memory will be scrambled Changing back will unscramble the memory To continue press ENTER then select either 7 x 256 7 strings of 256 cells or 28 x 64 28 strings of 64 cells After memory configuration is selected it remains as the default configuration even if the Cellcorder is powered off Refer to Memory Management After memory is configured select option 1 Mode Select from the Main Menu to display the following MODE SELECT MENU 1 MULTIMETER 2 VOLTMETER 3 SG TEMP OV Select which measuring function to use The voltmeter mode is automated to make it easy to use since this mode is used most It is recommended that the Cellcorder be used in voltmeter mode for quarterly float voltage readings CAUTION When voltage readings coincide with resistance measurements the voltage readings must be taken first 12 Skewing Effect When resistance readings are taken there is a skewing effect of the cell voltages that leads to a small error As the first half of the cells are resistance tested using an approximately 70 Amp load test those voltages become d
7. Codes and Warning Messages c sccesceesceeeeeeeeeeeteeeneeeseeenees 22 3 5 1 Resetting the Cellcorder 0 c cc ccccccccsseesseceteceteeeeeeeeeeeeesteeeneeaees 24 3 6 D TEO E E E ves beastchadocescbsteest ctv teesbadeses tenes 25 3 6 1 Keypad KEYBRD ccecscecsseessecssecsecesecesecnseeseeeseeeeeseeeseeeseeesaeensees 25 3 6 2 Displiyi nsin vauedonebon deb a A a E eaves 25 3 6 3 A D Channel AD CHAN ccccccssecsseceteceeceeceeececeeeseeeeaeeeseeesaeenaees 25 I6 Relays aa eGo Lahde iene a aed jae shesees beads 26 Soa URS 2232 is ces ca eck dis a a oneal scape So odeuk a bau eseck shes ebvban eee 26 3 7 Memory Management ernir iaie EAEE 27 3 8 CalibratiOniysissd oxtesiedsisacs E od ea Toeheie dots leas tended ANNE 28 3 8 1 Entering the Calibration Screen ccccceceesceseeeseeeneeeteeeseeseeentees 28 3 8 2 Entering the Password ccccccssecsssceseceseceseceeeceeeeeeeeeeseeeseeeeeeasees 28 3 8 3 Recording the Before Calibration ReadingS c ceseeseeteeeeees 29 3 8 4 Calibrating the Cellcorder oo cc ccccccccssecsteceteceseeeeeeeeeeeeeeeeseensees 31 3 8 5 Backing Up and Restoring the Calibration eeceesesseesteentees 35 APPENDIX A CELLCORDER PARTS LIST c cccccssccccesssececeesteceeeesseeeeeesseeeeees 36 APPENDIX B SYSTEM SPECIFICATIONS cccseeececcccccesessssececccecesnenseesess 37 APPENDIX C CELLCORDER CALIBRATION LOG cccccccessseceeessteeeeeesseeeeees 38 AP
8. Customer P O Calibration Date Serial Number Approx Input Actual Input Instrument Voltage Reading Reading Before Calibration Cell 2V cell 6V cell 12V cell Current Current 2V Intercell 10mV 10mV 38 Instrument Reading After Calibration 7 Appendix D Application Note CC 001 Internal Resistance and the Cellcorder This document is available at www alber com VALVE REGULATED Bectrolyte absorbed in separator VENTED an DoOArarum Liquid electrolyte INTRODUCTION With the changeover from vented cells to sealed VRLA cells and the proliferation of UPS systems an even greater impetus has been placed in finding economical and reliable ways to establish the state of a battery s capacity and its conduction path In this Application Note the primary focus will be on a new relatively low cost aid in determining a battery s health by virtue of its 39 cells internal resistances together with float voltages and intercell connection resistances All three of these variables are rapidly measured and conveniently recorded by the Albercorp Cellcorder the storage battery multimeter THE SEARCH The search for new approach to capacity and conduction path testing has been ongoing Traditionally a battery s capacity to store energy has been specified by its manufacturers as its ability to supply a constant amount of current or
9. R arran METALUG GRD R GRID To ASTE E CELL VOLTAGE R paste R ELECTROLYTE ReLecTROCHEMICAL Recocaagrog Fig 2 Internal Resistance Model Another group focusing on internal resistance is prestigious Nippon Telephone and Telegraph Their research and field personnel have shown that a major result of the lead acid battery deterioration mechanism is an increased internal resistance A 500 microsecond duration pulse technique is used to measure cell internal resistance Test results lead them to conclude that battery deterioration capacity can be estimated within 10 by internal resistance measure Note that Capacity vs Normalized Rinternat curve shown in Figure 3 is somewhat curved Some feel the relationship between most cell internal parameters and capacity is not a simple straight line as has been described in recent times but rather a more complex curvi linear function Ger ee a a ie ee Re f Fig 3 CAPACITY amp INTERNAL RESISTANCE ESTIMATED FROM PULSE DISCHARGES Capacity Ratio Im B3 r OE 07 S VE S Internal Resistance Ratio Unit Value Equal to R at 90 Capacity 13 IMTERHAL Part of this belief that a straight line cannot describe a capacity relationship is rooted in the differences exhibited during battery discharges from cells with metallic vs electrochemical resistance problems The typical discharge curve of a cell at 100 capacity is shown in Figure 4 VO
10. The function of every key except ON and ESC can be checked Press ESC to exit the diagnostic and return to the Diagnostics Menu 3 6 2 Display When the Display diagnostic is selected the Cellcorder lights each segment of the display This test takes about ten seconds and cannot be interrupted Upon completion the unit returns to the Diagnostics Menu 3 6 3 A D Channel AD CHAN Alb rcorp recommends that you use this diagnostic only when instructed by Alb rcorp technical support This diagnostic tests the input circuitry and the analog to digital converter When the A D Channel diagnostic is selected the following menu appears _ _A D CHANNEL DIAG 1 Chan 1 3 Chan 3 2 Chan 2 4 Ref F1 UNCALIB Calib In this mode the unit can display uncalibrated no internal calibration constant applied or calibrated values Use the F1 key to select uncalibrated or calibrated The selected option changes to uppercase letters 1 Chan 1 Displays the voltage connected to the standard two lead set of voltage leads supplied with the unit This input is for the cell voltage readings and must not exceed 16 volts 25 2 Chan 2 Displays the voltage connected to the negative clip and the small sense clip on the multimeter three lead lead set This input is for the voltage reading across the intercell connector under a test condition Typical input voltage is usually less than 10mV 3 Chan 3 Displays the voltage across the interna
11. and does not convert the temperature value 3 4 6 6 Overall Voltage Entry This selection can only be made when cell 001 is selected Refer to Cell Selection Press ENTER until the cursor is in the Overall Volts field Measure the overall volts with a separate voltmeter enter the value using the keypad then press ENTER 3 4 7 Uploading Specific Gravity and Temperature Readings This section describes how to use option 2 Auto Readings on the Mode Select SG Temp OV Menu to directly upload data from a compatible digital hydrometer To upload data directly to the computer refer to the Battery Analysis User s Guide 19 1 With power off connect the cable supplied with the digital hydrometer to the hydrometer and to the null modem adaptor Connect the adaptor to the Cellcorder serial port The null modem adaptor is normally supplied with the hydrometer and is only needed when connecting directly to the Cellcorder Not needed to connect directly to the computer 2 Power on both units It does not matter which is powered on first 3 Select the desired battery number on the hydrometer 4 Program the Cellcorder as follows a From the Main Menu select 1 Mode Select b From the Mode Select Menu select 3 SG Temp OV c From the SG Temperature Menu select 2 Auto Readings d Enter the battery string number to which readings will be stored then press ENTER e At the next menu to load data press ENTER After t
12. changed while the cells were discharged it can be concluded that 1 the changes noted in total internal resistance were due exclusively to electrochemical resistance change 2 the electrochemical resistance change is a small part of total internal resistance as the stored energy drops from 100 to substantially lower levels of charge In the real testing world this is good news It means that a battery can be reliably tested by the Cellcorder at float open circuit voltage and even partially discharged THE BASELINE AND WHEN BEST TO GET IT The fantasy of a battery literate person is that complete capacity and internal resistance test data from day zero is available for analysis He seeks to determine the typical internal resistance of cells at 100 and 80 as well as the trend from 100 through 80 capacity The fantasy begins with the battery s installation An acceptance capacity test is conducted and the cells internal resistances measured The results should be fairly uniform and he would safeguard this data He knows it serves as the ideal baseline or reference per IEEE ANSI P 1188 for future internal resistance tests He will then be able to make cut and dry decisions about maintenance or cell replacement Unfortunately it s a fantasy in most environments because in the rush and tumult of getting a facility on line establishing a baseline usually has low priority As a result
13. fev desl iar e Ha ein eee een 6 VAs ROWeD E EE E ae Pes de ie leet Sette atiaaehat hese ae tiene area dacs 6 RECEIVING AND ACCEPTANCE TESTING c cccccccecsssesssseceeccecsesesssseeeeeeeesenes 7 21 MUR PACKIN Ge eiee a E Seeded tua cee E ETE a e 7 2 2 Cellcorder Initial System Test 0 ccccccccescceesceeeeeeceeeseenseeseenseeeeenaeenes 7 OPERATING INSTRUCTION S parrait beaten set aa E E A AA EnS 10 3 1 General C ntepts coseireena hine A A A AE 10 3 2 Before Using the Cellcorder cccccccccsecssecsteceteceteceseeeeeeseeeeseeeseeeaees 11 3 3 General Operating Notes cccccccseesseesceestecseceseceteeseeeeseeseeeeeesaeeneees 11 34 Operation Notes iena tea anaE aeaa e e aa araa en Ea E Aa E Ea as 12 3 4 1 Multimeter Mode ssessseeeeeesseseessssssesersssestsresssesersessesesresesseseeses 13 3 4 2 Connecting the Test Leads 0 cc cccccsccssecsteceneeeseeeeeeeeeeeeeeeeessees 14 3 4 3 Taking the Readings cccccccsecsseceneceneceeeceeeeeeeeeeeeeeseeeseeeeeeatees 15 3 4 4 Storing Data for More Than One String eeceecseeseesteetteeneees 16 SAS Voltmeter Mode 2 cissitecacersecceat sucen gous tenease totais a EE 17 3 4 6 Entering Specific Gravity Temperature and Overall Volts 18 3 4 7 Uploading Specific Gravity and Temperature Readings 19 3 4 8 Programming Test Parameters ccccssccesececceeeeeeeeteeeseeesseesees 20 3 4 9 Battery Charging iorn ee e e a E p eaa 21 3 5 Error
14. hours to guarantee six hours of battery operation If the batteries wear down during testing plug in the charger module and keep testing If the battery is overdischarged let the unit charge for 15 to 30 minutes before using it plugged into the AC Data readings are stored in EEPROM memory chips and are not affected if the batteries are fully discharged Verify the Cellcorder is calibrated or has been calibrated within the last year The easiest way to check calibration is to read a known voltage and use a known shunt as an intercell connector Refer to Calibration 3 3 General Operating Notes At power up the Cellcorder displays the Main Menu _ MAIN MENU _ MODE SELECT DIAGNOSTICS SETUP wN e An asterisk on the top right of the menu indicates memory configuration is 7 x 256 Each menu function is explained in detail in following sections The Main Menu functions are as follows 11 Mode Select Allows you to determine whether the Cellcorder will be used as a voltmeter battery multimeter volts and resistance or as a recorder for specific gravity SG and temperature NOTE SG and temperature readings must be taken with a separate instrument Diagnostics Allows you to test the keyboard keys the front panel display and the individual measuring channels Setup Allows you to enter the Calibration Test Parameter or Memory Configuration setup screens 3 4 Operation Notes To power on the
15. in the software and its documentation will be as defined in Clause 51 227 19 c 2 of the FAR RESTRICTED RIGHTS LEGEND Use duplication or disclosure by the Government is subject to restrictions as set forth in subparagraph c 1 1i of the Rights in Technical Data and Computer Software clause at DFARS 252 227 7013 Alb rcorp 3103 No Andrews Ave Ext Pompano Beach FL 33064 Information in this document is subject to change without notice Cellcorder Instruction Manual 4200 001 Book Revision 5 0 1999 2000 Alb rcorp 3103 No Andrews Ave Ext Pompano Beach FL 33064 This manual may not be copied in whole or in part without express written permission from Alb rcorp Microsoft Windows is a registered trademark of Microsoft Corporation iii Safety Information e Except as explained in this manual do not attempt to service Alb rcorp equipment yourself Opening the equipment may expose you to dangerous voltages Refer servicing beyond that described in this manual to authorized personnel e Do not allow liquids or moisture to get into the equipment If liquid does get into the equipment unplug it immediately and contact your nearest authorized service center or Alb rcorp directly e Ensure equipment is provided adequate ventilation Do not block equipment ventilation openings e Do not exceed equipment voltage or power ratings and capabilities e Make sure that equipment is properly grounded e Do not let unauthorized
16. is a very high internal resistance the current will be low and the discharge will be instantaneously terminated Thus a cell with an exceptionally corroded internal conductor will not be further damaged After tens of thousands of cell tests there have been no reports indicating that the Cellcorder s test discharge has caused a cell to open circuit Interestingly many battery specialists feel disappointed that their most severely corroded cells have not opened They would rather have them open during a supervised test than during an actual emergency when no one is around ALBERCORP RESEARCH Carefully conducted Alb rcorp experiments have revealed other important properties of cell internal resistance One is the relationship between metallic resistance and electrochemical resistance Many would expect that as the energy stored in a fully charged cell diminishes the internal resistance of the cell would increase both proportionately and significantly This belief is widely held because of how the lead acid cell electrochemistry is envisioned Measured amounts of energy were methodically removed and each time the internal resistance was read It was found that the internal resistance rose no more than 3 after removal of 32 of the cell s energy Upon continued discharge the internal 44 resistance increased rapidly in a non linear fashion Since it is extremely unlikely that the cells metallic resistance could have
17. is approximately 70 Amps or 50 Amps for 4V through 12V modules 3 While current is flowing the unit reads cell voltage current and intercell voltage drop then calculates internal cell and intercell resistances 1 3 3 Specific Gravity and Temperature Specific gravity SG and temperature readings can be entered manually or automatically from a compatible data storing hydrometer In automatic mode the user connects the hydrometer to the Cellcorder via an RS 232 cable and transfers the readings by pressing the appropriate function key In manual mode the display prompts for the readings for each cell The Cellcorder automatically inserts the first two numbers of the specific gravity reading to speed up the entry process For example for a reading of 1215 the display shows SG 12 _ _ and the user enters the 1 and 5 After specific gravity is entered enter the temperature 1 4 System Features This section describes the features of the Cellcorder 1 4 1 Float Voltage Readings The Cellcorder measures the voltage applied during full float operation The voltage range covers all cells or modules up to 16 volts Reading accuracy is to four full digits 1 4 2 Internal Cell Resistance Internal resistance of a cell can be determined by how that cell responds to a momentary load The instantaneous voltage drop and load current applied are used to calculate the resistance The Cellcorder algorithms make this measurement possible on ce
18. life expectancy and lower reliability The Cellcorder saves time acquiring and analyzing these readings This is especially true of float voltage readings where the average time to measure 60 cells is less than five minutes The Cellcorder with its internal cell resistance measurement is very effective in locating weak or problem cells Because it is not susceptible to the normal noise sources present or the charger and pulsating load ripple currents the Cellcorder can be used on line on all battery installations 10 Cellcorder resistance measurements should be used in conjunction with baseline information on the batteries being maintained Either obtain the cell resistance baseline data from the battery manufacturer or Alb rcorp or acquire it with a capacity test Take Cellcorder readings according to the table above the resistance readings dictate which battery string should be subjected to capacity testing If one or more cells exhibit cell resistance 30 to 40 higher than the average or baseline value then those cells should be capacity tested using a single cell tester such as the Alb rcorp SCT 200 If the majority of cells are above the normal expected readings then the entire string should be capacity tested 3 2 Before Using the Cellcorder Check that the Cellcorder carrying case contains two sets of test leads the battery charger module and the RS 232 cable Prior to testing charge the Cellcorder for at least eight
19. persons operate the equipment e The maximum voltage the Cellcorder can read is 16V Do not attempt to read Overall Volts Use a separate meter then enter the reading manually under the SG TEMP OV mode e Never let any Cellcorder metal surfaces come in contact with a battery post or grounded rack while testing with the unit e Do not attempt to read internal resistance of an open cell module while the battery is on line iv 1 Table of Contents MINTRODUGCTION vcsicees a vcactedabees e ea rata e Penland Westecees Gres a ratte 3 lef General Descriptloniciescletesccorssseseilsaieses eheeestdeviaees ae ed aa se eas 3 1 2 Test Procedure Overview 0 cceseecceseesseescesecseeeeeseceaeeseeseeaecaeeaeeereaeeas 3 13a Test ModE Sirena ei u ro a e a E E EEEN 4 L31 Voltmeter enre EEEE R E 4 1325 Multimeter zasna e a E aT E a S coe 4 1 3 3 Specific Gravity and Temperature cccccccseesseceteeeeeeeeeeseeeeseetees 5 LA 7 SyStem Feature Soui asea r oa a EA E E a A E aTa 5 1 4 1 Float Voltage Readings ceccccccsecssecsteceteceteceeceeeseeeseeeeeeeeeneennes 5 1 4 2 Internal Cell Resistance cc ce ccccssccssecsteceseceteceecseeseeeseeeeeneeeseenaes 5 1 4 3 Intercell ResistahCenienieai oerni ei 5 1 4 4 Awto Ranging oo cece ccccecseeseeeneeececeecsaecaeceaecnseenseeeeeseeeeeeeeneeenaes 5 1 4 5 Data Extraction and Analysis ccccccccssscsseceseceteceseeeeeeeeeeeseeeeaeeenes 6 14 6 System Displays sie
20. power to the load for a defined time period to a final voltage The real test of the battery s actual capacity as opposed to its rated capacity frequently involves hours of manpower and load and data acquisition equipment Unfortunately a new approach has yet to gain industry wide acceptance The consensus of battery experts is still that load testing under controlled conditions is the only method with certainty of establishing a battery s actual capacity This is reflected in several national standards the latest of which was issued in 1995 7 However after many years of experience studies and experiments a wealth of information about battery behavior and measurements has been produced and some light has been shed on new tools that will help assess a battery s condition Metalic Fig 1 Resistance Classical Cell Model Acid Resistance Capacit apacitance Leakage Resistance between plates and other elements Inductance of Leads and Structures As early as 1959 the equivalent circuits of cells and typical circuit values were published See Figure 1 These circuit models of a battery s cell are critical to understanding how its condition relates to cell internal parameters conduction paths and capacity THE BASICS RESISTANCE INDUCTANCE AND CAPACITANCE The models circuit elements are resistance capacitance and inductance Researchers have investigated battery parameters from DC throu
21. some or all of the 7 or 28 battery locations have been used connect the Cellcorder to a computer using the RS 232 cable provided and copy the readings to the computer Refer to Managing Battery Data Files in the Battery Analysis User s Guide After copying to the computer either erase all Cellcorder memory locations or selectively erase one string at a time To erase the strings at the Main Menu press F1 Refer to Erasing String Data in Memory Management 3 4 5 Voltmeter Mode To enter this mode select option 2 Voltmeter from the Mode Select Menu When this mode is entered the display indicates the present cell number to be tested and the Battery ID as shown below _ _VOLTMETER CELL 001 BATT ID 01 xx eX Volts To select another cell at any time enter the cell number using the keypad then press ENTER To select another battery at any time press ENTER to move to the Batt ID field select the ID number using the keypad then press ENTER NOTE The ENTER key moves the cursor between the Cell and Batt ID fields When the cursor is in the Cell field the UP or DOWN arrow keys may be used to change to another cell number WARNING The maximum voltage the Cellcorder can read is 16V Do not attempt to read Overall Volts Use a separate meter then enter the reading manually under the SG TEMP OV mode 17 When you place the voltmeter probes onto the cell the Cellcorder reads the voltage and within two secon
22. the top right of the menu indicates memory configuration is 7 x 256 Press 2 on the numeric keypad to display the Diagnostics Menu _ DIAGNOSTICS MENU 1 KEYBRD 4 RELAYS 2 DISPLAY 5 RS232 3 AD CHAN You may select any option from the Diagnostics Menu to ensure the unit is in working condition Press the designated number on the keypad to select an option Keybrd Display This displays the Keypad Diagnostic screen Press any key except ON or ESC and the display indicates the key pressed Press ESC to return to the Diagnostics Menu The display goes through a self test illuminating each segment of the display When complete the unit returns to the Diagnostics Menu A D Channel Alb rcorp recommends that you use this diagnostic only when Relays instructed by Alb rcorp technical support This selection displays the reading from the analog to digital converter Press ESC to return to the Diagnostics Menu WARNING If this diagnostic is enabled while the unit is connected to a voltage source the Cellcorder can be permanently damaged Before you select the Relays diagnostic verify that no leads are connected to the Cellcorder A warning is displayed to ensure the leads are disconnected Press and hold TEST to activate this diagnostic A clicking noise will be heard as each relay is checked Release TEST to stop the relay drivers and press ESC to return to the Diagnostics Menu RS 232 Serial Port Diagnost
23. this modification reduces the risk of damage to the Cellcorder remember to never let any Cellcorder metal surfaces come in contact with a battery post or grounded rack while testing with the unit Firmware The new version of firmware incorporates changes that have resulted in some Cellcorder keypad entry changes The new changes described below are compared to the earlier methods of operation Relay Diagnostics This diagnostic requires that you now press and hold the TEST key to activate the relay drivers Release TEST to stop the relay drivers Previously you did not hold the TEST key and ESC exited the diagnostic Error Message for Low Current The error message for test current below 20 Amps now indicates that the TEST key must be pressed for at least one second to retry the test Reset for Locked Cellcorder The key sequence for resetting a locked up unit has changed To reset the unit press ON and F1 simultaneously The previous sequence was to press ON and TEST simultaneously See warning in the Resetting the Cellcorder section A D Channel 3 Diagnostic The key sequence to activate the A D Channel 3 Diagnostic now requires pressing the TEST key after selecting Chan 3 Previously pressing TEST was not required Calibration for Current The key sequence to activate the Current calibration now requires pressing the TEST key after selecting option 4 Current Previously pressing TEST was not required Performing a Resistance Tes
24. using the HP voltmeter Press the UP and DOWN arrow keys until the reading on the Cellcorder matches the HP DMM reading Select the Multimeter mode and verify the reading matches the input level If the reading is off by more than 0 1 return to the Calibration menu and readjust the calibration value with the arrow keys After readjustment return to the Multimeter mode and repeat this step Record the calibrated value displayed in the Multimeter mode on the Calibration Log under Cell 6V After Calibration 3 8 4 4 12V Cell Calibration 1 2 3 4 Using the two voltage leads connect the Cellcorder across the same 12V source used in the Cell Readings section From the Calibration menu select option 3 12V Cell Measure the voltage using the HP voltmeter Press the UP and DOWN arrow keys until the reading on the Cellcorder matches the HP DMM reading 32 5 Select the Multimeter mode and verify the reading matches the input level If the reading is off by more than 0 1 return to the Calibration menu and readjust the calibration value with the arrow keys After readjustment return to the Multimeter mode and repeat this step 6 Record the calibrated value displayed in the Multimeter mode on the Calibration Log under Cell 12V After Calibration 3 8 4 5 Current Calibration WARNING Current calibration should only be performed using a 2 volt source Do not attempt to perform this procedure with a 6 volt or 12 volt
25. voltmeter Record the value on the Calibration Log under Current at 2V Actual Input Measure the current using the Cellcorder 10 Record the value under Current at 2V Before Calibration NOTE This test allows current to flow for only 10 seconds before de energizing the load relay This prevents overheating of the load resistors and leaving the Cellcorder in a loading condition To resume the test press ESC and select option 4 Current again 30 3 8 3 3 Intercell Reading 1 2 3 4 5 6 7 8 9 Using the multimeter test leads connect the Cellcorder as follows Connect a 10mV source to the clips that normally attach across the intercell connector during a test That is connect the small black clip to the source positive and the large black clip to the source negative From the Calibration menu select option 5 Intercell Measure the voltage using the HP 5 digit voltmeter or equiv Record the value on the Calibration Log under Intercell 10mV Actual Input Measure the voltage using the Cellcorder Record the value under Intercell 10mV Before Calibration Reverse the polarity of the 10mV source Measure the voltage using the HP voltmeter Record the value under Intercell 10mV Actual Input 10 Measure the voltage using the Cellcorder 11 Record the value under Intercell 10mV Before Calibration 3 8 4 Calibrating the Cellcorder This section describes how to calibrate the
26. 3 5 Error Codes and Warning Messages This section covers error codes and warning messages If an error message or error code cannot be resolved contact Alb rcorp for assistance On power up the Cellcorder does a diagnostic check of several hardware parameters If more than three errors occur only the first three are displayed until the problems are resolved These messages are displayed along with audible beeps after the firmware revision number appears The tests are performed in the following order ERROR MESSAGES e CPU Failure e Program RAM Failure e Boot EPROM Failure e NV PROM Failure e PIO Failure e A D Failure e Data RAM Failure The following error messages may appear during a Multimeter Mode test ERROR CODE 1 Unit cannot lock in its autorange circuit Possible noisy environment ERROR CODE2 Voltage reading is less than 2V when test is executed The unit displays the message READING ERROR _ Voltage Too Low Possible Faulty Cell T EST Retry Test ERROR CODE 3 Intercell voltage greater than 0 1V Negative test lead could be across the adjacent cell instead of directly across intercell Test is performed before the current is applied to cell The unit displays the message READING ERROR Intercell V Detected Check Test Leads T EST Retry Test 22 ERROR CODE 4 ERROR CODE 5 ERROR CODE 6 ERROR CODE 7 ERROR CODE 8 ERROR CODE 9 ERROR CODE A
27. 5 TRIPLE POST VRLA For VRLA cells or flooded cells configured as shown in Figure 5 four readings are made forming two X s Terminal Posts A to E then B to D and B to F then C to E In all triple post strap measurements the positive a red clip Cellcorder lead should re main connected as shown to the same terminal post for all readings 50 9 Appendix F Application Note CC 003 Optimizing Cellcorder Battery Life Alb rcorp wants to remind all Cellcorder users that this unit uses an 8 volt 5 amp hour sealed lead acid battery for its operation This particular battery has been used for many years in some of our other products and we know from experience that it should last three to five years Unfortunately some users do not remember Battery Basics 101 which clearly States A lead acid battery if stored in a discharged condition will suffer permanent loss of capacity due to sulfation and in a fully discharged condition will be ruined by hydration Please make sure the Cellcorder is kept in or near a fully charged condition This means charging the unit within less than 24 hours after each use If the unit is only used to take a few readings it is obviously not as important to charge it as it is following several hours of use The battery was sized to last six hours in a 77 F environment and we guarantee that it will last for at least five hours of continuous use when it leaves the factory If you h
28. CAL RESISTANCE Cell paste electrolyte and separators form the electrochemical part of cell internal resistance Long term increases in Rerecrrocuemicar can be caused by loss of active material or paste due to aging Short term changes also occur naturally during parts of the charge or discharge processes when the specific gravity is altered or when the contents of the separators varies and or the chemical composition of the surfaces change Separator compression clogging or shorts and conditions like sulfation are frequently causes of abnormal increased electrochemical resistance however accelerated electrolyte dryout appears to be public enemy 1 when it comes to VRLA failures Figure 6 reveals how a battery with an electrochemical resistance problem behaves Its reduced capacity does not become apparent until much further into the discharge like running out of fuel On the other hand the metallic resistance problem can be viewed as pinching the fuel line In either case the worse the resistance the greater the shortfall between the cell s rated and actual capacity VOLTAGE Fig 6 TYPICAL DISCHARGE CURVE OF A CELL WITHAN ELECTROCHEMICAL RESISTANCE PROBLEM 42 BATTERY AGING AND INTERNAL RESISTANCE Internal resistance provides a clue to aging The aging process of a battery s cells is based upon the rates at which their materials and construction deteriorate under design conditions For example th
29. Cellcorder Instruction Manual Revision 5 0 Alber 7775 West Oakland Park Blvd Sunrise FL 33351 Tel 954 377 7101 Fax 954 377 7042 www alber com 1 WARRANTY AND LIMITATION OF LIABILITY LIMITED WARRANTY Alb rcorp warrants that the software product will perform in accordance with the accompanying written materials for a period of ninety 90 days from the date of receipt Some states and jurisdictions do not allow limitations on duration of an implied warranty so the above limitation may not apply to you To the extent allowed by applicable law implied warranties on the software product if any are limited to ninety 90 days CUSTOMER REMEDIES Alb rcorp s entire liability and your exclusive remedy shall be at Alb rcorp s option either return of the price paid or replacement of the software product that is returned to Alb rcorp with proof of purchase This Limited Warranty is void if failure of the software product has resulted from accident abuse or misapplication Any replacement software product will be warranted for the remainder of the original period or thirty 30 days whichever is longer Albercorp shall not be liable for any data or programs stored in or used in conjunction with this software product Without prejudice to the foregoing generality Alb rcorp shall not be liable for the loss or corruption of data or programs stored in or used in conjunction with this or any other software product nor shall Alb
30. Cellcorder or an out of calibration condition Press test for at least one second to retry the test LOW CURRENT CELL OR CONNECT PROBLEM SELECT TEST BUTTON gt 1 SECOND TO RETRY The discharge warning message appears when the battery is fully discharged When a low battery is detected the unit displays this message once a minute for five minutes and then shuts down Refer to Battery Charging _ _ _ WARNING _ Cellcorder BATTERY LOW RECHARGE The cool down fan message appears if an attempt is made to turn off the Cellcorder within five minutes of testing an 8V or 12V module COOL DOWN FAN ON ALLOW 5 MINUTE WAIT KEEP CASE OPEN 3 5 1 Resetting the Cellcorder If the Cellcorder locks up will not respond to any keys simultaneously press the ON and F1 buttons to manually reset the unit WARNING If a manual reset is needed disconnect any leads connected to the battery before initiating a reset 24 3 6 Diagnostics If the Cellcorder appears to have a malfunction the diagnostic features of the unit can help isolate the fault To access the diagnostics functions select option 2 Diagnostics from the Main Menu The following is displayed _ _DIAGNOSTICS MENU 1 KEYBRD 4 RELAYS 2 DISPLAY 5 RS232 3 AD CHAN 3 6 1 Keypad KEYBRD When the Keypad diagnostic is selected the Cellcorder displays the name of each key as it is pressed
31. Cellcorder Battery Analysis Software To erase the strings at the Main Menu press F1 The following menu appears _ MEMORY OPTIONS _ 1 CLEAR ALL STRINGS 2 CLEAR SINGLE STRG ESC QUIT 1 Clear All Strings Select the Clear All Strings option to clear memory The unit displays a message to verify this selection is correct 2 Clear Single String When the Clear Single String option is selected the screen prompts for the Batt ID To clear only one battery string enter a battery ID number then press ENTER 27 3 8 Calibration When calibrating the Cellcorder use a photocopy of the Cellcorder Calibration Log Appendix C in this manual to record the before and after readings Doing this will help keep track of any calibration discrepancies The following equipment is required to perform a complete calibration EQUIPMENT DESCRIPTION 2V cell capable of 100 amps or Current source for calibrating current a 2V 100 amp source 100A 100mV shunt or a clamp on Shunt for calibrating current ammeter may be used as an alternate HP8840 multimeter or equivalent 5 digit voltmeter 10mV power supply Power supply for 10mV source LPS152 power supply or equivalent Adjustable power supply for 6V and 12V sources 3 8 1 Entering the Calibration Screen At the Main Menu select 3 Setup then select 1 Calibrate The following screen appears _CALIBRATION _ Enter Password ESC Quit HHHH 3 8 2
32. Conductance Testing Application Note Form 41 7271 Aug 1994 Milwaukee WI and Alb rcorp in house data 9 G Alber Are Internal Cell Parameter Measurements a Substitute or Supplement to Capacity Testing Sep 1994 NE Utilities Battery Conference Albany N Y 47 8 Appendix E Application Note CC 002 Internal Resistance Measurement Procedures This document is available at www alber com INTRODUCTION Intercell resistance problems account for a great many battery system failures In UPS or other high current applications the failures can lead to explosions and fires that are not only costly but also represent safety hazards Most battery manufacturers unfortunately do not supply baseline resistance values so presently users must establish their own values The recommended procedures for establishing base lines are New systems read all the resistance values after installation and calculate the average value Older systems disassemble 10 sets of intercell connections burnish neutralize and clean them reapply corrosion inhibiting compound reconnect retorque and then calculate the average of the new readings Intercell resistance measurements should be taken once a year of all cells IEEE 450 1995 and forthcoming IEEE VRLA maintenance recommendations Any connection that is 20 or greater than the baseline or installation value requires corrective action The importance of these measurem
33. ER _ EST INITIALIZATION EASE WAIT W HI Continue reading until all the cells are measured If the leads are incorrectly connected or a bad connection is encountered the unit advises what to do If an error code is displayed refer to Error Codes and Warning Messages It is possible to find a cell that is failing so badly that the loaded voltage drops by more than 1 5 volts In this case the cell is declared as a failing cell and Error Code 9 is displayed 3 4 4 Storing Data for More Than One String The Cellcorder has two memory configurations available under the Setup selection on the Main Menu One mode is 7 x 256 7 batteries with 256 cells in each battery and the other is 28 x 64 28 batteries with 64 cells in each battery Select the proper configuration prior to using the unit and do not change it until all readings are transferred to the computer After Battery ID 1 location has been used the other Battery ID locations can be used by selecting a new string as follows e Verify the blinking cursor is located in the Cell number display If not already there press the CELL key e Press the ENTER key This moves the cursor to the Battery ID location e Select the desired number using the numeric keys then press ENTER 16 After the new battery storage location is selected the control program recognizes whether float readings exist or if they need to be taken Refer to Multimeter Mode After
34. Entering the Password When the Cellcorder is shipped from the factory or when software is updated via the RS 232 port the password defaults to 1234 If the password is unknown contact Alb r for a password based on the randomly generated four numbers at the bottom right of the screen When contacting Alb r have the unit available for reference After the correct password is entered press ENTER The Calibration screen appears The password may be changed to any four digit number by selecting option 6 New PW from the Calibration menu 28 _ _ CALIBRATION _ 1 2V CELL 4 CURRENT 2 6V CELL 5 INTCELL 3 12V CELL 6 NEW PW 3 8 3 Recording the Before Calibration Readings To simplify taking before calibration readings first clear the Cellcorder memory To erase the strings at the Main Menu press F1 Refer to Erasing String Data in Memory Management Record the before calibration as found readings onto a photocopy copy of the Calibration Log The values of the 2 volt 6 volt and 12 volt sources or cells used in the following tests are approximate Actual values may vary by a nominal amount 3 8 3 1 Cell Readings 1 Select Multimeter mode on the Cellcorder so the actual voltage is being read 2 Connect a 2V cell to the Cellcorder using the standard two lead voltage leads supplied with the Cellcorder 3 Measure the voltage using the HP 5 digit voltmeter or equiv 4 Record the value on th
35. KK KKKKK Where V mem is the cell voltage previously taken using the voltmeter mode If voltmeter readings were not previously taken a message requests that you either take the float readings first or use the active present cell voltages Refer to Skewing Effect in Operation Notes If the present readings are selected they are stored automatically with the resistance readings each time the TEST key is pressed Press ESC to return to the voltmeter mode or press TEST to go to the resistance screen ESC NO VFLOAT EADINGS EXIST USE VOLTMETER MODE FIRST TEST IGNORE VFLOAT Do After a choice of voltage readings is made the Cellcorder is ready to take readings on Battery 1 cells 3 4 2 Connecting the Test Leads The connection of the test leads for any type of resistance measuring instrument is very important and is directly related to the accuracy of the readings WARNING Never let any Cellcorder metal surfaces come in contact with a battery post or grounded rack while testing with the unit WARNING Do not attempt to read internal resistance of an open cell module while the battery is on line An open cell can be determined by the abnormally high voltage across it and the low voltage across all other cells modules Refer to Application Note CC 001 When measuring internal cell resistance place the voltage sense leads directly on the positive and negative terminal posts This way the measure
36. LTAGE FIG 4 Vo ren TYPICAL DISC HARGE CURVE OF A 100 CAPACITY CELL A battery s capacity is adversely affected by an increased internal resistance Obviously the power is dissipated internally 41 P x Rwrera and is not available where it is really needed at the load Thus actual capacity is diminished However during discharge this reduction in capacity appears differently depending upon whether the resistance change is primarily metallic or electrochemical in nature METALLIC RESISTANCE This portion of the internal conduction path troubles most battery test experts It is here that deterioration of a cell can occur most rapidly and then will often go undetected between the yearly integrity tests or even less frequently the capacity tests The tear down of failed batteries with abnormal internal resistances has proven that the terminal posts and the internal straps and grids are most often the victims of corrosion poor welds or burns Where found contact surfaces of a copper insert can corrode or loosen from its surrounding lead post The Cellcorder easily detects these types of problems Fig 5 clearly shows the loss of capacity due to a high internal metallic resistance The available voltage at the battery s terminals is reduced from the start of the discharge and continues to the end Fig 5 y TYPICAL DISCHARGE CURYE OPEN OF ACELL WITH A CIRCUIT METALLIC RESISTANCE PROBLEM ELECTROCHEMI
37. PENDIX D APPLICATION NOTE CC 001 u cceceessssececececeesesssceceeeceesssssssseeeeecs 39 APPENDIX E APPLICATION NOTE CC 002 cccecssssececececeessssececeeeceesenssseseeeeees 48 APPENDIX F APPLICATION NOTE CC 003 ccccccseseecenesceceeeececeeneeceaseseeeeaeeseees 51 APPENDIX G CELLCORDER CONNECTION OPTIONS ccc0ssececeeeeeceeeeseeceeeeseees 52 vi What s New This section describes some of the many new features and enhancements in the Cellcorder Several improvements have been made to both the Cellcorder hardware and software Hardware A new circuit now helps protect the unit if it is accidentally placed across a high voltage circuit The protection circuit senses the input voltage across the current carrying leads and if the input voltage exceeds 24 volts a beep sounds and the test current relays are disabled Earlier models without this feature can be upgraded As a reminder it is still potentially hazardous to exceed the rated voltage of the Cellcorder 16 volts A fuse on the Cellcorder rear panel now helps protect the operator and the Cellcorder if the unit comes in contact with a battery post or grounded rack during testing Replace this fuse with a ceramic 1 amp fuse only The symptoms of a blown fuse while testing are 1 the Cellcorder voltage reading indicates zero to one half of the cell voltage being tested and 2 the Cellcorder displays a Low Current Cell or Connect Problem error message Although
38. Reserved A D overflow excessive noise or too high of voltage Reserved Intercell voltage greater than 0 1V Bad intercell connection or possible poor test lead connections Test is performed during load of cell The unit displays the message _ _ READING ERROR_ _ Intercell R Too High Connection Problem TEST Retry Test V Load gt V Float Cell possibly opened up at start of test VF VL gt 1 5V Failing cell Cell cannot maintain test current VF VL I is too large Instrument overflow The unit displays the message _ _ READING ERROR_ _ Re gt 60000u Possible Faulty Cell TEST Retry Test The following error messages may appear at any time during use of the Cellcorder The voltage error message below appears when the input voltage exceeds 16V The maximum voltage the Cellcorder can read is 16V Never exceed the maximum input voltage or permanent damage may occur _ VOLTAGE ERROR _ _ Input voltage must be less than 16V ANY KEY 23 The reading error message appears when the test current exceeds 80 amps This error may be the result of a hardware failure in the Cellcorder or an out of calibration condition _ READING ERROR _ EXCESSIVE LOAD CHECK CONNECTION ANY KEY The low current message appears when the test current is below 20 Amps This may be the result of a poor test lead connection faulty cell hardware failure in the
39. ave any questions please call Alb rcorp 51 10 Appendix G Cellcorder Connection Options Alb r CELLCORDER CONNECTION OPTIONS CLO 004 CLC 008 12V Module Application Only NOTE Reference Drawing No CCM 304 A423 Rev C for addtional information on Spike Probe Leads For further information on which Cellcorder leads are best suited to your individual requirements contact your local ALBER representative or ALBERCORP directly at Phone 561 997 2299 Fax 561 997 5588 990 S Rogers Circle Suite 11 Boca Raton FL 33487 ALL ALBERCORP PRODUCTS ARE ENGINEERED DESIGNED AND MANUFACTURED IN THE U S 52 Index A D channel diag menu ee 25 A D channel diagnostic 8 25 AMP hours erei 13 asterisk on Menu eee 7 27 auto tangna G 5 patt ID field e innan ei 19 battery charging Cellcorder 11 21 battery low Cellcorder ee 21 battery maintenance eee 10 battery selection ccceeesseereeeees 19 Calibration cece eesseceeeseeceeees 28 31 LON celson a aha 32 QV COM urate E E O 31 OV Cell henson ater sta states 32 A D reference istic attest 31 backing Up eeceeeceeseeeeeeeeeseeeeees 35 battery charger ceeeeeeeeeeeeees 34 Cell readings seee 29 DEn LEES EEREN ER 33 current readings ssseseeseeseeeesseee e 30 TT t a I E E E 34 intercell readings ceeeeeeees 31 TOSCOTING ecceeeeeseesseee
40. ds automatically records the reading into memory The unit beeps to indicate the value was recorded and displays the message Recorded in Memory The unit ignores voltage polarity in this mode therefore you may connect the leads in either direction When the leads are lifted and moved to the next cell the Cellcorder increments to the next cell During testing you may review or retest previous readings To return to a selected cell press the UP or DOWN arrow keys with the cursor in the Cell field or enter a cell number and press ENTER When retesting select the desired cell then press TEST The following screen appears _ READING EXI STS _ TEST Overwrite ESC Quit Press TEST a second time to store the new voltage reading Or press ESC to return to the previous screen displaying the data of the cell being reviewed 3 4 6 Entering Specific Gravity Temperature and Overall Volts To enter this mode select option 3 SG Temp OV from the Mode Select Menu then select option 1 Manual Readings In this mode data must be entered manually The Cellcorder prompts you to input the data using the keypad When this mode is selected the following is displayed To enter or edit data follow the steps below _ _S G TEMP O V _ _ CELL 001 BATT ID 01 S Gl OV xx TEMP F Several items explained below can only be entered when cell 001 is selected This simplifies the entry of specific gravity and temp
41. e Calibration Log under Cell 2V Actual Input 5 Measure the voltage using the Cellcorder 6 Record the value under the Cell 2V Before Calibration 7 Connect a 6V source to the Cellcorder using the standard leads 8 Measure the voltage using the HP voltmeter 9 Record the value under Cell 6V Actual Input 10 Measure the voltage using the Cellcorder 11 Record the value under the Cell 6V Before Calibration 12 Connect a 12V to the Cellcorder using the standard leads 13 Measure the voltage using the HP voltmeter 14 Record the value under Cell 12V Actual Input 15 Measure the voltage using the Cellcorder 16 Record the value under the Cell 12V Before Calibration 29 3 8 3 2 Current Readings 1 2 3 4 5 6 7 8 9 Select the Calibration option as described in the Entering the Calibration Screen section Using the multimeter three lead test leads supplied with the Cellcorder connect the Cellcorder to a 2V test cell with a 100 Amp 100 mV shunt in series with one of the load cables Refer to the following figure CELLCORDER x 2V BATTERY Black Clip Figure 1 Cellcorder Connections Connect the small black clip to the same point the large black clip is connected to Connect the HP 5 4 digit voltmeter or equiv across the shunt From the Calibration menu select option 4 Current To start the test press TEST Measure the current mV reading across the shunt using the HP
42. e life of nearly all stationary cells is specified at 77 F under particular float charge conditions and discharges of stipulated depth and frequency Very slow corrosion of conduction paths the loosening of active materials from plates grid deformation and in the case of VRLA cells dry out of electrolyte are all natural processes that push a cell to its end life This aging process is marked by increasing cell internal resistance and decreasing capacity It is generally agreed that below 80 actual capacity the cell s deterioration will accelerate rapidly and replacement is recommended The internal resistance increases slowly but toward the end of a cell s life it accelerates greatly Its end life value is normally about 25 or so above its initial value but can be as high as 50 TEMPERATURE AND INTERNAL RESISTANCE Being aware of the effect of temperature on internal resistance is important Figure 7 for a typical AGM VRLA cell clearly shows rapid internal resistance and impedance increases below temperatures of about 45 F Fig 7 Normalized Internal Resistance Vs Temperature Per Cent of 77F Value Sra e Cea In temperate climates VRLA cells in unconditioned temperature environments may show considerable internal resistance variation between quarterly measurements Recording of the ambient temperatures at the time of mea
43. e the Cellcorder for at least eight hours to guarantee six hours of battery operation The front panel CHARGE light indicates charging only and does not indicate when the battery is fully charged The batteries are lead acid cells and do not exhibit the memory problems associated with nickel cadmium type batteries If the batteries wear down during testing plug in the charger module and keep testing If the battery has been overdischarged charge the unit for 15 to 30 minutes prior to using it plugged in to AC The life of the battery is directly related to how well it is charged Do not store the Cellcorder in a discharged condition Refer to Application Note CC 003 During use the unit indicates when the battery is near a discharged state by beeping four times and displaying the following WARNING _ Cellcorder BATTERY LOW RECHARGE In this state when any key is pressed the Cellcorder returns to the Main Menu This message appears once a minute for five minutes then the unit powers itself off All data will remain in memory and can be recovered after the battery is recharged If the unit is powered on without being recharged it will shut down without warning after one minute If you continue to use the Cellcorder in this state unpredictable results may occur and data storage could be affected To conserve battery life the Cellcorder automatically shuts down if unattended for more than eight minutes 21
44. eeeeeeeeeeteeesees 35 Calibration 10g eeceeseeseeseeteeeteeees 38 calibration menu eeseeeeeeeeteeeee 28 calibration screen 28 cell capacity menu ce eeeeeeeeeeeee 13 cell number changing secec c ccecieseieeshecestaceeecds 17 INDEXING scini 16 18 cell selection drenanti 18 charge indicator cceseseeeeeeeeeees 7 charger module c cecceesseeteeeeees 21 Clear all strings 27 clear single string eeeeeeeeeeee 27 configuration See memory configuration data extraction and analysis 6 diagnostics 00 eeeeeeeeeeeeeeeeeeeeees 12 25 diagnostics MENU ccceeeeeee 8 25 digital hydrometer ccceeeeeeeee 19 display diagnostic cceceeeee 8 25 erasing string data 27 53 ETOT COGS esaii o a 22 float voltage readings 5 12 13 hydrometer r snccerenanoan a 19 initial system test eeeeeeeeeeeeeeeees 7 intercell resistance cccceeeeees 5 15 intercell type MeNU eee 13 internal cell resistance 5 14 keypad diagnostic cceceseeeeeees 8 25 loop back connector eeeeeeees 26 MAIN MENU ceeeececeesseceeseeeeeeees 7 11 maximum voltage warning 17 memory configuration 12 16 27 memory options Menu 27 memory partitioning menu 27 MOS SELE Cts desecsts te e 12 mode select MeNU ceceeeeeeeeeees 12 multimeter cece ceeeeceeseeceee
45. ents is illustrated by the new VRLA standard that recommends quarterly sampling 25 of the intercell connection resistances If an upward trend is detected all connection resistances should be measured to aid in determining the cause and corrective actions 48 HOW TO TAKE READINGS When taking intercell connection resistance readings it is important that a the test leads are connected properly Measurements should include the post to intercell connector resistance Always check your connections and connect only to posts not nuts bolts or straps See figs 1 5 This is the main area where connection problems occur and b the test probe tips fingers make a good connection piercing any grease lead oxide or crud coating the posts or straps This is the leading cause of error messages after pressing the test button Often jiggling the probe will lower the readings significantly and save you the heartache of unnecessarily reworking a connection Fig 1 SINGLE INTERCONNECTIONS SINGLE INTERCONNECTIONS Figure 1 shows how the Alb rcorp Cellcorder should ideally be connected to obtain the proper measurement Note that ideally the reading includes both the intercell connector resistance and the post to intercell connection resistance Figure 2A shows the connection for VRLA cells such as the ABSOLYTE II batteries where the terminal post is accessible Figure 2B shows the connection for VRLA cells where t
46. epressed until the charger can bring them back to normal float levels This means that the voltages of the remaining cells have to increase to make up the difference since the overall voltage is controlled by the charger The skewing effect is particularly noticeable on small and weak cells For large batteries such as mini tank cells the effect is not as noticeable but there is still a small error in the voltage readings 3 4 1 Multimeter Mode When this mode is selected the screen prompts the user to specify how many intercell connection readings are to be taken Refer to Connecting the Test Leads and to Application Note CC 002 Select Combine when using test leads that do not support intercell readings The intercell readings will be zero on the display ENTER INTERCELL TYPE 1 SINGLE 3 TRIPLE 2 DUAL 4 QUAD 5 COMBINE After selecting the number of intercell readings the screen prompts the user to specify whether the battery is smaller or larger than 1000 ampere hours This selection has to do with the timing of the load being applied _ CELL CAPACITY _ ELECT AMP HOUR RATE O 1000 AH MORE THAN 1000 AH MOF wl After the amp hour selection is made the Cellcorder checks if float voltage readings using the voltmeter mode were already taken If they were the following screen appears 13 __MULTIMETER _ CELL 001 BAT ID 1 V mem RC Ric 02 225 KKK
47. erature values since they are the majority of the entries that will be made 3 4 6 1 Cell Selection If the cursor is in the Cell field enter the cell number with the keypad then press ENTER If the cursor is in any other field press CELL then select the desired cell 18 3 4 6 2 Battery Selection To select another battery the cell number must be cell 001 Refer to Cell Selection Press ENTER until the cursor is at the Batt ID field Select the desired battery number then press ENTER 3 4 6 3 Specific Gravity SG Entry When the cursor is in the SG field a 12 is automatically inserted to simplify entry For example for a specific gravity of 1215 you only have to enter 15 then press ENTER Note that the value entered is not temperature corrected However most digital hydrometers provide correction automatically Check with the manufacturer of the hydrometer to see if the unit has this feature 3 4 6 4 Temperature Entry When the cursor is in the Temperature field round the temperature reading to the nearest whole number and enter it using the keypad then press ENTER 3 4 6 5 Temperature Type Selection This selection can only be made when cell 001 is selected Refer to Cell Selection Press ENTER until the cursor is in the temperature type F or C field To change the selection from F to C or from C to F press the UP or DOWN arrow keys and wait two seconds This function is independent of the temperature entry
48. es 4 13 multimeter SCLeCN eeeeeeeteeseeee 13 multiple stringS eceeseeeereeeeees 16 no float readings screen 14 null modem adaptor c eee 20 out of tolerance readings 20 Overall Volts cece ceeeseceeeereeeee 18 19 Parts Listes 20s Soles fetiton eon sti 36 password 00 eeeeeeeceteeeteeeseeeeeeeee 20 28 POlarity sieht E AET 18 POW C0 EE E thi oss ET 6 RO fie A enine hen a tag aon 15 reading exists Screen eee 18 TOACINGS soo ss en iniii iiie 15 relays diagnostic 8 26 reset the Cellcorder 0 0 0 24 resistance readings eeeeseereeeee 14 RIG iescisseni auaa e nA 15 RS 232 diagnostic c eeeeeeee 9 26 safety information cece eeeeeeeeeeees iv SUP nAn iinn n a aR 12 SG Temp OV menu ceeeeees 18 skewing effect ceceseeseesseereereeees 13 Specific Bravity cece 5 18 19 specifications neirinne na 37 system display ccceseseeseeseeeeeeeees 6 SYSE TESEI G4 saat Secesiev cotter a 24 SV SLEI LOS AE EE capes 7 temperature ieii 5 18 19 temperature type C F e eee 19 test initialization message 16 test initialization screen c 14 test leads cccecssccessceessceeeeeesseeeeees 14 test modes 0 ceeecesceescecsseceeeeecsteeeeeeees 4 MUItimeter c cece eeseceeeceesseeeeeeees 4 54 specific gravity temperature voltmeter test parameters test pa
49. gh several thousand hertz and have made measurements in all units They tried to relate those to cell capacity often with mixed or conflicting results In almost all typical battery applications the inductance has no practical impact on battery performance because of its small magnitude from 0 05 to 0 2 microhenries On the other hand the actual capacitance of cells is surprisingly large as much as 1 7 Farads per 100 Amp Hours This cell characteristic is put to good use by charger manufacturers They depend on it to filter their charger output However little evidence has evolved that ties capacitance with the actual capacity of a cell It s worth noting that one researcher felt capacitive reactance obscures the predominant indicator of cell capacity elec 40 trochemical resistance More so as the test frequency is increased Impedance and admittance measurements include both capacitance and inductance in their readings THE NATURE OF INTERNAL RESISTANCE At Alb rcorp we have centered our efforts on cell internal resistance A refined cell model has been developed which subdivides the internal resistances of a cell as shown in Figure 2 into its metallic and electrochemical components These resistances do not change with test frequency Indeed researchers have concluded that a zero frequency DC or extremely low frequencies yield the best results when studying capacity relationships R TRUI LPOST
50. he load is removed is due to the internal resistance The Cellcorder reads the current and the cell voltage just prior to removal of the load and then measures the re covered cell s voltage The resultant resistance is simply RiyterNnar AV I CELL VOLTAGE a 2 281 V2 2 088 2 253 V 2 061 4 76 AMPS 1 re V2 Ya Av LOAD CURRENT e 3 25 SECONDS oe R intemal Av 375 Microhms Fig 8 Measuring Internal Resistance THE MOMENTARY TEST DISCHARGE This is a feature worth your time to understand It is in part what distinguishes the Cellcorder from most instruments presently on the market and will help provide readings in which you can be confident For rated cell capacities of less than 1000 amp hours the discharge is short only three to four seconds in the order of 20 to 75 amps For larger capacities the duration is close to 10 seconds To prove a point about safety and the effects of short term high currents we performed the following experiment We imagined an internal conductor corroded down to the size of a dot We found that passing the Cellcorder s test current through a skinny wire 27 inches of 20 gauge wire caused no damage nor barely heated it Try it The reason is that very little energy is involved It amounts to only a maximum of 5 watts per 000 microhms and lasts only seconds In an actual test within milliseconds of starting the Cellcorder senses the current level If there
51. he terminal post is not accessible In this type of cell the intercell to post connection resistance is included in the internal cell resistance measurement NOTE Do not connect to the stainless steel bolt heads to make this measurement DUAL INTERCONNECTIONS Figures 3A and 3B show the typical intercell connections for dual post cells This type of interconnection requires that two readings be taken The first one shown should be with the intercell leads connected from Terminal Post A to Terminal Post C Take the second reading with the intercell leads connected from Terminal Post B to Terminal Post D The positive a red clip Cellcorder lead should remain connected as shown to the same terminal post for both measurements a SQ 7 RED RED WZ ae o ert eo At B pn E Seer E LN LN f BLACK YF BLK Figures Figure3B BLACK vy DUALINTERCONNECTIONS 49 TRIPLE INTERCONNECTIONS Figures 4 and 5 show the typical intercell connections for triple post cells For cells arranged as in Fig 4 three readings are made The first one shown should be with the intercell leads connected from Terminal Post A to Terminal Post D Take the second reading with the intercell leads connected from Terminal Post B to Post E The third reading is with the intercell leads connected from Terminal Post C to Post F TRIPLE INTERCONNECTIONS Fig
52. he transfer starts the Cellcorder displays the cell number that has been loaded When the display reaches 64 or 256 depending on the configuration selected all readings have been loaded Note that all uploaded temperature values are rounded off to the nearest whole number If a message requests a password when attempting to upload the Cellcorder is not enabled to upload readings This is a Cellcorder option purchased separately from the basic unit To add this function in the field have the Cellcorder unit available and call Alb rcorp for instructions 3 4 8 Programming Test Parameters The Cellcorder can be programmed to warn if the measurements taken are out of tolerance After test parameters are programmed the unit will display failed readings with a darkened background and sound a series of beeps To program the test parameters from the Main Menu select option 3 Setup In the Setup Menu select option 2 Test Parameters to display the Test Parameters Menu To set the parameters select the item enter the threshold value then press ENTER The following table shows the description and ranges for each programmable entry 20 V HIGH Cell voltage high value 0 900v 16 000V V LOW Cell voltage low value 0 900v 16 000V Rc High Cell resistance high value 00000u 60000uQ Rc Low Cell resistance low value 00000u 60000uQ Ric High Intercell resistance high 0000u 2000nQ 3 4 9 Battery Charging Prior to doing any testing charg
53. ic requires the use of a loopback connector not supplied The loopback connector can be simulated by connecting pin 2 to pin 3 of the RS 232 port After connection press TEST The unit sequences through a series of transmit and receive signals and logs the errors on the display After the sequence is started the unit counts from 0 to 255 and continues cycling 0 to 255 until ESC is pressed If errors exist the error count field increments This completes Cellcorder diagnostic acceptance testing Before beginning operation turn the Cellcorder off by pressing the ON key on the keypad the ON key operates as an ON OFF key 3 Operating Instructions This section describes the operation of the Cellcorder 3 1 General Concepts The Cellcorder is designed to improve the ease and accuracy of taking periodic maintenance readings An effective maintenance program that meets the recommendations of most battery manufacturers calls for the following measurements INTERVAL PARAMETER Monthly Quarterly Semi Annually Annually Cell Voltages X Intercell Resistance X Internal Resistance X Vented Cells Internal Resistance X Sealed Cells Specific Gravity X Temperature Profile X Capacity Every 3 to 5 years until signs of degradation Vented Cells then once every year Capacity Every year Sealed Cells NOTE VRLA or sealed cells need to be tested more frequently because of their shorter
54. ing Reverse the polarity of the 10mV source and verify the Cellcorder reading does not change by more than 30uV If the value is within this 30uV range go to step 5 If the reading changed more than 30uV then the offset adjustment on the input preamp must be adjusted Adjust RV3 until the value is within 30uV when changing polarity on the input Press the UP and DOWN arrow keys until the Cellcorder reading matches the input value If the input is not a fixed 10mV standard source then use the HP DVM to verify the input value Record the Cellcorder readings in the Calibration Log under the Intercell 10mV and 10mV After Calibration locations 3 8 4 7 Battery Charger Adjustment As the battery charges the voltage drop across current sensing register R24 decreases When the battery approaches full charge this voltage is about 30mV with the AC adaptor plugged in RV1 must be readjusted periodically during the adjustment process to achieve a nominal float voltage of 9 40 volts at TP3 GND and TP2 8V BAT This process could take from one to ten hours depending on the initial state of charge of the battery 34 Only make fine adjustments when the voltage across R24 is near 30mV When making adjustments the effect is not immediate therefore make the adjustment and recheck after the battery has time to respond The battery charger should only require minor adjustments if the battery has been replaced otherwise no adjustment sh
55. ing us or the cell s manufacturer INTERNAL RESISTANCE TEST FREQUENCY The whole purpose of the internal resistance check is to determine whether a cell has deteriorated and if so how much and how fast Logically checks are done periodically At least quarterly check cells that have exhibited signs of abnormality either from inspection or an earlier capacity integrity or internal resistance test Since neither specific gravity nor visual checks can be done on sealed cells you would want to do much more frequent testing than on vented cells For that reason it s no surprise the P 1188 VRLA proposed Standard recommends internal measurements be taken quarterly On the other hand the standard for vented batteries 450 doesn t specify this type of check However it does call for annual connection resistance readings and you would want to take the internal resistances at the same time That s the nicest part of the Cellcorder its multimeter functions measure and record both the internal and connection resistances at the same time It saves you time and you don t even move the test leads for single post cells For detailed information request Cellcorder Application Note CC002 Intercell Resistance Measurement Procedures which covers single and multiple post cells measurements MANAGING THE CELLCORDER S DATA FILES As a testing program progresses the number of computer data files will increase rapidly
56. is is done press TEST to transmit and receive known data If the data has been corrupted the error count field increments Press ESC for at least two seconds to return to the Diagnostics Menu 26 3 7 Memory Management The Cellcorder has the capability of storing data for either 7 strings of 256 cells or 28 strings of 64 cells To change modes from 7 x 256 to 28 x 64 at the Main Menu select 3 Setup then select 3 Memory Configs A warning appears CHANGING MODE WILL SCRAMBLE READINGS CAUTION Do not change memory configuration after data has been taken or the memory will be scrambled Changing back will unscramble the memory At the warning message to continue press ENTER At the Memory Partitioning menu choose 7 x 256 or 28 x 64 configuration After a configuration is selected the Cellcorder always defaults to it That is if you select 7 x 256 then every time the Cellcorder is powered on the configuration will be in 7 x 256 mode until it is changed An asterisk on the top right corner of a menu indicates the memory configuration is set to 7 x 256 No asterisk indicates a 28 x 64 configuration Erasing String Data After uploading Cellcorder data to the computer or at any other time you may erase data in all Cellcorder memory locations or in selected strings CAUTION After the memory is cleared there is no way to recover the data Be sure to upload any data to be saved to the computer via the
57. isplayed in an easy to read bar graph format You also have the option of defining a custom generated report or generating a report using Alb r standard analysis 1 3 Test Modes This section describes the test modes of the Cellcorder 1 3 1 Voltmeter In this mode the Cellcorder is used with standard voltmeter probes to take monthly or quarterly float voltage readings When the probes access the first cell the reading is displayed and within two seconds the unit beeps and indicates on the display that the reading has been stored As the probes are lifted and make contact with the next cell the Cellcorder automatically indexes the display and memory storage to the next higher number This mode allows you to take valid recorded readings at a rate of ten to twelve per minute 1 3 2 Multimeter The Cellcorder is used in this mode to take internal cell resistance and intercell connection resistance readings on each cell A test harness consisting of three clips is connected as follows 1 Large red clip to the positive post of the cell being tested 2 Small black clip to the negative post of the cell being tested 3 Large black clip to the positive post of the next cell After connection the Cellcorder tests and reads in the following sequence 1 The cell voltage is read to automatically scale the Cellcorder for the correct range 2 A load resistor is connected across the cell and associated intercell The resulting test current
58. l reference resistor The multimeter three lead lead set must be properly connected across a 2 volt cell The test will not start if the voltage is less than 0 5V or higher than 3 volts After Chan 3 is selected on the A D Channel Diag menu press TEST to start the test The test times out and turns off the load after ten seconds to prevent overheating To restart the test press ESC and select the test again 4 Ref Displays the internal reference for the analog to digital converter The value should be approximately 2048 2 counts This reading cannot be displayed if the calibrated mode is selected 3 6 4 Relays WARNING If the Relays diagnostic is enabled while the Cellcorder is connected to a voltage source the Cellcorder can be permanently damaged Before you select the Relays diagnostic verify that no leads are connected to the Cellcorder A warning is displayed to ensure the leads are disconnected Press and hold TEST to activate this diagnostic While TEST is pressed the unit energizes each load relay one at a time The clicking of the relays verifies drive circuits are working properly Release TEST to stop the relay drivers and press ESC to return to the Diagnostics Menu 3 6 5 RS 232 When the RS 232 diagnostic is selected the display prompts you to install a loop back connector This connector is not supplied with the Cellcorder however one can be simulated by connecting pin 2 to pin 3 on the RS 232 connector After th
59. lation or use of this software product constitutes your acceptance of and agreement with the terms of this Software License Agreement LICENSORS All software on this media is licensed to you by Alb rcorp GRANT OF LICENSE You are granted the right to use the Alb rcorp Software on a single personal computer You may copy the software to use with this personal computer to any one hard disk drive of this personal computer and to the memory of this personal computer provided that you reproduce all copyright and trademark notices restricted rights legends and other proprietary markings RESTRICTIONS You may not sublicense rent or lease the Alb rcorp Software You may not reverse engineer decompile disassemble modify translate or create derivative works of the Software LIMITED WARRANTIES AND LIMITATION OF LIABILITY The limited warranties and limitation of liability in Section 1 of this file apply to are incorporated in and are made a part of this Software License Agreement EXPORT LAW ASSURANCES You acknowledge and agree that the Software is subject to restrictions and controls imposed by the United States Export Administration Act the Act and the regulations there under You agree and certify that neither the Software nor any direct product thereof is being or will be acquired shipped transferred or exported directly or indirectly into any country or used for any purpose except as authorized by the Act and the regulations
60. lls that are floating on line This method is useful for determining weak potentially failing cells when comparing internal cell resistance of all the like cells in the string For more information refer to Application Note CC 001 1 4 3 Intercell Resistance The Cellcorder measures and displays the total resistance of the connection between the terminals of two cells electrically connected to each other This measurement includes resistance of the connector and the contact resistance at the points of connection to the cell terminals 1 4 4 Auto Ranging The Cellcorder automatically selects the correct voltage range and load resistor for the test being performed 5 1 4 5 Data Extraction and Analysis Upon completion of testing the user connects the Cellcorder to a PC compatible computer with the supplied RS 232 cable The Alb r data extraction program is executed and test results are imported into the program Data is analyzed and displayed in an easy to read bar graph or tabulated format Refer to the Battery Analysis User s Guide 1 4 6 System Display The test sequence instructions and test results appear on a bright easy to read fluorescent display 1 4 7 Power The Cellcorder is powered by a self contained sealed lead acid rechargeable battery Refer to Application Note CC 003 for optimizing battery life Recharge or AC power operation is via a wall plug transformer module 2 Receiving and Acceptance Testing This
61. ment will not include any part of the external circuit Remember consistency in the way readings are taken is necessary when comparing them from one time interval to the next 14 When reading intercell connector resistance place the voltage sense leads on the terminal posts The primary reason for taking intercell measurements is to check the quality of the connection between the intercell bar and the terminal post Typical applications are shown in Application Note CC 002 Unfortunately on some batteries typically most VRLA modules it is impossible to access the posts because they are covered by the intercell connector For valve regulated batteries where only the intercell and the stainless steel mounting bolt are accessible connect the current lead to the bolt head and the voltage sensing lead to the intercell Measuring from bolt head to bolt head is not a true measure of the connection between the post and intercell bar In most cases the reading will be unusually high because of the high resistance of the bolt itself Refer to Application Note CC 002 Most battery terminal posts have a layer of lead dioxide lead sulfate copper oxide or dirt mixed with No Ox grease All of these are high in resistance so make sure the test leads have good connection to the metal surfaces 3 4 3 Taking the Readings After the test leads are connected press TEST for at least one second The following occurs e A check is done for excessi
62. module The Cellcorder will report an error message and not allow calibration to continue 1 Using the multimeter three lead test leads supplied with the Cellcorder connect the Cellcorder to a 2V test cell with a 100 Amp 100 mV shunt in series with one of the load cables See figure below 2 Connect the small black clip to the same point the large black clip is connected to Refer to the following figure CELLCORDER 2V BATTERY Black Clip Figure 2 Cellcorder Connections 3 Connect the HP 5 digit voltmeter or equiv across the shunt 4 From the Calibration menu select option 4 Current 5 To start the test press TEST 33 6 7 Press the UP and DOWN arrow keys until the reading on the Cellcorder matches the current value mV reading across the shunt read across the shunt NOTE After the TEST key is pressed this test allows current to flow for only 10 seconds before de energizing the load relay This prevents overheating of the load resistors and leaving the Cellcorder in a loading condition To resume the test press ESC and select option 4 current again Record the current reading from the Cellcorder onto the Calibration Log under Current at 2V After Calibration 3 8 4 6 Intercell Adjustment 1 2 3 4 5 6 Connect a 10mV source to the small sense clip and the large black current clip From the Calibration menu select option 5 Intercell Observe the Cellcorder read
63. ould be needed The life of the battery is directly related to how well it is charged 3 8 5 Backing Up and Restoring the Calibration Refer to the Battery Analysis User s Guide for information about backing up and restoring Cellcorder data 35 4 Appendix A Cellcorder Parts List Quantity and Description 1 Cellcorder Unit Ser No Initial 1 Power Adaptor for Cellcorder 1 RS 232 Cable 1 Voltage Lead Cable Set 2 Leads 1 Resistance Test Cable 3 Leads 1 Cellcorder Operation Manual 1 Battery Analysis Software BAS 1 BAS Manual 1 Carrying Case 1 Quick Start Card 1 Warranty Card Checked By Date 36 5 Appendix B System Specifications Reading Range Accuracy Voltage 0 16 00 volts 0 1 of reading 1 LSD Cell Resistance 0 99 99 milliohms Readings are repeatable from 2 to 5 Refer to Albercorp Application Note CC 001 for details Intercell Resistance 0 2 000 milliohms 0 25 of reading 2 microhm Power Source 8V 5 amp hour battery Will power unit for up to 6 hours Display Screen 4 Line x 20 character bright vacuum fluorescent Weight 8 5 pounds Not including leads or carrying case Dimensions 11 5 wide 10 deep 4 high Warranty One year from date of purchase Note Specifications are subject to change without notice 37 6 Appendix C Cellcorder Calibration Log General Information
64. rameters menu upload readings voltmeter voltmeter screen warning messages
65. s manufacturer be contacted Above 43 a load test be done 45 ASAP Actually the standard is expressed in the reciprocal of internal resistance conduc tance mhos DATA ANOMALIES Another part of the battery literates fantasy is also likely to be shattered that all the data gathered for the baseline or test readings taken afterward would fall reasonably close to any trendline That is higher capacity cells will have uniformly lower internal resistances and lower capacity cells will have proportionately higher internal resistances Even cells fresh off of a tightly controlled production line fail to completely conform with this expected behavior In the course of your own testing you will find tested high capacity cells with an unusually high internal resistance Similarly there will be cells with the ow internal resis tance characteristic of a good cell that would fail a capacity test Unfortunately the current state of the art does not permit impedance conductance admittance or resistance testing to definitively identify the cells with anomalies without the assistance of a load test If you are fortunate to have large amounts of both capacity and corresponding internal resistance data developing a baseline should be no problem When a program is just start ing or there are few cells of a particular mod el some educated guess timating helps in sorting out data If you need baseline data try call
66. section describes the receiving and initial testing of the Cellcorder 2 1 Unpacking Upon receipt of the Cellcorder inventory all contents of the shipment If there is any visible damage to the case or box notify the freight carrier immediately for a damage claim Unless otherwise noted shipment of the unit is F O B Boca Raton Florida Any shipping damage claims must be made by the purchaser directly to the freight carrier The Cellcorder is designed to provide many years of service The components of the Cellcorder are like those in a computer and proper care should be provided when handling The carrying case will help protect the unit from minor bumps during daily use Verify that all contents are in the box and carrying case Each system should include the materials described in Cellcorder Parts List This equipment has passed several phases of quality control however if any of the contents are missing contact Alb rcorp immediately 2 2 Cellcorder Initial System Test Connect the AC adaptor to the POWER port on the rear of the Cellcorder then plug the adaptor into a wall receptacle The CHARGE indicator should light Do not connect any other leads to the unit at this time Press the ON key on the front of the Cellcorder After a series of beeps and a system self test the unit defaults to the Cellcorder Main Menu _ _MAIN MENU 1 MODE SELECT 2 DIAGNOSTICS 3 SETUP NOTE An asterisk on
67. surement will might save you further testing and false alarms Similarly cells chilled by air conditioning exhibit higher readings than their sheltered neighbors If possible try to re direct the air flow THE CELLCORDER The Cellcorder is invaluable in determining what a battery or cell s internal resistance is and in helping to identify abnormal conditions and normal aging While a battery or cell is on line it accurately and repetitively measures the internal resistance using DC techniques The AC filtering currents stray 60 hertz fields noise and normal float currents have virtually no effect on its readings The authors can t help but wonder what earlier researchers could have accomplished if they had access to microprocessor and solid state technology The microprocessor of the Cellcorder permits it to not only control measurements but to also precisely time the readings and performs calculations To boot it can tell whether a reading is valid and then records the results 43 The battery manufacturers have customarily determined the internal resistance of cells using simple Ohms Law They usually measure the voltage differences and current during a battery discharge The Cellcorder does the same thing but very quickly and accurately Figure 8 reveals what happens when a battery is subjected to a load The instantaneous voltage drop when the load is applied or the instantaneous voltage recovery when t
68. t The Test button must be pressed for longer than 1 second before the test will begin WARNING The maximum voltage the Cellcorder can read is 16V Do not attempt to read Overall Volts Use a separate meter then enter the reading manually under the SG TEMP OV mode WARNING Never let any Cellcorder metal surfaces come in contact with a battery post or grounded rack while testing with the unit WARNING Do not attempt to read internal resistance of an open cell module while the battery is on line An open cell can be determined by the abnormally high voltage across it and the low voltage across all other cells modules Refer to Application Note CC 001 for further details 1 Introduction This section describes the features of the Cellcorder 1 1 General Description The Alb rcorp Cellcorder is a data storing battery multimeter that provides fast accurate information in a fraction of the normal test time Compact and light weight in design this intelligent test unit displays and records readings of cell float voltage internal cell resistance and intercell connection resistance Other data such as specific gravity and temperature can be entered manually The Cellcorder may be used on a single cell or multicell module Readings up to seven strings of 256 cells each or 28 strings of 64 cells can be stored and displayed on a bright fluorescent display The Cellcorder features are further enhanced by a comp
69. the other end Make sure no potentially damaging voltage is present POWER UP the Cellcorder before connecting it to a battery This activates additional protective circuitry CLEAN UP is also important especially in preserving the jaws and clips of the test leads Wipe off all grease and then apply an acid neutralizing solution REFERENCES 1 ANSI IEEE 450 1995 IEEE Recommended Practice for Maintenance Testing and Replacement of Vented Lead Acid Batteries for Stationary Batteries ANSI New York NY 1995 2 ANSI IEEE PAR 1188 IEEE Recommended Practice for Maintenance Testing and Replacement of Valve Regulated Lead Acid Batteries for Stationary Batteries ANSI New York NY 1994 3 E Willihnganz and P Rohner Battery Impedance Farads Milliohms Microhenries AIEE 1959 4 S DeBardelaben Determining the End of Battery Life Intelec 86 Toronto Canada 5 S Misra T Noveske L Holden S Mraz Use of AC Impedance Conductance and DC Resistance for Determining the Reliability of VRLA Battery Systems Intelec 93 Paris France 6 Y Konya T Takeda K Takano M Kohno Et Al 4 Deterioration Estimating System for 200 AH Sealed Lead Acid Batteries Intelec 94 Vancouver B C 7 K Peters Ten Years Experience of VRLA Batteries in Telecommunications Service May 1994 8th Battery Conference amp Exhibition Solihull UK 8 Johnson Controls Impedance and
70. uter link and software that allows the transfer of readings to a personal computer PC for further analysis and report generation 1 2 Test Procedure Overview The Cellcorder is a self contained battery powered unit comprised of a microprocessor load resistor display and rechargeable battery Two sets of test leads are provided a standard set of digital voltmeter probes and a three clip set used in the multimeter mode Optional test leads are available from Alb rcorp When using the three clip set connect the two larger test clips across the cell and its associated intercell connector from the positive post of the cell being tested to the positive of the next cell and connect the third smaller conductor clip to the negative terminal of the cell being tested Refer to Application Note CC 002 After the leads are connected the test sequence is initiated First the Cellcorder reads and records the cell float voltage Next the unit connects a fixed resistance across the cell and intercell being tested and forces a current of approximately 70 Amps to flow for a few seconds During the load condition the unit reads the current and voltage and calculates the intercell connection resistance and internal cell resistance Upon completion of testing you can connect the Cellcorder to a PC compatible computer via the RS 232 serial port and initiate the menu driven data extraction analysis and report program The imported information can be d
71. ve intercell voltage e Float voltage reading is stored unless already stored in voltmeter mode e A 70 Amp load is connected across the two current carrying conductors NOTE This is a 50 Amp load if the test is for 4V through 12V modules e While the current is flowing typically 3 to 4 seconds the display indicates READING If for some reason the test current is less than 20 amps the test stops and the screen displays a message to check test lead connections The leads are either connected wrong or there is a bad connection on one of the current leads The Cellcorder measures the current flow cell voltage and intercell voltage and calculates both internal and external resistances e The screen displays the internal cell resistance Rc and the intercell resistance Ric 15 The test leads can now be moved to the next cell The cell number display automatically indexes to the next higher number as soon as the cell voltage sense leads are lifted If the test requires taking two or more separate intercell readings the display fills in the first resistance reading when TEST is initially pressed and fills in the next reading after the test leads have been moved and TEST is pressed a second time In this case the cell display does not automatically index until the last resistance reading has been taken Allow 15 seconds between tests If TEST is pressed immediately after a test the following message appears _ MULTIMET

4200-001 Rev 5.0

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