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C7000 & C7000ER Battery Analyzer User`s Manual Notes

1. 1234567890 Bar Code Label with Battery ID CADEX ELECTRONICS 19 Jan 2000 1234567890 Service Date Battery ID PASS 92 CADEX ELECTRONICS 19 Jan 2000 Battery Labels with capacity and 1234567890 545mOhm resistance readings 48 C7000 amp 7000ER Battery Analyzer V3 5 True and False Statements Option Custom Programs 7 Description THEN Goto Next Phase THEN Goto Phase 1 THEN Goto Phase 2 THEN Goto Phase 3 THEN Goto Phase 4 THEN Goto Phase 5 THEN Goto Done THEN REPEAT 0 times THEN REST for 000 00 00 THEN FAIL Go to the next phase Go to Phase 1 Go to Phase 2 Go to Phase 3 Go to Phase 4 Go to Phase 5 Go to Phase Done Repeat actions in the current phase by the number of times specified Available settings 1 8 and Forever If Forever is selected the cycle repeats for 255 times Refer to IF Loop Count Max and the IF Loop Count Max in Test Apply no current for the specified time period in hhh mm ss format The Resting xx xx message code 19 is displayed After resting the program goes to the next phase Fail the battery The battery is electrically disconnected and the Fail 16 code will be displayed with the FAIL light on 37 Phase Done Example Option Description System Setup 9 Ready No Charge Complete the program The READY light will be on and no trickle charge is applied Ready Trickle Charge Trickle charge the battery accor
2. 27 Extended C Code Parameter Description Charge Rate Discharge Rate Trickle Charge Rate NiCd and NiMH only Recondition Discharge Rate NiCd and NiMH only Capacity Offset Temperature Sensing Negative Slope NiCd and NiMH only A 1000mAh capacity with a charge current of 500mA will have a Charge C rate of 0 50C A lower Charge C rate reduces the charge current and increases service time The maximum charge current is 2000mA 2A A 1000mAh capacity with a discharge current of 500mA will have a Discharge C rate of 0 50C A lower Discharge C rate reduces the discharge current and increases service time The maximum discharge current is 2000mA 2A Amount of trickle applied to maintain the charge ona battery after service From 1 to 10 in increments of 1 A slow and gradual discharge after the battery reaches the End of Discharge voltage During this process the crystalline build up memory on the cell plates dissolves and the battery often restores itself From 2 to 20 in increments of 2 Adjusts the capacity readings when discharging a battery at a higher or lower C rate than specified by the manufacturer Mainly used for SLA batteries From 50 to 49 in increments of 196 The temperature range in which a station will service the battery Effective only for batteries or adapters equipped with temperature sensor A measure of the voltage drop when the battery reaches full charge The
3. Resistance of battery is too high Discharge battery before performing the OhmTest Invalid value in selected C Code Modify the C Code or delete and re enter the C Code The C Code is not compatible with the firmware the adapter could have been configured with a newer firmware Delete and re enter the C Code reset the Extended C Code to default values or upgrade the analyzer with the latest firmware Adapter is detected on a station Global message should be displayed If not remove and re insert adapter If the message persists re enter the C Code Adapter is not programmed with a C Code or the C Code is invalid Re enter a C Code Adapter is removed from a station If message persists press Esc Adapter is not recognized by the analyzer Remove and re insert the adapter Clean the gold contacts on the underside of the adapter Reset the Extended C Code to default values or delete and re enter a C Code The analyzer is not able to supply current to the battery through its current drivers Very low values of current about OmAh may be displayed on the analyzer before this code appears and processing stops Check and replace the station fuse If fuses are ok then the current drivers could have failed on the analyzer Before calling Cadex for service check the following items for other causes of faults Ensure that battery and adapter contacts are clean Verify that mAh rating of the battery matches the C Code mA
4. Battery temperature is below set value when inserted The battery will automatically start processing when temperature reaches minimum value set in the C Code Warm the battery to room temperature For non OEM battery turn off temperature sensing in the C Code see code 14 Battery over temp Battery temperature is too hot when inserted Cool the battery or use the analyzer in a cooler room For non OEM battery turn off temperature sensing see code 14 Battery over temp Battery Configuration C Codes 6 Selecting Correct Voltage The voltage is based on a nominal cell voltage of 1 2V Cell for NiCd and NiMH 2V Cell for SLA and 3 6V Cell for Li lon On some NiCd and NiMH batteries manufacturers may rate their batteries based on 1 25V Cell rather than 1 2V Cell In this case as an example the batteries may state 7 5V or 12 5V To obtain the correct voltage multiply this voltage by 0 96 to get the correct value to use Test results are not affected by this change since these voltages are definitions only Some manufacturers may state the number of cells of their batteries To get the correct voltage multiply the number of cells by the chemistry type For example the voltage of a 6 cell NiCd would be 6 x 1 2V 7 2V Use 7 2V on the analyzer Intrinsically Safe Settings gt Before servicing intrinsically safe I S batteries select the following settings Charge method DC Charge End of Discharge 0 96V Cell Charge
5. If the number of cycle the loop count is less than the value set in THEN REPEAT 0 times of the True statement or ELSE REPEAT 0 times in the False statement go to the True statement Otherwise the False statement is selected If the number of cycle the loop count is more than the value set in THEN REPEAT 0 times of the True statement or ELSE REPEAT 0 times in the False statement go to the True statement Otherwise the False statement is selected BATTERY SERVICE REPORT Company CADEX ELECTRONICS Date 01 19 2000 Time 16 47 11 BATTERY STATUS Battery STATION 2 Battery ID 1234567890 Current Cycle PROCESS COMPLETE Cycle Capacities 3096 8296 9896 Battery Resistance 122m Q Cell Voltage 3 91V cell Charge Cycles 3 Discharge Cycles 3 Recondition Cycles 0 Elapsed Time 0 Days 6 Hours 40 Minutes BATTERY PARAMETERS Battery C Code 40 02 016 0505 505 3407 Program Auto Target Capacity 8096 Battery Type 42 Lithium lon Number of Cells 2 7 2V Battery Rating 400mAh Charge Rate 0 50C 200mA Max Charge Voltage 4 10V Cell Discharge Rate 0 50C 200mA End Discharge 4 10V Cell End of Charge 0 10C 40mA Max Standby Voltage 4 05V Cell Capacity Offset 096 Temperature Sensing 5 C 45 C FAULT CODES FINAL STATUS Ready Printing Report or Label Select the report or label on the menu 10 Battery Service Report Please visit the Cadex Web site for a print sample of the
6. 208 ADAPTER NOT SETUP FAIL 208 209 ADAPTER DATA INVALID FAIL 209 210 BAD ADAPTER FAIL 210 211 NULL C CODE IN ADAPTER FAIL 211 212 PIC COMMUNICATIONS ERROR PIC ERROR 65 Code Detail Global 031 DISCHARGE CYCLE COMPLETE END CYCLE 032 CYCLE RESUMED RESUMED 033 USER PROGRAMMED TIMEOUT END CYCLE 034 BATSHOP MODE WAIT BATSHOP 035 SM BUS ADAPTER INSERTED SM ADP IN 036 SMART BATTERY INSERTED SM BAT IN 112 CELL MISMATCH WARNING 113 PLATEAU TIMEOUT WARNING 115 TARGET CAPACITY NOT MET WARNING 118 SOFT BATTERY STEP DOWN WARNING 120 OVER VOLTAGE FAIL 120 121 SHORTED OR REVERSED SHORT REV 122 BATTERY SHORTED FAIL 122 123 LOW VOLTAGE TIMEOUT 1 FAIL 123 124 LOW VOLTAGE TIMEOUT 2 FAIL 124 125 NO SLOPE TIMEOUT ZONE 1 FAIL 125 126 LOW VOLTAGE NEGATIVE SLOPE FAIL 126 127 LOW VOLTAGE TIMEOUT 3 FAIL 127 128 SOFT BATTERY FAIL 128 129 INTERMITTENT BATTERY FAIL 129 130 CURRENT RISE WARNING 135 RESISTANCE THRS EXCEEDED FAIL 135 142 DISCHARGE TIMEOUT FAIL 142 144 CHARGE TIMEOUT FAIL 144 146 RECONDITION TIMEOUT WARNING 150 THERMISTOR FAILURE FAIL 150 152 LOW VOLTAGE TEMP RISE FAIL 152 154 CHRG COMPLETE TEMP RISE WARNING 156 HOT AT LOW VOLTAGE FAIL 156 158 CHARGE COMPLETE HOT WARNING 159 TRICKLE CHARGE OVERHEAT FAIL 159 160 BAD FUSE OR DRIVER FAIL 160 64 C7000 amp 7000ER Battery Analyzer V3 5 5 Battery Service Programs The Cadex analyzer can be programmed with any combination of service functions to suit special battery needs The 10 pre prog
7. Life Cycling Discharge Only Extended Prime and 4 programmable Custom Programs Function Use Tests internal resistance against the user definable Resistance Threshold Passes or Fails the battery Measures length of time a battery can provide a given current and remain above its End of Voltage Runtime Cycles are editable Reads fully charged battery capacity recharges and reads the capacity again after a user definable wait period If the second reading is lower by 30 or more the battery is failed Continuously cycles battery until capacity drops below Target Capacity Displays initial and final capacity OhmrTest result and self discharge readings if self discharge is included Discharges a battery to its End of Discharge voltage Applies a 16 hour trickle charge followed by cycling to obtain peak capacity Fully programmable by the user See Custom Programs 22 C7000 amp 7000ER Battery Analyzer V3 5 Check if the battery is in good condition Determine if the battery requires to be further analyzed Tests runtime of batteries for wireless communications equipment Identify high self discharge on batteries that otherwise may have good capacity readings Verify battery life cycle Estimate performance time Determine residual capacity of battery Prepare batteries for storage Warning Do not store Smart Batteries in discharged state See on p 21 Determine battery performance under l
8. Press To Fn 5 Fn 7 Fn 8 View number of batteries serviced View firmware version Calibrate adapter station You can also calibrate adapter station using the menu Refer to Calibrating Station 15 3 16 Lights LEDs Light Status Explanation RUN Yellow on READY Green on flashing FAIL Red on flashing All flashing randomly C7000 amp 7000ER Battery Analyzer V3 5 Service completed Service in progress Cold battery Service resumes when battery warms up Code 12 Battery failed Hot battery Service resumes when battery cools down Code 13 System failed Turn off the analyzer and turn it back on Contact Cadex if the condition persists Services and Upgrades 13 Replacing the Station Fuses Each station is protected by its own fuse An open station fuse is identified by the absence of charge or discharge current with a battery in service and or a message shown on the display such as code 160 Bad fuse or driver Cadex P N 52 526 0250 Model Station Fuse Size All F2 5 Amp 250V 5x20mm Littlefuse 217 02 5 Replacement Standard Model C7000 1 C7000 2 C7000 9 1 Remove all batteries and adapters turn off the analyzer and unplug power cord 2 Unscrew the 3 screws located on the rear The cover will still be attached to the analyzer by a grounding strap Put the cover to one side Rear Cover Screws 3 Remove the open fuse from the holder taking c
9. S1 Press ENTER and verify settings then ENTER again to START Warning Make sure that the battery contacts are clean before inserting the battery otherwise melting can occur To clean the battery contacts use a lint free cotton swab dipped in 100 6 Isopropyl Alcohol 3 View the battery configurations C Codes by pressing the ENTER key Nominal Voltage Program Setting Battery Chemistry Capacity 1 C4 NiMH 6 00V 500mAh Auto Press CCCode to Edit T Station C Code Refer to Battery Configuration C Codes for details on C Codes If the active C Code indicated by the is correct proceed to step 7 to start service 17 4 Select the correct C Code gt Use the 4 S2 and S1 keys to scroll through the available C Codes in the adapter then press ENTER when the correct C Code is displayed Press ENTER again to confirm the selection The selected C Code now becomes active indicated by the k If a Smart Cable Adapter is first used create a custom C Code gt Press CCode gt Use the N S2 and S1 keys to select or the keypad to enter the settings Advance or go back using the S4 and S3 keys gt Press ENTER and select Yes Now you can proceed to step 7 to start service Refer to Battery Configuration C Codes to add or edit C Codes gt Warning Always use the correct C Code especially the correct chemistry Failure to do so may cause damage to the ba
10. The Charge rate in the Extended C Code may have to be lowered Observe battery performance The battery may be old For non OEM battery turn off temperature sensing Generally for SLA only Battery current suddenly increased as the End of Charge condition was achieved If the SLA battery is a Hawker cell use the Hawker C Code settings refer to Default Settings for Extended C Codes Allow the station to complete service Power resumed or the battery is re inserted into the adapter The analyzer is not able to discharge the battery Very low values of current lt 50mA are displayed on the analyzer before this code appears See code 160 Bad fuses or driver Discharge cycle completed Program is going into the next step Parameter Battery Configuration C Codes 6 Description End of Discharge End of Recondition NiCd and NiMH only Charge Method NiCd and NiMH only Max Standby Voltage SLA and Li lon only Max Charge Voltage SLA and Li lon only End of Charge SLA and Li lon only The threshold point at which the discharge cycle is terminated Chemistry dependent Available settings 0 76 1 12V Cell NiCd NiMH 1 36 1 95V Cell SLA 2 30 3 20V Cell Li lon The threshold point at which the reconditioning cycle is complete Available settings Disabled or 0 40 0 80V Cell Allows setting of Reverse Load The Reverse Load method intersperses discharge pulses between charge pulses to keep b
11. messages 52 by code 63 65 by detail 53 62 Overview The Cadex C7000 and C7000ER Battery Analyzers are sophisticated programmable battery analyzers capable of servicing batteries with different electrical properties and mechanical dimensions Product Features Service Nickel Cadmium NiCd Nickel Metal Hydride NiMH Sealed Lead Acid SLA and Lithium lon Li lon The C7000 and C7000ER are also capable of supporting Smart Batteries based on the single wire and SMBus system Operate each station simultaneously and independently of each other Support over 600 interchangeable Battery Adapters for easy interface with most commercially available battery models The Battery Adapter contains the battery configuration code also known as C Code which automatically sets the analyzer to the correct parameters for serving the battery Each adapter contains 10 C Codes to accommodate different batteries in the same product family Offer a variety of programs for battery services 3 Basic Programs Auto Charge Prime 6 Specialty Programs and 4 user programmable Custom Programs Easy to use menu driven interface plain English messages and status lights Support fleet management Support bar code entry print Bar Code Labels and Battery Labels and produce a range of reports Can be networked for automated battery maintenance with BatteryShop Safety Notice and Warranty 16 What s New in the C7000 V3 5 firmware War
12. transcribed stored in a retrieval system or translated into any language or computer language in any form or by any means without the express written permission of Cadex Electronics Inc Cadex Electronics Inc reserves the right to revise this publication and make changes in its contents without obligation to notify any person of such changes Trademark CADEX is a registered trademark of Cadex Electronics Inc All other trademarks mentioned herein are the property of their respective owners 89 207 1001 Rev 8 March 2000 Printed in Canada Overview 1 Prod ct FeatUres dee eir ett neis 1 What s New in the C7000 V3 5 firmware ee 2 Firmware Upgrade Resetting the System iese see ee ee ee ee ee ee 3 Connecting to BatteryShop M ee ee ee Re ee ee Re ee ee 3 Peripherals nii OE ER EE ER EA N 4 Getting Started 5 Contents oF BOX iere ee scie EE 5 About this Manual rette e tee aeneis 5 Converitions croi EER nen VE e 5 Symbols EE ER N ET RE eer N 6 Abbreviations and Acronyms ees ee ee RR Re ee ee ee ee ee 6 Commonly Used Terms ee ee ee ee ee ee ee ee ee ee ee 7 Operating Principles 8 Seile els ORR ER OE e ERU EHE e OE ER ER EE AN ra 8 Option Boards 2 5 OE RE NE te 9 Gombponerts 2 2 nct tiet ee eg ets 9 Battery Adapters isso iss ueni iE dues 10 Special Handling Tip for Smart Cable Adapters sssss 11 MAG ER ER LL 12 BILE 12 ME RR EE RR RE EE 14 GOMMANGS E
13. 72 C7000 amp 7000ER Battery Analyzer V3 5 13 14 Menu The menu driven interface allows access to the various functions of the analyzer Refer to the individual functions for details and instructions SYSTEM ENTER Set Securit SECURITY EMEN Change Password Remove Security s2 SYSTEM ENTER Date Time SETUP Battery Startup N Program Settings Company Name Calibration st se Output Devices Sound Control Voltage Display PRINT enter Battery Service Report UTILITIES ace Battery Label A Bar Code Label System Setup Report Auto Print ee v EVENT LOG enter gt View Event Log Print Event Log Clear Event Log Events to Log 1 2 to scroll ENTER to select Esc to exit C7000 amp 7000ER Battery Analyzer V3 5 PROGRAM _ ENTER Auto SETTINGS s Charge Prime SPECIALTY PROG PROGRAM ENTER _ OhmTest SETTINGS Runtime Self Discharge Life Cycling Discharge Only Extended Prime Custom 1 Custom 2 Custom 3 Custom 4 BASIC PROGRAMS l CALIBRATION ENTER Voltage Calibration Station Calibration OUTPUT _ enter Serial Port Device DEVICES Serial Port Settings Parallel Port Device v BatteryShop Services and Upgrades 13 Replacing Backup Battery with OP 70 or OP 72 only An analyzer equipped with the OP 70 or OP 72 option board contains a backup ba
14. Allow cold batteries to warm up and hot batteries to cool before charging Use only a grounded AC outlet to power the analyzer Do not attempt to charge non rechargeable batteries such as alkaline carbon zinc or non rechargeable lithium Do not short the positive and negative battery terminals together at any time Do not connect leads from one station to another or to the case An electrical short to any point outside the station bypasses the current regulation loop and may cause a fuse to blow and or damage to the unit Do not exceed the manufacturer s recommended charge current and voltage limits for batteries Do not restrict the airflow of the analyzer Leave the fan opening clear Fan operation is automatic 81 Safety Notice and Warranty Radio Interference 80 This equipment generates uses and can radiate radio frequency energy and if not installed and used in accordance with the instruction manual may cause interference to radio communications It has been tested and found to comply with the limits for a Class A digital device pursuant to Subpart B of Part 15 of the FCC Rules which are designed to provide reasonable protection against such interference when operated in a commercial environment Operation of this equipment in a residential area may cause interference in which case the user at his own expense will be required to take whatever measures required to correct the interference EN55022 Warning This i
15. Battery voltage rising too quickly while charging Analyzer down is cutting the Charge rate in half and will attempt to Start battery process START Station calibrating CALIBRATE Station off line OFFLINE Suspended Process INTERRUPT Aborted Target capacity not WARNING met Temperature hold SYS TEMP Cooling complete service at lower current rate Wait until processing is complete If voltage rises again code 118 Soft battery will appear and the program terminated Charge rate in the Extended C Code may have to be reduced If the battery is new or in storage use the Prime program Battery service has started Station is in calibration Process takes about 10 seconds Station is not reading the adapter Remove the adapter and restart the analyzer Delete the C Code that was selected for the battery Make sure all your analyzers have the same firmware version number Press Alt 0 to reset the system Battery is removed during service for more than 5 seconds Program terminated For non OEM battery turn off temperature sensing Final capacity of the battery is below the Target Capacity The analyzer will attempt to improve the capacity by reconditioning the battery Wait until processing is complete The Auto and Prime programs will attempt to correct this warning If corrected code 195 Cap improved to target will appear Check that the mAh rating of the battery matches the C Code mAh setting Battery may be old and o
16. Code Set Security Change Password Remove Security Time Date Program Settings Output Devices Auto Print Clear Event Log Events to Log Edit C Code Set Default C Code Set Security Change Password Remove Security Time Date Battery Startup Program Settings Company Name Calibration Output Devices Sound Control Voltage Display Battery Service Report Battery Label Bar Code Label System Setup Report Auto Print Clear Event Log Events to Log 41 Setting Security 1 Select Set Security on the menu 2 Enter the desired security level 0 1 or 2 or select the security level using the N and W keys Then select Yes to accept changes Changing Password and Removing Security gt Select Change Password or Remove Security on the menu To change the password for Level 1 and Level 2 enter the old password Then enter and re enter the new password To remove security select Yes Then enter the password 42 C7000 amp 7000ER Battery Analyzer V3 5 Feature System Setup Description Time Date Battery Startup Program Settings Company Name Calibration Shortcut Fn 8 Output Device Sound Control Voltage Display Set up the time and date information printed on Battery Labels Battery Service Reports and Event Log Analyzers with an option board have battery backup RAM that retains dates and times on power interruption or when the analyzer is turned off Default current date
17. End of Discharge voltage For intrinsically safe battery use VS settings Refer to Intrinsically Safe Settings The battery is losing charge faster than it is being supplied into the battery in the initial charge cycle For NiCd and NiMH batteries only The Charge rate in the C Code may have to be reduced If battery is a high capacity NiCd reduce the Charge rate to 0 5C Otherwise reduce to 0 6C If all fails discard the battery 57 Detail Global Possible Reason s Solution s Charge timeout Charge wait Charging Chrg complete temp rise Current rise Cycle resumed D Discharge current low Discharge cycle complete 56 C7000 amp 7000ER Battery Analyzer V3 5 FAIL 144 CHG WAIT CHARGE WARNING WARNING RESUMED FAIL 162 END CYCLE Charge time has exceeded the expected value for the battery Check that the mAh rating of the battery matches the C Code mAh setting The Charge rate in the Extended C Code may have to be raised Station is on hold until sufficient power is available This is normal if large batteries are being serviced Service will automatically resume when sufficient power is available to the station Battery is being charged normally Battery is being charged normally but temperature is rising rapidly towards its end of charge state Wait until processing is complete An appropriate WAIT code may appear until the battery has cooled before the next process begins
18. If the ribbon cable was removed replace the cable 6 Replace the upper cover make sure the front edge of the top cover is properly inserted into the notches in the plastic cups for the C7000 and re install the e Menu Display provides access to various functions of the analyzer when Screws to secure the cover the Menu key is pressed me IEC320 Power Cord MAIN MENU 17 52 55 System Security The C7000 and C7000ER use a standard IEC320 power connector allowing you to obtain suitable power cords for connection to any standard line voltage source If you need a special power cord for your particular wall socket obtain an approved cord fitted with an IEC320 socket at one end and the appropriate local fitting at the gt Use the S1 and 4 S2 keys to scroll through the menu and press ENTER when the desired function is displayed For example you will see the following if System Security is selected other end If you obtain a universal IEC320 power cord with a socket but no plug the EE ER appropriate plug should be connected as follows Set Security 1 255 System Security Brown Line AC Hot feature Blug Neutral IEC320 Socket Ground Earth See Menu for the overview of the functions connects to Battery Analyzer Green or Green Yellow e Brown Line AC Hot e Blue Neutral AC Neutral e Green or Green Yellow Ground Earth Warning Make sure this is conducted by a licensed electrician
19. WARNING FAIL 164 END CYCLE Calibration in process Process will complete in 10 seconds Current cannot pass through shorted terminal during calibration Repeat calibration procedures An AWG 10 2 5mm wire is recommended to short contacts leads Target Capacity is achieved or exceeded after an initial warning code 115 Target capacity not met C Code is locked and cannot be edited Use an unlocked C Code or delete and re enter the C Code For NiCd batteries only The cells reach full charge at different times so the negative slope is not well defined The program proceeds to the next cycle as normal Wait until processing is complete since the Auto and Prime programs will attempt to correct this warning If corrected code 192 Cell mismatch corrected will appear The negative slope in Extended C Code may have to be increased to 32mV Cell or more Battery may be old and operating time is reduced Either monitor battery use or discard the battery If the battery is new use the Prime program Cell mismatch code 112 is corrected through several Charge Discharge cycles Use the battery as normal Battery is fully charged but the temperature is at or above the maximum set value in the C Code See code 154 Chrg complete temp rise for details For non OEM battery turn off temperature sensing in the C Code Current driver cannot provide the requested charge current See code 160 Bad fuses or driver Charge cyc
20. a RS 232 Serial Port that connects to a label printer or to BatteryShop There are 2 option boards OP 70 and OP 72 that can be purchased for additional support The C7000ER is already equipped with the OP 70 option board The option board sticker is at the back of the analyzer The option board configuration is also displayed during 6 Printing Problems Check the serial port setup of the serial printer Check that the serial or parallel port is enabled for correct print device Set the other port to Disabled start up The LabelMaker option in the Serial Port Device or Parallel Port Device of System Power Input 5 pin DIN Bar Code Wand Setup is wrongly selected Select Printer ER model on side panel RS 485 Ports Not Used Option Board instead Input Fuse Drawer Check if the serial cable is correctly configured Parallel Printer Port mm refer to Serial Port Settings for serial cable PE PECES ef 7 pin configurations ohhh 7 Battery service does not Ensure that the adapter is firmly inserted into Mi kl the analyzer On Off Switch Fan Outlet RS 232 Serial Port Check that the battery is correctly and firmly inserted into the adapter Make sure that the contacts on the battery are meeting the contacts on the adapter Note that the option board is blank unless purchased Turn on the battery switch if applicable Pre
21. an analyzer and provide battery For questions related to batteries or adapters nformalcn Target Capacity The battery capacity benchmark for pass fail set by the e Battery Model Number user e Adapter Number e C Code being used e Display message and or code 78 C7000 amp 7000ER Battery Analyzer V3 5 7 Operating Principles Components Component Ji Ventilation Grill Battery Stations Prog Key Print Key LU Esc Key M Fn Key l i Alt Ke Station LCD n N y Keys Numeric ENTER Key Indicators Keypad Menu Key Function Battery Stations Prog Key Print Key CCode Key Esc Key Fn Key Alt Key ENTER Key Menu Key Numeric Keypad LED Indicators LCD Station Keys Take Battery Adapter Access service programs and Target Capacity Print labels and reports Access battery parameters Exit menus or cancel changes Shortcuts to common functions when pressed with a second key Reset to factory defaults when pressed with the 0 key after a firmware upgrade or as a general system reboot Save settings and start servicing Access menu Enter numeric parameter settings Provide current status of batteries in service Activated when a service starts View status for each station and detailed service information View C Codes details of a service or as cursor keys in editing mode 8 C7000 amp 7000ER Battery Analyzer V3 5 9 Problem Getting Help Problem
22. charge cycle is terminated when the voltage drop reaches the set value From 16 to 64mV Cell 28 C7000 amp 7000ER Battery Analyzer V3 5 Detail Global Messages and Warnings 12 Possible Reason s Solution s Discharge timeout Discharge wait Discharging H Hot at low voltage Insert the battery Intermittent battery L Low voltage negative slope FAIL 142 DCHG WAIT DISCHARGE FAIL 156 INSERT FAIL 129 FAIL 126 Battery capacity has exceeded 250 of the rated capacity Check that the mAh rating of the battery matches the C Code mAh setting The Discharge rate in the Extended C Code may have to be raised Station is on hold until sufficient power is available Wait until other stations have completed battery service Battery is being discharged normally Battery temperature went to its maximum setting in the initial charge cycle Cool the battery to the service temperature Raise the temperature sensing in the C Code The internal cells may have shorted or the battery is old Either monitor battery use or discard For non OEM battery turn off temperature sensing Insert battery into the station Battery connection opened 5 times in 1 minute Check and clean the battery contacts Check that correct contacts are used Check that the battery is properly inserted The Charge rate in Extended C Code may have to be reduced Protection circuitry opened at End of Discharge voltage Raise
23. es agent neh 41 Setting ei ARE eg Eae OE EE iiaia 42 Changing Password and Removing Security esse ee ee ee ee 42 9 System Setup 43 Setting Up System Information see Re EA RA Re ee ee ee 44 Calibration Procedures essen enne nnnm 44 Calibrating Vot getos EE cer D Ee t De geek tex VEE Reese dt 44 Calibrating Statio cc uc ER cce teri ento e serat ce ENE e 45 OUIPUt DEVICES Rt 46 Serial Port Settings es EE Ero ced ies ie ode ciere opcs 46 Serial and Parallel Port Device Settings iese ee ee ee Re ee 47 10 Print Utilities 48 Printing Report or Label oo see ee ee ee ee ee ee ee ee ee ee ee 49 11 Event Log 50 bog Events ui utet Senge ee e EUR EE adt 51 Managing Event Log sse eee 51 12 Messages and Warnings 52 AE EE REC 53 BY COG RE EE EE OE Pee N EE EH ees 63 13 Services and Upgrades 66 Replacing the Primary Input Fuse ee 67 Standard Model C7000 1 C7000 2 C7000 9 sss 67 Extended Range Model C7000ER sss 68 Replacing the Station Fuses ees ee ee ee ee ee ee ee ee ee ee ee 69 Standard Model C7000 1 C7000 2 C7000 9 sss 69 Extended Range Model C7000ER sss 70 Replacing Backup Battery with OP 70 or OP 72 only 71 IEC320 Power Cord cecinit er reip Tode gee gre NEE See ERE teens 72 14 Specifications 73 Hardware oet iie enn uie 73 g
24. selected If the capacity during the last discharge is below the Target Capacity go to the True statement Otherwise the False statement is selected If the improvement in capacity during the last two discharge cycles is less than 596 for example the last one is 88 and the one before is 85 or 80 and 90 go to the True statement Otherwise for example 90 and 80 the False statement is selected If the improvement in capacity during the last two discharge cycles is more than 5 for example the last one is 90 and the one before is 80 go to the True statement Otherwise for example 88 and 85 or 80 and 90 the False statement is selected 35 36 Test continued Option Description IF Total Capacity lt 5 IF Total Capacity gt 5 IF User Defined Timeout IF Loop Count lt Max IF Loop Count gt Max C7000 amp 7000ER Battery Analyzer V3 5 If the capacity during the last discharge cycle is less than 5 go to the True statement Otherwise the False statement is selected If the capacity during the last discharge cycle is greater than 595 go to the True statement Otherwise the False statement is selected If the time period set in Cycle 1 or Cycle 2 has expired before the battery is fully charged discharged or reconditioned go to the True statement Otherwise the False statement is selected For Trickle Charge and Rest the program will proceed to the True statement only
25. specified time period in hhh mm ss format The Reconditioning Discharge rate is set in the Extended C Code This cycle will be skipped for SLA or Li lon as these chemistries cannot be reconditioned This cycle can only be applied after a discharge cycle Trickle charge the battery for the specified time period in hhh mm ss format The Trickle Charge rate is set in the Extended C Code and only applies to NiCd NiMH Apply no current for the specified time period in hhh mm ss format The time must be specified or the cycle wil be skipped Perform the OhmTest on the battery In this case the resistance threshold is not definable Log Events Log Event 11 Description Errors Warnings System Events Battery Events Battery Cycles Echo to Printer Managing Event Log Problems that stop the service Problems that do not stop the service but may affect the battery performance Events recorded by the system Battery completion events in the battery s service cycle Detailed events in the battery s service cycle Whether to send the events to the printer gt Select the feature on the menu To view the event log use the N and vv keys to scroll through When you reach the end of the log you can go back to the first event by pressing the 4 key twice Press Esc to exit To clear the event log select Yes to confirm To cancel press Esc To specify events to log select Yes to activate or
26. to positive and negative terminals Custom Adapter Smart Cable Adapter Universal Adapter Dual station Custom Adapter 10 C7000 amp 7000ER Battery Analyzer V3 5 Getting Help Problem Solving Troubleshooting The common problems and solutions listed below will answer most of your questions The detailed alphabetical list of display messages in Messages and Warnings can help to sort out problems not listed here If personalized help becomes necessary contact Cadex Technical Support Problem The C7000 does not power up The fan turns off and on even when no battery is being analyzed Password is not accepted even though no password is stored in the analyzer Dates are changing or negative dates are appearing Bar Code Wand reads intermittently Possible Reason s Solution s Check that the power input on the rear label is correct Make sure that the power cord is firmly inserted in the back connector Check the input fuses This is normal Replace the backup battery Replace the backup battery Use correct bar code format C Code 2 of 5 ID 3 of 9 or bar 128 format The label is damaged or dirty A fast swipe reads better than a slow swipe Try a different angle and speed Artificial lights fluorescent lights and direct sunlight can affect the wand 75 Firmware Firmware Version Version 3 5 Supported Chemistries NiCd NiMH SLA Li lon Supported Settings
27. 20 analyzers to service 480 batteries simultaneously e Contains a database of over 2000 battery models that provides easy access to C Code settings and other information Even a novice user can perform a variety of tests and programs Refer to Serial and Parallel Device Settings or BatteryShop Help on preparing the analyzer for BatteryShop To find out how BatteryShop can enhance your battery maintenance system contact Cadex 1 Peripherals The C7000 and C7000ER support the following peripherals to maximize performance e Epson compatible dot matrix printer to print reports e Label Printer to print labels The DYMO LabelWriter SE300 is recommended For more information on label printers contact Cadex or DYMO CoStar e Bar Code Scanner to scan bar coded labels The bar code scanner is included with the purchase of the OP 72 option board C7000 amp 7000ER Battery Analyzer V3 5 16 Explosion Hazard Batteries can burst if treated improperly Follow these precautions at all times v Clean battery contacts before servicing Press the battery firmly into the adapter to ensure a good connection Ensure that the selected C Code is correct for the chemistry voltage and current rating of the battery being serviced Observe battery temperature Stop service if battery becomes very hot Service batteries between 0 C 32 F and 60 C 140 F Fast charging outside this temperature range may cause damage to the battery
28. Acronyms Abbreviation Name or Term AWG BMS LCD LED Li lon NiCd NiMH OEM RF P N SLA American Wire Gauge A U S wire size standard Battery Maintenance System Liquid Crystal Display Referred to as Display Light Emitting Diode Referred to as Light Lithium lon battery chemistry Nickel Cadmium battery chemistry Nickel Metal Hydride battery chemistry Original Equipment Manufacturer Radio Frequency Part Number Sealed Lead Acid battery chemistry C7000 amp 7000ER Battery Analyzer V3 5 Getting Help Problem Solving 15 You can reach Cadex Technical Support by phone at 8 00 am 4 30pm Pacific Time GMT 08 00 Monday through Friday Technical Support Phone 1 604 231 7777 Toll Free 1 800 565 5228 US and Canada only Fax 1 604 231 7755 Email service cadex com Mail Cadex Electronics Inc 22000 Fraserwood Way Richmond BC Canada V6W 1J6 Attn Product Support 79 Getting Started 2 Manual Updates and Other References Commonly Used Terms We maintain an Internet Web site as an additional resource and reference for those who work with batteries Detailed technical and practical information about all aspects of battery maintenance is available at www cadex com Ampere Hour Ah Battery capacity or rating A battery that provides a current of 1 ampere for 1 hour is rated at 1Ah Term Explanation e Articles and Technical Papers Configuration Code Battery parameters stored in Batte
29. All Types All Types Gell Hawker All Types Voltage C7000 1 2 amp 9 1 2V 14 4V 1 2V 14 4V 2 0V 16 0V 3 6V 14 4V C7000 ER 1 2V 28 8V 1 2V 28 8V 2 0V 30 0V 3 6V 28 8V Battery Rating 100mAh 100mAh 100mAh 100mAh Capacity 24 975mAh 24 975mAh 24 975mAh 24 975mAh Charge Method Display Format Capacity Voltage Temperature Resistance Auto Service Frequency Standby Security Outputs Printer Support Reverse Load Percentage of nominal rating Volts Cell or Volts C mQ 30 Days 30 Days Constant voltage with current limit 180 Days 30 Days 3 Level Password Enabled Security Off Low High Battery Labels Bar Code Labels Battery Service Reports System Setup Reports Epson compatible dot matrix 9 pin DYMO LabelMaker SE300 Printer 74 C7000 amp 7000ER Battery Analyzer V3 5 Operating Principles Each adapter contains up to 10 battery parameters C Codes for optimal battery services Once the adapter is inserted the battery station receiving the adapter automatically chooses the last selected C Code as the active C Code Note that Smart Cable Adapters need to be programmed and the user must enter the correct C Code settings for the battery to be serviced Refer to C Codes for more information For Li lon batteries of greater than 7 2V 2 cells a custom designed adapter is strongly recommended Cadex continuously designs adapters for new battery models and also designs custom adapters for a nominal fee
30. Enter the required information or select the settings gt Use the and W keys to scroll through and select the option numbers or characters in both upper and lower cases gt Use the gt and keys to move the insertion point 3 Select Yes to accept changes Calibration Procedures CALIBRATION ENTER Voltage Calibration Station Calibration Calibrating Voltage You need a calibration kit P N 92 770 0210 This kit can be purchased from Cadex or through your Cadex Representative The C7000 calibration kit consists of 4 calibration adapters P N 07 130 0000 and an instruction sheet P N 89 204 1017 Servicing the Voltage Calibration Adapters Return the Voltage Calibration Adapters to the factory every 3 years for authorized calibration Call Cadex for a Return Authorization number 44 C7000 amp 7000ER Battery Analyzer V3 5 some features System Security The C7000 and C7000ER offer three security levels for protection against tampering Level 0 Off is the default Level 1 Low and Level 2 High Depending on the security level you will be asked to enter the password for A password must have at least 3 digits You can control the access to the features by setting the security level Password Requirement Level 0 Off Level 1 Low Level 2 High C Code Not required Security Not required System Setup Not required Print Utilities Not required Event Log Not required Edit C
31. No to de activate Use the gt and keys to toggle between the events Then select Yes to accept changes 51 50 Event Log Test The Event Log stores the last 50 selected event data for later viewing or printing This allows tracking of general battery service trends identification of potential problems and tracing battery or system events Feature Description View Event Log View the last 50 events in the event log Print Event Log Print the event log Clear Event Log Clear all events in the event log Events to Log Specify events to record or ignore DATE TIME STN CODE DESCRIPTION 01 18 2000 14 07 0 200 POWER ON 01 18 2000 14 07 0 1 201 ADAPTER INSERTED 01 18 2000 14 07 0 2 201 ADAPTER INSERTED 01 18 2000 18 57 0 1 115 TARGET CAPACITY NOT MET 01 18 2000 19 00 0 1 26 BATTERY REMOVED 01 19 2000 10 25 0 2 18 PROCESS SUSPENDED 01 19 2000 10 25 0 2 188 SUSPENDED PROCESS ABORTED 01 19 2000 10 25 0 2 17 BATTERY REMOVED Event Log C7000 amp 7000ER Battery Analyzer V3 5 Custom Programs 7 Test provides the condition for selecting the True or False statement Option Description Skip Test IF Target Capacity Met IF Target Capacity Not Met IF 596 Capacity Increase IF 596 Capacity Increase Go to the True statement The False statement is ignored If the capacity during the last discharge cycle meets the Target Capacity go to the True statement Otherwise the False statement is
32. Notes C7000 amp C7000ER Battery Analyzer User s Manual Disclaimer While every effort is made to ensure that the information contained in this manual is accurate and up to date Cadex Electronics Inc does not warrant or guarantee the accuracy of the contents of this manual Further Cadex makes no warranties either expressed or implied as to the merchantability or fitness for a particular purpose of the C7000 and C7000ER Battery Analyzer equipment and or its documentation In no event will Cadex or its officers or employees be responsible for any consequential incidental or indirect damages including damages for loss of business profits business interruption and the like arising out of the use or inability to use the C7000 and C7000ER Battery Analyzer equipment and or its documentation Year 2000 Compliance All functions and performance of the Cadex C7000 and C7000ER Battery Analyzers are independent of the date stored in the analyzer Therefore all functions and the performance of the C7000 and C7000ER Battery Analyzers are not affected by dates during and after the year 2000 Cadex Electronics Inc 22000 Fraserwood Way Richmond British Columbia Canada V6W 1J6 Tel 1 604 231 7777 Fax 1 604 231 7755 Web www cadex com Email info cadex com Copyright Copyright 2000 by Cadex Electronics Inc All rights reserved No part of this publication or the firmware controlling Cadex product s may be reproduced transmitted
33. Please contact Cadex for a current adapter catalog or download a copy from our Web site www cadex com Special Handling Tip for Smart Cable Adapters gt Insert a battery only when the Smart Cable Adapter is inserted into the station Likewise do not remove the adapter before the battery is removed 11 3 User Interface Display e Global Display provides status information of stations and batteries in service at a glance Adapter inserted Adapter ju inserted EMPTY EMPTY NO ADAPT NO ADAPT Auto Charge Program Process CHARGE EMPTY NO ADAPT NO ADAPT 1 35V Charge Voltage Current e Detailed Display provides detailed information about the battery service or station when the appropriate station key is pressed For example during a service in Station 1 the following is displayed when the S1 key is pressed Station Process 1 CHARGING 1 35V Cell 1006mA 233m2 32 C 1 05 Average Cell Voltage Pressing the station key again will give additional details such as warning codes Charge Discharge Current Resistance Program Duration hh mm Temperature cycles and program phases C7000 amp 7000ER Battery Analyzer V3 5 14 Specifications Hardware C7000 1 C7000 2 C7000 9 C7000 ER Standard Standard Standard Extended Range Part Number 07 771 0000 07 772 0000 07 779 0000 07 778 0000 Line Voltage 115VAC 10 100VAC 10 220 240VAC 5 90 250VAC Frequenc
34. Rate 0 10C Discharge Rate 0 10C The Charge rate and Discharge rate can be set to higher values to speed up servicing if no fault code appears 31 Default Settings for Extended C Codes Parameter Default Settings Charge Discharge Trickle Charge Rate Recondition Discharge Rate Capacity Offset Temperature Sensing Negative slope End of Discharge End of Recondition Charge Method Max Standby Voltage Max Charge Voltage End of Charge 1 00C NiCd 1 00C NiMH 0 30C SLA 1 00C Li lon 1 00C NiCd 1 00 NiMH 0 10C SLA Gell 0 40C SLA Hawker 1 00C Li lon 5 NiCd 2 NiMH 12 NiCd NiMH EER ER EER ORE RR 0 Disabled adapters without temperature sensor 0 45 C NiCd NiMH SLA 5 45 C Li lon 32mV Cell NiCd 16mV Cell NiMH 1 00V Cell NiCd NiMH 1 75V Cell SLA Gell 1 62V Cell SLA Hawker 3 00V Cell Li lon 0 40V Cell NiCd NiMH Rev Load 9 2 25V Cell SLA Gell 2 35V Cell SLA Hawker 4 05V Cell Li lon 2 40V Cell SLA Gell 2 60V Cell SLA Hawker 4 20V Cell Li lon 0 05C SLA Li lon 32 C7000 amp 7000ER Battery Analyzer V3 5 By Detail Detail Global 12 Possible Reason s Solution s gt 2000 MQ Adapter data invalid Adapter inserted Adapter not set up Adapter removed Bad adapter Bad fuse or driver FAIL 209 ADAPT IN FAIL 208 ADAPT OUT FAIL 210 FAIL 160
35. Solving 15 Possible Reason s Solution s Program did not resume after a power failure Single cell gives inconsistent results Capacity readings between stations are inconsistent Resistance readings are consistently high Battery passes on analyzer but fails in the field Check if an option board OP 70 or OP 72 is installed The option board sticker is at the back of the analyzer The option board configuration is also displayed during start up The analyzer was saving the battery information when the power failed Battery information is saved once a minute If the power fails during the information save the program will not continue when power resumes Replace the backup battery Calibrate the station Set the charge method in the Extended C Code to DC Charge due to low terminal voltage Single cells are discharging and or charging too quickly Lower the Discharge rate and Charge rate to about 0 2C Verify that the C Codes are the same between stations Calibrate the stations Calibrate the station The battery or adapter contacts may be damaged The battery is faulty Use the OhmTest If the resistance is high the battery may not be able to hold charge Use the Self Discharge program to check the difference of the last two readings If it is more than 3095 the battery fails 77 Option Boards Problem Possible Reason s Solution s All models of the C7000 and the C7000ER come with
36. System Setup Report For Battery Service Report and Battery Label press the station key of the corresponding station then select Yes to start printing For Bar Code Label specify the label type and press the station key of the corresponding station Then select Yes to start printing For auto print select the option then Yes to confirm 49 Print Utilities Battery Service Reports and Battery Labels must be printed before removing the battery with the exception of Auto Print Once the battery is removed the station resets to prepare for the next battery and the battery information is lost Report Label Description Battery Service Report Lists Battery ID type number of cells rating and cell voltage Also describes the C Code cycles performed Charge Discharge rates any applicable fault codes and final capacities Battery Label Contains company name date test result with any fault codes and the Battery ID number if available To be attached to the batteries after service Bar Code Label Contains Battery ID or C code System Setup Report Lists time date company name serial port and printer port settings event logging setup adapter setup and Custom Program information Auto Print The system automatically prints a Battery Service Report or Battery Label when a battery is removed from the analyzer after service Default setting is TEE 40 02 016 0505 505 3407 0110 Bar Code Label with C Code
37. UR 15 Function Keys doe EE it adco 15 Lights LEDS EER Ite tee EPI ee 16 Basic Battery Service 17 Servicing Batteries with Bar Code iese ee ee ee ee ee ee ee ee 20 Battery Service Programs 21 Basic PrOQralms oit uie OE RE OR ER RR HAE 21 Specialty Programs see ee Be ee ee ee eene nennen enn 22 Target Capacily ee ee P eh AE A eSI N AD eed 23 Selecting a Program or Setting Target Capacity sess 24 Editing Program Settings sse 25 Duration of Service iese ee ee ee ee ee ee ee ee ee enne 26 C7000 amp 7000ER Battery Analyzer V3 5 Notes Notes Contents 6 Battery Configuration C Codes 27 Basic 6 G0d6 3i eere ege ede Jostens oe poe erede ient 27 Extended G Code RE EE RE Ln e ure d seein 28 Viewing C Codes ee ee ee ee ee seen 30 Managing Gs Codes 1 3 RE EER EG Se N a ee E eI a ee ee og 30 Selecting Correct Voltage ees ee ee ee ee ee ee ee Ge ee ee 31 Intrinsically Safe Settings 0 0 eee ee ee ee ee ee ee ee ee ee 31 Default Settings for Extended C Codes iese ee ee ee ee Re ee ee 32 7 Custom Programs 33 Cycle Tand Cycle 2 RE EE EE OE OR satan ER teats 34 SEE EE EE ER EE N 35 True and False Statements essen 37 Phase DONG iri ER EE eue EE 38 Example AR RE OR ut Ee 38 Creating or Modifying a Custom Program sss 40 8 System Security 41 Password Requirement eire ee ee De
38. and time Specify if the analyzer will ask for the Battery ID and or C Code when a battery is inserted Specifying the Battery ID and C Code prevents the use of wrong settings Default No for Battery ID and Yes for Battery C Code Edit program settings Refer to Editing Program Settings Set up the company name for printing on Battery Labels and Battery Service Reports You can enter up 20 characters numbers Default CADEX ELECTRONICS Correct variations of component tolerances due to aging Calibrating the voltage once a year maintains performance specifications especially for Li lon batteries Station Calibration compensates for voltage loss from cables and electrical contacts Connect the analyzer to a printer label printer or BatteryShop Turn on or off the audible signals for Key Press events and Alert events Default Yes for both Key Press events and Alert events Set voltage display mode to Volts Cell or Volts Default Volts Cell 43
39. and turn on the analyzer 67 Basic Battery Service 4 Services and Upg rades 7 Start service by pressing ENTER The analyzer will now proceed through the instructions in the selected Caution program The display and lights show the status of the process e Unauthorized disassembly and or repair of the analyzer by other than an Status authorized Cadex Service Center will void the warranty STSERARCE NG AGAPI NOS KDART ANU ADAPT e Observe anti static precautions before and during service The circuitry 592mA used in the analyzer is sensitive to electrostatic discharge and may be damaged if not handled properly Static charge is generated through the contact of non conductive materials such as plastic bags synthetic Current Voltage mV clothing and carpeted floors gt To view details press the station key e Itis recommended that a grounded wrist and or foot band be used when S1 DISCHARGING CAP 0 1 28V Cell 592mA N AmO N A C 0 02 dismantling the analyzer If a wrist or foot band is not available firmly grasp the metal edge of the RS 232 Serial Port before touching any components Repeat often during service 8 Service is complete READY NO ADAPT NO ADAPT NO ADAPT i 620mA Warning e Before performing any service remove all Battery Adapters turn off the gt To view details press the station key analyzer and disconnect the power cord gt To remove the adapter press the latc
40. are not to touch any of the electrical components The station fuses are located in the left rear corner of the analyzer on the motherboard Station 1 Fuse Station 2 Fuse Station 3 Fuse 69 68 Extended Range Model C7000ER 1 Remove all batteries and adapters turn off the analyzer and unplug the power cord 2 Locate the fuse holder under the rear metal cover extension Fuse Holder 3 Use a small screwdriver to turn the fuse holder clockwise until it is released Then pull the holder 4 Ifthe primary input fuse needs to be replaced remove the fuse from the holder and replace the fuse 5 Insert the fuse drawer taking care that the side springs are inserted into the socket Turn counterclockwise to close the holder 6 Insert power cord and turn on the analyzer C7000 amp 7000ER Battery Analyzer V3 5 Basic Battery Service This section covers the basic general procedures on how to service a battery 1 Turnthe power on and insert the Battery Adapter into a station gt Slide the lower front part of the adapter into the station towards the display Press the back end down to close the snap lock with a click For example if you insert the adapter in Station 1 the following is displayed Adapter inserted No Adapter inserted EMPTY NO ADAPT NO ADAPT NO ADAPT Auto UE 2 Insert the battery into the adapter The following message appears on the display when the battery is detected
41. atteries cool and promotes the recombination of gases Available settings DC Charge No Rev Load Rev Load 5 12 Maintains the battery at full charge state after service is complete Available settings 2 15 2 45V Cell SLA 3 90 4 35V Cell Li lon The threshold point at which the analyzer stops charging the battery At this point the current charge drops while maintaining the Max Charge Voltage Available settings 2 20 2 65V Cell SLA 3 90 4 35V Cell Li lon Detects full charge state When the End of Charge condition is reached Charge rate difference is less than the specified value the battery is considered fully charged and the analyzer completes the charge cycle on the battery From 0 01 to 0 10C 29 Viewing C Codes gt Press the station key then use the 4 and W keys to scroll through the Basic C Codes and the gt and keys to view the Extended C Code parameters Managing C Codes gt Press the station key to display the Basic C Code then To Procedures Select a C Code Edit a C Code Delete a C Code Create a C Code Reset Extended C Code to default Copy a C Code Copy all C Codes to another adapter Add edit or erase a battery setup name Scroll to the C Code with the N and W keys then press ENTER and select Yes The appears beside the C Code number on the display Scroll to the C Code with the N and keys then press CCode Use the and W keys or the k
42. d False statements Previous Phase Cycle 1 o Cycle 2 o Test lt Tive Falsa Next Phase e Phase Done consists of one cycle The analyzer will go through the first phase then follow the paths taken by the decision making True and False statements in each phase The following lists describe values allowed for the cycles the True and False statements and the Done phase 52 C7000 amp 7000ER Battery Analyzer V3 5 33 Cycle 1 and Cycle 2 Option Description Skip Cycle Discharge Time Discharge for 000 00 00 100 Charge Time Charge for 000 00 00 Recondition Time Recondition for 000 00 00 Trickle Charge Time Trickle Chg for 000 00 00 Rest Time Rest for 000 00 00 OhmTest If the default time period of 000 00 00 is used the analyzer will service the battery according to End of Charge End of Discharge or End of Recondition set in the Extended C Code 34 C7000 amp 7000ER Battery Analyzer V3 Skip the cycle and go to the next cycle or the Test statement Discharge the battery for the specified time period in hhh mm ss format at the specified setting A setting of 50 will give a discharge current that is 50 of the Discharge rate The Discharge rate is set in the Extended C Code Charge the battery for the specified time period in hhh mm ss format The Charge rate is set in the Extended C Code Recondition Deep discharge the battery for the
43. ding to the Trickle Charge rate in the Extended C Code Includes the Standby maintenance cycle which periodically performs discharge charge every 30 days 180 days for SLA Trickle Charge Trickle charge the battery according to the Trickle Charge rate in the Extended C Code NiCd or NiMH batteries that do not meet the Target Capacity should always be reconditioned If the battery does not meet the Target Capacity after reconditioning the program will fail the battery This is a shortened version of the Auto program because this program does not determine the initial capacity of the battery when it came from the field Phase Action Phase 1 Phase 2 Phase 3 Phase 4 Phase 5 Phase Done Discharge for 10 minutes to avoid charging a fully charged battery Then fully charge the battery Discharge to find the battery capacity If the capacity meets the Target Capacity complete the program Phase Done If the Target Capacity is not met apply the recondition cycle Phase 3 Recondition and charge the battery Discharge to find capacity after the recondition cycle If the capacity meets the Target Capacity charge the battery Phase 5 If the Target Capacity is not met fail the battery Fully charge the battery Complete the program with a trickle charge to maintain capacity 38 C7000 amp 7000ER Battery Analyzer V3 5 DB 9 to DB 9 i DES 2 BE Note If connecting to a serial printer it may als
44. el number serial number or safety markings Product used for rental purposes Obtaining Warranty Service 1 Contact Cadex Technical Support If the service representative has determined that your product needs to be returned for service or replacement the representative will fax or provide a Return Authorization number with the location of the nearest service center Ship the product to the service center with freight insurance and customs duties prepaid Include the Return Authorization number provided by Cadex or the service center All products must be returned with a Return Authorization number supplied by Cadex or a Cadex service center Products returned from warranty service will be sent with freight prepaid by Cadex Non warranty Repairs Cadex will provide an estimate and will proceed with the repairs only after you have provided a written authorization or a Purchase Order number You will also need a Return Authorization number 2 C7000 amp 7000ER Battery Analyzer V3 5 83 Shock Hazard 82 The C7000 C7000ER Battery Analyzer contains high voltage circuits and can pose a shock hazard when the upper cover is removed Do not attempt to perform any service procedures on the analyzer other than replacement of the fuses or internal backup battery v Use the analyzer only as specified in the documentation Other uses may impair the protection provided by the unit Use only a grounded AC outlet to power the analyze
45. eypad to change the settings Advance or go back using the gt and keys Then press ENTER and select Yes Scroll to the C Code with the 4 and W keys then press Fn 0 and select Yes Scroll to an empty C Code with the and W keys then press CCode Use the and W keys to select or the keypad to enter the settings Advance or go back using the and keys Then press ENTER and select Yes Select Yes again to select the new C Code Scroll to the C Code with the N and V keys then press Fn 1 and select Yes Scroll to the C Code with the the and W keys then press Fn 3 Press the station key of the adapter to copy to scroll to the C Code usually an empty one and press ENTER then select Yes again Press Fn 6 Then press the station key of the adapter to copy to and select Yes Scroll to the C Code with the and W keys then press Fn 7 Use the and Y keys or the keypad to enter edit or erase the battery setup name Advance or go back using the gt and keys Then select Yes Refer to Default Settings for Extended C Codes 30 C7000 amp 7000ER Battery Analyzer V3 5 Detail Global Messages and Warnings 12 Possible Reason s Solution s Calibrate Calibration fault Cap improved to target C Code locked Cell mismatch Cell mismatch corrected Charge complete hot Charge current low Charge current complete CALIBRATE FAIL 170 READY C CODE LOCKED WARNING READY
46. h bar behind the label and lift e For C7000ER a high voltage is present on the power supply circuit board the adapter upwards and the capacitors for at least 30 minutes after the power switch is turned off To ensure satisfactory discharge of energy allow the analyzer to sit for at least 30 minutes before removing the chassis cover 66 C7000 amp 7000ER Battery Analyzer V3 5 19 Servicing Batteries with Bar Code 20 This applies when the analyzer is equipped with the OP 72 option board which supports a bar code reader 1 Print Bar Code Labels one with Battery ID one with C Code Refer to Print Utilities tor detailed procedures Place the labels onto the battery Scan the Battery ID Scan the C Code o ao R oO LD start service Note that the active C Code displayed is C11 a read only position in the adapter reserved for bar code entries C7000 amp 7000ER Battery Analyzer V3 5 Messages and Warnings 12 With the Battery Adapter inserted select the station by pressing the station key When the READY green light flashes insert the battery and press ENTER to Code Detail Global 162 DISCHARGE CURRENT LOW FAIL 162 164 CHARGE CURRENT LOW FAIL 164 170 CALIBRATION FAULT FAIL 170 188 SUSPENDED PROCESS ABORTED INTERRUPT 192 CELL MISMATCH CORRECTED READY 195 CAP IMPROVED TO TARGET READY 200 POWER ON POWER ON 201 ADAPTER INSERTED ADAPT IN 202 ADAPTER REMOVED ADAPT OUT 207 TEMPERATURE HOLD COOLING SYS TEMP
47. h setting The battery may not be able to accept the current load Lower or raise the Charge rate in the Extended C Code The battery may be intrinsically safe Use VS settings Refer to Intrinsically Safe Settings Try a different battery in the same station 53 Messages and Warnings Custom Programs This section describes all the messages and warnings that can appear on the display Warning Creating a Custom Program requires a good understanding of rechargeable batteries and the analyzer Applying routines that conflict with the battery manufacturer s specifications or recommendations can damage a battery Global message is the first message that appears usually with the Code For example Global Message tali If you regularly modify Custom Programs we strongly recommend BatteryShop FAIL 120 EMPTY NO ADAPT NO ADAPT The graphical user interface of Battery Shop allows easy programming Refer to OmA Charge BatteryShop Help for detailed instructions TO view the Detail message press the Station key Custom Programs run virtually any sequence of service cycles They are stored in the analyzer and can be assigned to any C Codes in the adapters When you get a message or warning you can look into the possible reason s and A Custom Program consists of 6 phases Phase 1 5 and Phase Done solution s by detail or code number e Eachofthe first 5 phases consists of 2 cycles Cycle 1 and Cycle 2 Test and the True an
48. ina 74 15 Getting Help Problem Solving 75 droubleshootlng 255i Ete peter epe t tete 75 Manual Updates and Other References ss 78 Technical SUpport 5 5 9 e td tiere E eran nnde Hatte oes 78 16 Safety Notice and Warranty 80 Radio Interference RR EE EE N 80 Explosion Hazard EE Dee Maine 81 ooie dal ek AR EA RE ce foe e esce D IE 82 Wairanty amp Services RE AR AR ARE HORE EN 83 Obtaining Warranty Service ee ee ee ee ee Re ee ee ee een 83 Non warranty Repairs sess 83 Index 84 iv C7000 amp 7000ER Battery Analyzer V3 5 O OP 70 9 OP 72 4 9 20 option boards 9 71 P parallel ports 11 47 device settings 47 password requirement 41 passwords changing 42 peripherals 4 primary fuses replacing 67 68 print utilities 48 programs Basic Programs 21 selecting 18 24 Specialty Programs 22 program settings editing 25 R recondition 7 21 reports 1 4 48 printing 15 49 Residual Capacity 7 22 S safety notice 81 security 41 removing 42 setting 42 serial cable pin configurations 46 47 serial ports 11 46 device settings 47 settings 46 service duration 26 service procedures 17 19 batteries with bar code 20 Index services and upgrades 66 Smart Batteries 1 7 storage of 21 22 specifications 73 74 station fuses replacing 69 70 system resetting 3 system information setting up 44 system setup 43 T Targe
49. ions A maximum of 10 C Codes can be stored allowing you to conveniently service all battery types The unused positions Null Codes remain empty and can be programmed You can view select create copy and edit a C Code Refer to Managing C Codes Note that the C Code in active service cannot be edited When a Smart Cable Adapter is first used the NULL status appears on the display You will need to create a custom C Code before servicing Refer to Managing C Codes on how to create a C Code A C Code is divided into 2 parts e Basic C Code that includes chemistry voltage and capacity e Extended C Code that consists of Charge Discharge C rates Trickle Charge rate recondition settings and other parameters specific to the battery Extended C Code parameters are preset to default settings and normally do not need to be changed Basic C Code Parameter Description Chemistry Often labeled on the battery refers to the battery type Includes Nickel Cadmium NiCd Nickel Metal Hydride NiMH Sealed Lead Acid SLA and Lithium lon Li lon Battery Voltage Terminal voltage of the battery Voltage range depends on the model and chemistry Refer to Specification Firmware Battery Rating Capacity mAh specified by the manufacturer Ranges Capacity from 100mAh to 24 975mAh in increments of 25mAh The battery types of SLA are Gell for most batteries and Hawker for cylindrical SLA batteries manufactured by Hawker
50. le completed Program is going into the next step 55 Detail Global Possible Reason s Solution s Batshop mode wait Battery inserted Battery over temp Battery removed Battery removed Battery shorted Battery too cold Battery too hot 54 C7000 amp 7000ER Battery Analyzer V3 5 BATSHOP INSERTED OVERHEAT REMOVED Code 17 REMOVED Code 26 FAIL 122 COLD WAIT HOT WAIT Battery is detected on an analyzer connected to BatteryShop Global message should be displayed If not check the C Code in BatteryShop and ensure that all the settings are correct for the battery Battery is detected on an adapter Battery is overheated during charge Station will go to Resting 00 00 code 19 until the battery cools If using a non OEM battery the battery thermistor may be incorrect for the adapter Turn off temperature sensing in the C Code Note For safety purposes this step is not possible if the C Code chemistry is Li lon Contact Cadex to upgrade the adapter for your particular battery Battery is removed when the program completed This message appears instantaneously when the battery is removed A 5 second delay after the battery is removed when the program completed Battery is not accepting charge in the initial charge cycle the voltage remains low Check that the battery voltage is above 0 30V Cell The Charge rate may have to be lowered If all else fails discard the battery
51. mmed in the Custom Program completed 9 PRU P g timeout The program is moving into the next step For example a battery with a 90 capacity will pass if the Target Capacity is 80 but fail if the Target Capacity is 100 The batteries are always fully charged 62 C7000 amp 7000ER Battery Analyzer V3 5 23 Selecting a Program or Setting Target Capacity The following procedures describe how to select a program and or set the Target Capacity before a battery is inserted To select a program and or set the Target Capacity when a battery is inserted for service follow the procedures in Basic Battery Service 1 Press the station key then use the and keys to find the C Code for which you want to select the program and or set the Target Capacity 2 Press Prog 3 Select the desired program depending on which program list you are in If you are in the Basic Program list PROGRAM _ enter y Auto SETTINGS E Charge Prime J SPECIALTY PROG If you are in the Specialty Program list PROGRAM ENTER OhmTest SETTINGS N Runtime Self Discharge Life Cycling Discharge Only Extended Prime Custom 1 Custom 2 Custom 3 Custom 4 BASIC PROGRAMS 4 Set the Target Capacity using the keypad or and V keys 5 Press ENTER to confirm 24 C7000 amp 7000ER Battery Analyzer V3 5 Messages and Warnings 12 Detail Global Possible Reason s Solution s Soft battery step WARNING
52. o be RD 2 3 TD necessary to jumper pins 6 DSR 1 DCD and 4 pd i ie DTR together on the printer s DB 9 connector Other RTS 7 8 CTS jumpers may be also required Check your printer SG 5 5 SG or manual for specific information Serial and Parallel Port Device Settings The serial port is a DB9 connector which is standard on all models and is located at the back of the analyzer Option Description Disabled Printer LabelMaker Computer BatteryShop No output is provided to the serial port Print reports and labels on a serial printer Default Setting Print Bar Code Labels and Battery Labels on a DYMO LabelWriter SE300 Printer Transfer service data to the computer Connect to BatteryShop The parallel port is a DB25 connector available only to analyzers with the OP 70 or OP 72 option board Option Description Disabled Printer LabelMaker No output is provided to the parallel port Default Setting Print reports and labels on a parallel printer Print Bar Code Labels and Battery Labels on a DYMO LabelWriter SE300 Printer 47 Output Devices l OUTPUT DEVICES enter L Serial Port Device J Serial Port Settings Parallel Port Device M BatteryShop Serial Port Settings Before connecting any device to the serial port match the serial port settings with those of the device being connected Consult the device s manual for the proper setting
53. oad Recommended for new batteries or batteries in extended storage Accommodate special needs The codes are listed in ascending numeric order and cross referenced to both the Detail and Global display Refer back to By Detail for possible reason s solution s Messages and Warnings 12 Code Detail Global 000 STATION OFF LINE OFFLINE 001 NO ADAPTER NO ADAPT 002 CHARGING CHARGE 003 TRICKLE CHARGE TRKL CHRG 004 RECONDITIONING RECOND 005 READY READY 006 DISCHARGE WAIT DCHG WAIT 007 DISCHARGING DISCHARGE 008 INSERT THE BATTERY INSERT 009 CHARGE WAIT CHG WAIT 010 NO BATTERY EMPTY 011 START BATTERY PROCESSING START 012 BATTERY TOO COLD COLD WAIT 013 BATTERY TOO HOT HOT WAIT 014 BATTERY OVER TEMP OVERHEAT 015 PROCESS COMPLETED FINISHED 016 PROGRAM FAULT DETECTED WARNING 017 BATTERY REMOVED REMOVED 018 PROCESS SUSPENDED INTERRUPT 019 RESTING XX XX RESTING 020 BATTERY INSERTED INSERTED 021 RESTING XX XX RESTING 022 SETTING UP CALIBRATION CAL WAIT 023 STATION CALIBRATING CALIBRATE 026 BATTERY REMOVED REMOVED 027 RESISTANCE TEST OHMTEST 028 RESISTANCE TEST OHMTEST 029 CALIBRATE CALIBRATE 030 CHARGE CYCLE COMPLETE END CYCLE 63 Battery Service Programs 5 Target Capacity Detail Global Possible Reason s Solution s Target Capacity is the percentage of the battery capacity compared to the Thermistor failure FAIL 150 Battery or adapter thermistor is open or shorted Clean the nominal capacity It serves as the threshold for
54. perating time will be less than manufacturer s specification This is normal All cycles are briefly suspended due to high temperature inside the analyzer Service will resume ina few minutes or after the board has cooled This may occur a number of times per hour If it reoccurs continually move the analyzer to a cooler room 61 60 Detail Global Possible Reason s Solution s Resistance test OHMTEST A manually selected or programmed resistance test for the Code 27 battery is in progress Program completes in 5 seconds Resistance test OHMTEST An automatic resistance test under the Life Cycling Code 28 program is in progress The program should complete in 5 seconds Resistance thrs FAIL 135 The battery resistance has exceeded the set resistance Exceeded threshold in OhmTest Program has terminated Resting XX XX RESTING Station is in rest period as specified in the Custom Code 19 Program Resting XX XX RESTING Station is in an automatic rest period specified in the Code 21 Charge program for NiMH batteries The procedure is automatic if temperature sensing for the adapter is not enabled Setting up CAL WAIT Station is preparing for a calibration process calibration Shorted or SHORT REV Battery voltage is too low on insertion Battery may be reversed connected backwards in the adapter Ensure battery leads are connected properly Battery may be fully discharged Recharge battery in its original charger before placing it in
55. r Before attempting any internal service remove all batteries from the battery stations turn the analyzer off and disconnect the power cord from the wall socket Wait a few minutes 30 minutes for the C7000ER before opening the cover Replace fuses only with fuses of the same type and rating Replace the internal backup battery only with the same type Observe the correct polarity when installing the backup battery Discard the used battery according to the battery manufacturer s instructions C7000 amp 7000ER Battery Analyzer V3 5 Overview Firmware Upgrade Resetting the System If you are upgrading the analyzer firmware to V3 5 from an older version you need to reset the system to the factory defaults to erase the old system parameters Some of the parameters that are reset include e OhmrTest Runtime Self Discharge Life Cycling and Custom Programs e Battery Startup settings e Parallel Port Device to Printer e Serial Port Device to LabelMaker e Voltage Display to Volts Cell e Number of batteries serviced Service Counter to 0 gt Press and release the Alt key then press 0 Note that this function also serves as a general system reboot Connecting to BatteryShop BatteryShop is a powerful Windows based battery management tool that allows automation of the C7000 and C7000ER functions to increase productivity e Provides control and monitoring of large scale battery services by connecting up to 1
56. rammed service programs combine discharge charge recondition and resistance test to achieve results as required Basic Programs Auto Charge Prime The basic programs include Auto Charge and Prime Each program performs functions for different purposes Function Use Exercises batteries to maintain optimum performance If the Target Capacity cannot be reached recondition is applied Applies fast charge No capacity readings are taken and no discharge is applied Repeatedly cycles battery until maximum capacity is reached If capacity improvement is more than 5 over previous reading an additional cycle is applied Restore batteries affected by memory Routine battery maintenance Identify marginally performing batteries Service batteries in unknown condition Verify battery condition for warranty claim Fast charge Topping up of partially discharged or partially used batteries Prepare new batteries for field use Condition batteries that have been in storage Warning Do not store Smart Batteries in discharged state If the voltage drops below the level required by the processor within the Smart Battery information can be lost In some cases this can cause the battery to become non operative 21 Specialty Programs OhmTest Runtime Self Discharge Life Cycling Discharge Only Extended Prime By Code Specialty programs include OhmTest Runtime Self Discharge
57. ranty amp Services At Cadex it is our goal to continue to listen to feedback and suggestions from customers and improve our products Below is a list of product enhancements Cadex Electronics Inc warrants the Cadex C7000 and C7000ER Battery Analyzers against defective materials and workmanship for a period of two 2 Version New Features Changes 3 5 Runtime program Support for BatteryShop 3 0 Definable Resistance Threshold in OhmTest Recognition of 16Kb Battery Adapters Improved NiMH charge algorithm Reorganized programs separated Basic and Specialty Programs 4 additional Custom Programs Improved user interface 3 4 Support for BatteryShop General updates 3 3 Improved OhmTest Incorporation of OhmTest into the Auto Prime and Charge programs Automatic identification of battery parameters through Battery Adapters 3 2 OhmTest to test battery internal resistance in 5 seconds Support for label printer Temperature sensor to improve safety Display of battery model numbers Improved NiMH charge algorithm Improved bar code years from the original purchase date The warranty does not cover Any damage due to abusive operation negligence accident or improper installation Any damage caused by an attempted repair not authorized by Cadex Cosmetic damage caused by normal wear and tear External causes of damage such as leakage spills power fluctuations or failure or shipping Product received without the appropriate mod
58. reconditioning a battery in the contacts on the battery Warm the battery to room Auto program temperature i 9 15096 Followi re th The battery thermistor may be damaged Use another good The Target Capacity can be set between 50 and 150 Following are the battery to check and discard battery if damaged If the recommended values battery is still good and code 150 Thermistor failure appears contact Cadex Service Trickle charge TRKL CHRG The reconditioning process completed and the battery is 90 Maintains batteries for critical applications which require maximum Relig sechatged energy reserve and high reliability Fewer batteries will pass The program has specified a trickle charge 80 Recommended default setting which provides a balance between Trickle charge FAIL 159 The temperature on the battery has risen over its maximum UNE overheat setting The trickle charge stops The Trickle Charge rate adequate energy reserve and long service life or the Max Standby voltage in the Extended C Code may M art have to be reduced Check that the mAh rating of the 70 Recommended tor less singen applications where EED power battery matches the C Code mAh setting Lower the room demand is not critical or is of brief duration More batteries will pass temperature For non OEM battery turn off temperature sensing Target Capacity is a pass fail mark and does not affect the final charge level U User programmed END CYCLE The time progra
59. removed during service Re insert battery within 5 seconds to resume service The Custom Program has produced an error and the Next statement is not processed The program is terminated Check the Custom Program statements Battery is ready Faults or warnings if any were corrected Remove battery and use as normal Recondition time has exceeded the expected value for the battery Program proceeds to the next cycle The Recondition Discharge in the Extended C Code may have to be raised The battery may be intrinsically safe preventing deep discharge Use VS settings for the battery Refer to Intrinsically Safe Settings Cells are mismatched or if battery is new use the Prime program Battery is currently being reconditioned 59 58 Detail Global Possible Reason s Solution s Low voltage temp rise Low voltage timeout 1 Low voltage timeout 2 Low voltage timeout 3 N A mQ No adapter No battery No slope timeout zone 1 Null C Code in adapter C7000 amp 7000ER Battery Analyzer V3 5 FAIL 152 FAIL 123 FAIL 124 FAIL 127 NO ADAPT EMPTY FAIL 125 FAIL 211 Battery temperature is rising rapidly at low voltage usually at the initial stage of charge Charging is terminated The Charge rate in the Extended C Code may have to be reduced The battery may be old or have shorted cells Discard the battery For non OEM battery turn off temperature sensing The battery s
60. ry Adapters to service e Frequently Asked Questions about Batteries C Code a battery Refer to Battery Configuration C Codes e Battery Adapter Catalog C Rate Unit by which charge and discharge times are scaled For example a battery rated at 1000mAh provides 1000mA for 1 hour if discharged at 1C A discharge of 1C draws a current equal to the rated capacity The same battery discharged at 0 5C would provide 500mA for two e Updates of User s Manuals Technical Support hours If you have a technical problem that cannot be solved with this manual or the Cadex Intrinsically Safe VS Battery with built in safety protection circuitry These Web site you can contact our Technical Support department by phone fax email or batteries are primarily used in explosive environments mail Please provide the following information Recondition A deep discharge below 1 0V Cell with a controlled current Recondition helps to revert large crystals as a result of memory to small desirable sizes often restoring e Firmware Version You can find the version number by pressing Fn 7 the battery to its full capacity Applies to NiCd and NiMH only e Serial Number of the analyzer e Display message and or code e LED lights that are on or flashing Residual Capacity PER M remaining in the battery when inserted in Mara periode what you werg doing when dde problem occurred Smart Battery Battery equipped with specialized circuitry that can communicate with
61. s Option Available Settings Default Baud Rate 1200 2400 4800 9600 9600 Handshake NONE CTS RTS XON XOFF CTS RTS Data Bits 7 8 8 Stop Bits 1 2 1 Parity NONE ODD EVEN NONE Serial Cable Pin Configurations 46 C7000 amp 7000ER Battery Analyzer V3 5 LPS to mE Note If connecting to a serial printer it may also be RD 2 2 TD necessary to jumper pins 6 DSR 8 DCD and 20 B i i Pd DTR together on the printer s DB 25 connector Other RIS 7 5 CIS jumpers may also be required Check your printer Sd uw ETSA manual for specific information Phase 1 Cycle 1 Cycle 2 Test True False Phase 3 Cycle 1 Phase 4 Cycle 1 Phase Done Ready True Discharge Charge Skip True Goto Phase 2 Discharge Skip C Me Goto Done Trickle Charge Custom Programs 7 The following flowchart demonstrates the routines of the program 10 mins False Goto Phase 3 True Ready Trickle Charge Goto Phase 4 39 Creating or Modifying a Custom Program System Setup 9 Make sure that no Battery Adapter is inserted Select Program Settings on the menu Refer to Menu 2 Select Voltage Calibration on the menu Select the program For example Custom 1 3 Firmly insert the 4 Voltage Calibration Adapters into each station Press Prog If applicable enter the program name
62. s 6 20 hours Charge 1 5 hours 10 hours 4 hours Prime 5 10 hours 40 80 hours 12 25 hours OhmTest 5 seconds 5 seconds 5 seconds Runtime z Self 30 hours 60 hours 50 hours Discharge Life 1500 Cycles NiCd 200 500 Cycles 1000 Cycles Cycling 500 Cycles NiMH Discharge 1 5 hours 20 hours 4 hours Only Extended 21 26 hours 56 96 hours 28 41 hours Prime Custom P 3 1 2 3 4 Duration depends on settings 26 C7000 amp 7000ER Battery Analyzer V3 5 Detail Global Messages and Warnings 12 Possible Reason s Solution s Over voltage PIC communications error Plateau timeout Power on Process completed Process suspended Program fault detected Ready Recondition timeout Reconditioning FAIL 120 PIC ERROR WARNING POWER ON FINISHED INTERRUPT WARNING READY WARNING RECOND Battery voltage is too high on insertion Discharge the battery in its original equipment Check the electrolyte If all fails discard the battery An internal communication error has occurred inside the analyzer Turn off and turn on the analyzer or press Alt 0 to reset the system Battery was fully charged before full charge conditions were met For SLA and Li lon batteries only The End of Charge setting in the C Code may have to be increased Battery may be old and operating time will be less than manufacturer s specifications Power is detected inside the analyzer Battery service completed Battery is
63. s a Class A product according to EN55022 In a domestic environment this product may cause radio interference in which case the user may be required to take adequate corrective measures The equipment is designed with adequate safeguards to protect the user from shock and other hazards when used as specified within this documentation If the equipment is used in a manner not specified by the documentation the protection provided by the equipment may be impaired Please read the documentation and equipment labeling before using the equipment C7000 amp 7000ER Battery Analyzer V3 5 Contents of Box Getting Started The Cadex C7000 C7000ER Battery Analyzer package includes e 10C7000 C7000ER Battery Analyzer e 1 1EC320 Power Cord C7000 1 only 1 User s Manual About this Manual The C7000 amp C7000ER Battery Analyzer User s Manual contains the concept procedures and information that is necessary to operate the analyzer Conventions Typeface Meaning Italic Bold Bold amp Italic Bold Bold Words that are emphasized Keys to press Options to select on the menu Service Programs Name of sections in this manual Warnings Press and release the first key then the remaining key s 6 Symbols Symbol Meaning ir Information that if ignored can result in damage to the C7000 C7000ER Battery Analyzer Battery Adapters or the battery Shock Hazard Explosion Hazard Abbreviations and
64. ss ENTER after selecting the C Code and the service program Components e Parallel Printer Port connects to a parallel printer Refer to System Check that the selected C Code is correct for Setup on how to set up the parallel port device settings the battery RE e Battery Backup RAM retains test data on power interruption resumes 8 Connection between battery The battery may be intrinsically safe Change and the analyzer is the charge method in the Extended C Code to service when power is restored and retains dates and time intermittent DC Charge lower the Charge rate and e Bar Code Wand reads bar coded labels Discharge rate reduce the End of Discharge to 0 92V Cell OP 70 OP 72 Parallel Port v v Battery Backup RAM v v Bar Code Wand Not Activated v You can upgrade your standard analyzer to OP 70 or OP 72 Contact Cadex for upgrade information 76 C7000 amp 7000ER Battery Analyzer V3 5 Battery Adapters Adapters are designed to fit specific battery types and shapes The snap lock latch allows easy insertion and removal There are 3 types of Battery Adapters Adapter Type Description Custom Adapters Accommodate any specific battery shape There are over 600 Custom Adapters available Dual station Designed to handle dual packs that contain 2 Custom Adapters separate battery systems Smart Cable Adapters Used when a Custom Adapter for a battery is Universal Adapters not available Alligator clips attach
65. t Capacity 7 23 setting 19 24 Technical Support 78 troubleshooting 75 U upgrade to firmware V3 5 3 upgrades See services and upgrades W warnings 52 by code 63 65 by detail 53 63 warranty 83 84 85 A abbreviations and acronyms 6 adapters See Battery Adapters Adapters Voltage Calibration 44 Auto Print 48 49 B backup battery replacing 71 72 bar code scanner 4 bar codes 1 20 Battery Adapters 10 27 Custom Adapters 10 Dual station Adapters 10 inserting 17 removing 18 Smart Cable Adapters Universal Adapters 3 10 11 18 27 battery configuration codes See C Codes Battery ID 20 48 BatteryShop 1 3 9 33 C C Codes 1 11 27 active 17 20 48 Basic 27 Extended 27 28 32 managing 30 viewing 17 30 calibrations 15 44 45 commands 15 commonly used terms 7 components 8 Custom Programs 33 creating or modifying 40 D display 12 13 C7000 amp 7000ER Battery Analyzer V3 5 E Event Log 50 log events 51 managing 51 F features 1 firmware upgrade 2 3 firmware version viewing 15 function keys 15 fuses See primary fuses replacing station fuses replacing l IEC320 Power Cord 5 72 internal resistance 22 threshold 22 25 intrinsically safe I S 7 settings 31 K keys functions of 8 L labels 1 4 48 printing 15 49 LCD See display LEDs See lights Li lon 6 10 27 lights 16 M memory 7 21 menu 14
66. the analyzer Battery may have shorted cells Discard the battery SM Bus adapter SM ADP IN SMBus Adapter is detected on a station inserted Smart battery SM BAT IN Smart battery is detected on a SMBus Adapter inserted Soft battery FAIL 128 Battery voltage is rising quickly during charging even after code 118 Soft battery step down Processing has terminated Battery may be overcharged Discharge the battery for 10 minutes then charge again Battery may be a high capacity type battery Reduce the Charge rate Battery is new Use the Prime program to prepare the battery for use Check that correct contacts are used C7000 amp 7000ER Battery Analyzer V3 5 Battery Service Programs 5 Editing Program Settings Only the following program settings can be edited Threshold of internal resistance in OhmTest Wait period in Self Discharge Inclusion of Self Discharge test in Life Cycling Cycle time and load current in Runtime Custom Programs refer to Custom Programs Select Program Settings on the menu Refer to Menu Select the program to edit Press Prog then edit the program settings gt Use the N and W keys to select or the keypad to enter the new settings Advance or go back using the 2 and keys Select Yes to accept changes 25 Duration of Service The following table displays the approximate service times at default Charge Discharge rates NiCd and NiMH SLA Li lon Auto 2 5 10 hours 20 40 hour
67. then press ENTER You 4 Wait for the prompt then remove the calibration adapters h Otherwi E kip can enter up to 9 characters numbers Otherwise press Esc to skip 5 Press Menu to return to the Global Display 4 E h ings MEE Progra SCIMUS 6 Press Fn 7 The sign should appear in the upper right corner of the gt Use the N and W keys to scroll through the phases and cycles or select startup screen indicating successful completion of voltage calibration the settings Move between the fields using the gt and keys 5 Press ENTER when all the settings are entered then select Yes to accept changes Calibrating Station Failing to calibrate Battery Adapters could cause inaccurate capacity readings especially on low voltage batteries or single cells Recalibrate adapters when they are moved from one station to another 1 Make sure that there is no battery inserted into the adapter 2 SelectStation Calibration on the menu You can also press Fn 8 3 For each station select the station and short the battery leads on the adapter together using a short length of heavy gauge wire AWG 10 Warning Never short the contacts on the battery 4 Once the display indicates that a good connection has been established press ENTER to start calibrating 5 Wait for a few seconds and remove the wire when prompted 40 C7000 amp 7000ER Battery Analyzer V3 5 45 Setting Up System Information 1 Select the feature on the menu 2
68. topped accepting charge 1 C minute into the charge cycle See code 122 Battery shorted The battery stopped accepting charge 10 C minutes into the charge cycle See code 122 Battery shorted Charge terminated Correct voltage could not be obtained in allotted time due to high battery capacity for set charge current incorrect voltage setting or shorted cells Check C Code settings and battery rating Replace battery if low voltage remains OhmrTest has not been performed yet so no resistance reading is available No Battery Adapter is inserted or the inserted adapter is not detected Check contacts Clean with a lint free cotton swab dipped in 100 Isopropyl Alcohol No battery is inserted or the inserted battery is not detected Check contacts Turn on battery switch if applicable Check for correct battery for the adapter and adapter contacts Clean all contacts The battery is losing charge faster that it is being supplied in the initial charge cycle For SLA and Li lon batteries only The Charge rate in the C Code may have to be increased If all fails discard the battery An empty C Code is selected Select a programmed C Code or program the selected empty C Code Battery Configuration C Codes Configuration Codes or C Codes are battery parameters to service a battery Battery Adapters are pre programmed with the available C Codes for that battery type The adapters store C Codes once entered and can be moved between stat
69. ttery fire or explosion 5 Select a program Refer to Battery Service Programs for the various programs and their uses gt gt gt Press the PROG key Use the 4 S2 and V S1 keys to scroll through the available programs then press ENTER when the desired program is displayed Press ENTER to confirm the selection To cancel press Esc 6 Verify the settings again after pressing ENTER 18 C7000 amp 7000ER Battery Analyzer V3 5 13 Replacing the Primary Input Fuse If the analyzer does not power up but the input line is checked and power cord is firmly inserted the primary input fuse may need to be replaced Model Primary Fuse Size Replacement Cadex P N C7000 1 T1 6 Amp 250V 5x20mm Schurter 034 3119 52 546 0160 C7000 2 T1 6 Amp 250V 5x20mm Schurter 034 3119 52 546 0160 C7000 9 T0 8 Amp 250V 5x20mm Bussman GDC800mA 52 546 0080 C7000ER 13 5 Amp 250V 5x20mm Littlefuse 216 31 5 52 546 0315 Standard Model C7000 1 C7000 2 C7000 9 1 Remove all batteries and adapters turn off the analyzer and unplug the power cord 2 Locate the fuse drawer below the power cord socket Fuse Drawer 3 Openthe fuse drawer by pulling the release tab outward with a fingernail or small screwdriver 4 Ifthe primary input fuse needs to be replaced remove the fuse from the fuse drawer and replace the fuse 5 Push the release tab back to the fuse drawer until it clicks shut 6 Insert the power cord
70. ttery to retain date time print formats and other information when the power is off or interrupted With the analyzer off the battery lasts for 2 to 3 years with the analyzer on the backup battery can last for 10 years Replace the battery if the date time setting is no longer retained after the analyzer is turned off Model Backup Battery Size Replacement Cadex P N All 3V 200mAh 200 x 3 2mm Panasonic BR2032 45 206 0001 or Standard CR2032 Warning Make sure the polarity is correct when replacing the backup battery Discard the used battery according to the battery manufacturer s instructions Failure to do so may cause explosion 1 Remove all batteries and adapters turn the analyzer off and unplug power cord 2 Unscrew the 3 screws located on the rear of the C7000 2 screws on the C7000ER to remove the top cover The cover will still be attached to the C7000 by a grounding strap Put the cover to one side 3 Locate the backup battery on the option board mounted vertically in the rear corner of the analyzer 4 Gently lift the retainer arm which holds the backup battery and slide the battery out Take care not to short circuit the backup battery or touch any of the other electronic components inside the analyzer Do not use a metal screwdriver or something similar The ribbon cable or the option board may have to be removed in order to access the backup battery 71 70 Extended ake If necessary check the remo
71. ved fuse with an ohmmeter to confirm diagnosis and or replace the station fuse Replace the upper cover of the C7000 make sure the front edge of the top cover is properly inserted into the notches in the plastic cups and re install the screws to secure cover Range Model C7000ER Remove all batteries and adapters turn off the analyzer and unplug power cord Wait 30 minutes to allow the voltage to discharge Unscrew the 2 screws located on the rear to remove the top cover Disconnect the wire on the power supply circuit board that is attached to the power assembly filter Remove the open fuse from the holder taking care not to touch any of the electrical components The station fuses are located in the left rear corner of the analyzer on the motherboard refer to the diagram for standard model If necessary check the removed fuse with an ohmmeter to confirm diagnosis and or replace the station fuse Reconnect the wire on the power supply board and re install the screws to secure cover C7000 amp 7000ER Battery Analyzer V3 5 Commands To Operation Principles Press Select a value Scroll through menu levels or fields Print a report or label Discard changes or go back in menu Vy S1 or N S2 then ENTER S3 or 2 S4 Station key Print N or to select format then ENTER Esc You can also print a report or label using the menu Refer to Printing Report or Label Function Keys
72. y 60Hz 50 60Hz 50 60Hz 47 63Hz Main Input Load max 180W max 180W max 180W 225W Power Factor Corrected Output Load Total max80W max 80W max 80W max 160W Current Station max 2A max 2A max 2A max 2A Operating Temp 0 C to 40 C 32 F to 104 F Dimensions Width 280mm 11 0 280mm 11 0 280mm 11 0 280mm 11 0 Depth 374mm 14 7 374mm 14 7 374mm 14 7 412mm 16 7 Height 88mm 3 6 88mm 3 6 88mm 3 6 95mm 3 75 Weight 6 3kg 13 9lb with option board 6 4kg 14 11b 5 7kg 12 6lb Accuracy Voltage 1 at max rated voltage Current 2 5 at 1A Throughput 4 batteries every 4 8 hours up to 160 batteries per month based on 2 batches per day Connectors 3 pin AC plug IEC320 Power Cord only available on C7000 1 Serial DB 9 RS 232 standard on all models Parallel DB 25 OP70 and OP 72 only DIN Jack 5 pin for Bar Code Wand OP 72 only Interface LCD 80 Character with multiple display formats Global Detailed Menu LED 3 Status lights RUN READY FAIL for each station Keypad Numeric pad with 8 function keys 4 station selection cursor keys Warranty Limited 2 years parts and labor Approvals Tested and approved by ITS to comply with CSA UL CE standards Options Battery Backup RAM OP 70 and OP 72 Bar Code Reader OP 72 Windows based BatteryShop Continuous intelligent overload protection 73 Operating Principles 3 5 Install a new backup battery and make sure that the battery is inserted properly

C7000 & C7000ER Battery Analyzer User`s Manual Notes

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C7000 &amp; C7000ER Battery Analyzer User`s Manual Notes

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C7000 & C7000ER Battery Analyzer User`s Manual Notes