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Cellcorder CRT-300 User's Guide

1. 37 display setup cceeeeeee 17 editing a Site eee 19 23 enter Key enara 7 error codes eeeeeeeeeeeee 37 40 A a E EE 8 FT button 2 nie naerata 7 PQ Dutton i 02 neaihectese ites 7 F3 button ennei eee 7 F4 Dutton ennnen sata 7 factory defaults 42 Fahrenheit button 16 29 TAM es ae hee RR Sees 28 fan diagnostics eee 39 faults screen 35 file deleting a CDF file 14 firmware upgrading 44 using IR port eee 44 using memory card 44 float voltage readings 25 27 frequency setup cece 18 HEX Plenier ina 44 45 HI described cece 21 HR described eee 21 HSG described ce eee 21 HT described ce eee 21 HV described e eee 21 hydrometer s s s 29 30 ICr channel diagnostics 39 indicators 0 0 eeeeeeteeseeeeeeeeeeeeees 7 infrared POrt cece 8 initializing message 28 intercell readings 26 28 intercell resistance leads 11 intercell type selection 27 internal cell resistance leads 10 IR infrared port eee 8 IR port diagnostics 37 keypad diagnostics 37 leads connections for resistance 27 connections for voltage 25 linking a file and site 22 load button cece 10 load module diagnostics 38 loading a file eee 32 LOC described eee 21 LR descr
2. DATA ANOMALIES Another part of the battery literates fantasy is also likely to be shattered that all the data gathered for the baseline or test readings taken afterward would fall reasonably close to any trend line That is higher capacity cells will have uniformly lower internal resistances and lower capacity cells will have proportionately higher internal resistances Even cells fresh off of a tightly controlled production line fail to completely conform with this expected behavior In the course of your own testing you will find tested high capacity cells with an unusually high internal resistance Similarly there will be cells with the ow internal resistance characteristic of a good cell that would fail a capacity test Unfortunately the current state of the art does not permit impedance conductance admittance or resistance testing to definitively identify the cells with anomalies without the assistance of a load test If you are fortunate to have large amounts of both capacity and corresponding internal resistance data developing a baseline should be no problem When a program is just starting or there are few cells of a particular model some educated guess timating helps in sorting out data If you need baseline data try calling us or the cell s manufacturer INTERNAL RESISTANCE TEST FREQUENCY The whole purpose of the internal resistance check is to determine whether a cell has deteriorated and if so how muc
3. In the Battery Data area on the CRT 300 Interface box to include site configuration data click Include Configuration Click Capture If an ADF file is not open select or create one On the Battery Data Capture box select the number of cells to download the starting cell number and the read date then click OK The Cellcorder displays Sending data for cell nnn and the cell number counts up When the Cellcorder count stops the bottom of the CRT 300 Interface box displays Data transfer completed On the computer click Close on the CRT 300 Interface box On the computer Main Menu select File Save name the ADF file and click Save The ADF files are usually stored under Programs Alber Alber Battery Analysis Cellcorder ADF Files To use the Cellcorder Previewer program refer to the user s guide 10 7 Printing Test Results You may print test results using the optional thermal printer that interfaces to the Cellcorder via IR You are not limited to using this printer however because data may be transferred to a computer via IR memory card or modem and sent to any printer on your system A complete test printout contains the following Site Information for Location Location name Battery Battery name String String name Model Battery model number Total Vo The string overall voltage OV cells oc Number of cells in the string Installed Battery installation date Read
4. amp Resistance E Intercell R2 Specific Gravity amp Intercell R3 Temperature f IntercellR4 Figure 37 Print Options Page 23 File Transfer from PDA to PC The PDA can transfer cell data to a computer using the standard IRDA Palm interface or other Palm interfaces such as e mail attachment To transfer the file select Print from the Options menu or press the PC button on the View String Data page The Upload File to PC box appears Battery 1 String1 2 Upload File to PC Cell Volt Resist SG Temp i 12 6788 1045 000 O Filename StringS_7 9 03 2df 14 0 995 984 000 0 d Beam Ensure PC ON and Upload File to PC line up IR ports A Email Enter email address Filename String 1_ 4 03 cdf Place email in outbox Beam Ensure PC ON and 4 Open email application to line up IR ports send email Email Enter email address Status Pending Figure 38 Upload File to PC A non editable file name is created based on the string name and date of readings Press Upload if the PDA can send e mail attachments a Send With option box appears To send via IR select Beam to transfer via e mail 3 75M maximum attachment size select MultiMail send 57 PDA Mobile Software User s Guide 24 Adding or Replacing String Data To add or replace data in an existing file with data downloaded from the Cellcorder or hydrometer on the Main Page select the string name On the View String Data page press the top bar t
5. memory card modem and infrared IR communication a graphical LCD display and redesigned cables and clamps Voltage and Current Protection An internal circuit helps protect the Cellcorder if it is accidentally placed across a high voltage The protection circuit senses the input voltage across the current carrying leads and if the input voltage exceeds 20 volts a beep sounds and the test current relays are disabled As a reminder it is still potentially hazardous to exceed the rated voltage of the Cellcorder 20 volts This manual contains a complete description of all Cellcorder features and specifications System Requirements 3 System Requirements A typical Cellcorder system requires the following manuals Cellcorder CRT 300 User s Guide 4200 038 Battery Analysis System User s Guide 4200 002 if a computer is used UPS uninterruptible power supply manufacturer s instruction manual if a UPS is used USB Media Reader Writer manufacturer s instruction manual Belkin Components Smart Media or other Hydrometer manual if a hydrometer is used Data storage module used with the hydrometer General Description 4 General Description The Cellcorder CRT 300 battery cell voltage and resistance tester features a Smart Media memory card modem and infrared communication graphical reflective LCD display and newly designed cables and clamps The Cellcorder reads single cells and multicell modules It displays and r
6. Internal Resistance and the Cellcorder This document is available at www alber com VALVE REGULATED VENTED mortrauruma Bectrolyte absorbed in separator Liquid electrolyte INTRODUCTION With the changeover from vented cells to sealed VRLA cells and the proliferation of UPS systems an even greater impetus has been placed in finding economical and reliable ways to establish the state of a battery s capacity and its conduction path In this Application Note the primary focus will be on a new relatively low cost aid in determining a battery s health by virtue of its cells internal resistances together with float voltages and intercell connection resistances All three of these variables are rapidly measured and conveniently recorded by the Alb rcorp Cellcorder the storage battery multimeter THE SEARCH The search for new approach to capacity and conduction path testing has been ongoing Traditionally a battery s capacity to store energy has been specified by its manufacturers as its ability to supply a constant amount of current or power to the load for a defined time period to a final voltage The real test of the battery s actual capacity as opposed to its rated capacity frequently involves hours of manpower and load and data acquisition equipment 64 Application Note CC 001 Unfortunately a new approach has yet to gain industry wide acceptance The consensus of battery experts is still that loa
7. Refer to Using the Test Leads to ensure good test lead connection and to Application Note CC 002 which discusses internal resistance measurement procedures Before testing cell voltage or resistance you should select a site though not mandatory To create or select a site refer to Setting Up a Site WARNING Do not test any cells when the Cellcorder AC Power indicator is lit Injury to personnel or damage to equipment could result 10 1 Mode Select Voltage Use the Voltage mode and voltage probes to take float voltage readings The Cellcorder ignores polarity in Voltage mode so you may connect the leads in either direction When the probes contact a cell the Cellcorder displays the voltage and beeps to indicate the reading is stored When the probes are lifted off the cell the Cellcorder steps to the next cell number 10 1 1 Taking Voltage Readings Before taking readings you should select a site though not mandatory Refer to Selecting a Site for Test WARNING The maximum voltage the Cellcorder can read is 20V Do not attempt to read Overall Volts OV The Cellcorder calculates OV based on cell voltage readings Connect the voltage test leads to the Cellcorder At the Main Menu select Mode Voltage The voltage screen displays the cell number and voltage and either Resume testing or Stored in Memory To select another cell number type the number then press Enter or use the Up Down Arrows Mode Select 1 Voltage CELL 2 R
8. the abnormally high voltage across it and the low voltage across all other cells modules Refer to Application Note CC 001 When measuring internal cell resistance place the sense leads directly on the positive and negative terminal posts so the measurement does not include any part of the external circuit Remember consistency in the way readings are taken is necessary when comparing readings over time 10 CRT 300 Basics When reading intercell connector resistance place the sense leads on the terminal posts Intercell measurement checks the quality of the connection between the intercell bar and the terminal post On some batteries typically VRLA the posts are inaccessible because they are covered by the intercell connector For valve regulated batteries where only the intercell and the mounting bolt are accessible connect the current lead to the bolt head and the voltage sensing lead to the intercell Measuring from bolt head to bolt head is not a true measure of the connection between the post and intercell bar in most cases the reading will be high because of the high resistance of the bolt itself Refer to Application Note CC 002 Most battery terminal posts have a layer of lead dioxide lead sulfate copper oxide or dirt mixed with No Ox grease All are high in resistance so make sure the test leads have good connection to the metal surfaces 6 5 Using the Modem The Cellcorder internal modem can send cell data to a c
9. Displays current when voltage is applied to test pins Internal jumpers need to be changed and an external voltage applied Move the jumper on JP9 from pins 2 and 3 to pins 1 and 2 Move the jumper on JP10 from pins 2 and 3 to pins 1 and 2 Inject up to a 65mV signal on pins 10 and 12 on the test lead connector Input voltage must not exceed 65mV The display indicates 1 Amp for each 1 mV Replace the jumpers to their original positions after testing Do not use this diagnostic for calibration 38 Diagnostics Menu 12 7 3 ICr Channel Displays the voltage connected to the black clip and the red black sense clip on the resistance three lead lead set This input is for the voltage reading across the intercell connector under a test condition Input voltage must not exceed 130mV 12 7 4 A D Reference Displays the internal reference for the analog to digital converter The raw count A D value should be approximately 10000 Press Esc to exit this diagnostic 12 8 Diagnostics Protection Circuit To test the circuitry that protects the Cellcorder against overload conditions select Diagnostics Protection Ckt To return to the Diagnostics menu press Cancel 12 9 Diagnostics Modem Tests the Cellcorder internal modem and telephone line Requires a modem connection from the Cellcorder to a Telco line or line simulator The modem connector is under the accessory cover To return to the Diagnostics menu press Continue 12 10 Diagn
10. Menu select Setup Sound Use the Up Down Arrows to select off or on then press Accept To return to the Main Menu from the System Setup menu press Back twice NOTE You may also use Shift Mute to access Sound 8 5 System Setup Modem NOTE ZZ The modem function is not supported as of the printing of this manual Skip this section To set up the Cellcorder modem at the Main Menu select Setup Modem NOTE There is no keypad shortcut for modem setup Setting Up the Cellcorder 8 6 System Setup Frequency Frequency setup lets the Cellcorder A D circuitry filter out the fundamental line frequency and harmonics To select line frequency at the Main Menu select Setup Frequency Use the Up Down Arrows to select 50Hz or 60Hz then press Accept To return to the Main Menu from the System Setup menu press Back twice NOTE You may also use Shift Hz to access this function 8 7 System Setup Date Time To set the date time and date format at the Main Menu select Setup Date Time then choose Date Time or Format Use the Arrow keys to set the date and time then press Accept To select date format MM DD YY or other press the corresponding keypad key To return to the Main Menu from the Date Time menu press Back three times NOTE You may also use Shift Time to access this function Setting Up and Editing a Site 9 Setting Up and Editing a Site Setting up a site involves defining site names model numbers thresholds a
11. Readings in temporary memory can also be sent to a computer via IR or modem The CDF files can be imported into an existing ADF file using the BAS program or viewed using the CRT 300 Data Viewer 10 5 1 Saving to the Memory Card To save readings to the memory card press Shift Save At Enter File Name type the file name up to eight characters You cannot insert a space in a file name Press the Save F2 key If the file exists a message prompts to overwrite After the file is saved you may copy it from the memory card to the computer After the file is copied you may delete it from the memory card to free up space on the card NOTE Saving readings to the memory card does not delete them from Cellcorder temporary memory NOTE Subdirectories are not supported when saving to the memory card Save all files in the root directory 10 5 2 Clearing Cellcorder Memory Before taking readings on another battery clear data from the Cellcorder temporary memory Save the data to the memory card before clearing memory At power up if data is in temporary memory a message appears To save the data to the memory card press Yes and refer to the instructions in Saving to the Memory Card If you are certain you want to clear temporary memory press Clear then at the All data will be erased warning press Yes SYSTEM MESSAGE WARNING Data is present in All Data in temporary storage Temporary Storage area Do you want to m archive to
12. a E nnar 59 hydrometer button 51 insert data 0 eeeeeees 53 IR transfer eee eee 51 location name s s s 55 MAIN Page soseer 48 model numbet 00 55 N button eee 48 options menu 49 54 PDA manual 48 preferences s s s 49 printing option 57 replace data 58 serial receive error 59 site info Option 55 SOM files aeeie cen 48 Stats Option eee 55 String NAMEC eee 55 system requirements 48 temperature C F 06 49 thresholds option 56 upload file page 57 view data n se 52 view string data page 52 power AC LED eee 7 power button eee eee 7 power Connector n s 8 power on off 9 piintingessniesin iini 33 protection circuit diagnostics 39 reset SWitch eee 8 9 resistance cell readings c eee 26 intercell readings 26 leads connection 27 measuring s s s 25 35 readings sisses 26 resistance mode 26 tESt KEY erei doine aes ees 28 test OVeErVieW essee 5 resume testing message 26 retest button seee 26 retest faults button 35 safety information 1 safety relay diagnostics 37 SAVING data 31 select button 24 selecting a site cece 24 Service MENU 41 setting up a site eee 19 setup button ssesessseseeeeseeeee 10 shift key sesser 8 shift symbol s s s 9 site del
13. automaticallyin 5 minutes CONTINUE CONTINUE time remaining Figure 2 Typical Battery Power Warnings Cellcorder Data Storage 7 Cellcorder Data Storage The Cellcorder stores firmware and updates in Flash memory and cell data threshold settings and calibration factors in EEPROM Both Flash and EEPROM retain data with power off Site setup and cell readings are first stored in EEPROM and then to the removable memory card when saved Memory card data may be transferred to a computer Memory device use is described in this section and elsewhere in this manual 7 1 Using the Memory Card The Cellcorder stores data on an 8 megabyte memory card Cards up to 128M are available You can use the memory card to transfer cell data to a computer for analysis transfer firmware upgrades from computer to Cellcorder back up and restore calibration constants and store site setup information Use Windows Explorer to access the card drive and data Refer to Firmware Upgrades Before transferring memory card data connect the card reader writer drive to a USB port on the computer and install the drive software Follow the manufacturer s drive instructions If a USB connection is not available contact Alb r for alternate card drives Insert the memory card into the drive on the computer or Cellcorder to read or write data You may insert or remove the card from the Cellcorder with the power on or off but the yellow Smart Media Card LED
14. damaged 71 Application Note CC 001 After tens of thousands of cell tests there have been no reports indicating that the Cellcorder s test discharge has caused a cell to open circuit Interestingly many battery specialists feel disappointed that their most severely corroded cells have not opened They would rather have them open during a supervised test than during an actual emergency when no one is around ALBER RESEARCH Carefully conducted Alb r experiments have revealed other important properties of cell internal resistance One is the relationship between metallic resistance and electrochemical resistance Many would expect that as the energy stored in a fully charged cell diminishes the internal resistance of the cell would increase both proportionately and significantly This belief is widely held because of how the lead acid cell electrochemistry is envisioned Measured amounts of energy were methodically removed and each time the internal resistance was read It was found that the internal resistance rose no more than 3 after removal of 32 of the cell s energy Upon continued discharge the internal resistance increased rapidly in a non linear fashion Since it is extremely unlikely that the cells metallic resistance could have changed while the cells were discharged it can be concluded that 1 the changes noted in total internal resistance were due exclusively to electrochemical resistance change 2 the electr
15. data displays Refer to Taking Resistance Readings Type a cell number and press Enter or use the Arrows to display a cell number Resume testing on cells with no data not yet tested or press Retest to test cells previously tested 10 5 5 Storing Data for Multiple Strings To read and store data for a new battery first save the previous battery data to the memory card then clear the data from Cellcorder temporary memory Refer to Saving to the Memory Card and Clearing Cellcorder Memory 10 6 Sending Readings via IR to a Computer While the easiest way of transferring data from Cellcorder to computer is with the memory card cell readings and setup data can also be sent via IR using the BAS program or CRT 300 Previewer This section outlines using IR to send readings Refer to the Battery Analysis User s Guide or the CRT 300 Previewer User s Guide for more about dialog boxes creating an ADF file or importing to an existing ADF file 32 Measuring Voltage and Resistance To send readings from Cellcorder memory to a computer via IR on the Cellcorder press Shift Send then select Send data to PC via IR interface If using a Palm PDA refer to the PDA section of this manual On the computer desktop click the Battery Analysis System BAS icon to start the program On the menu bar click the Start the Cellcorder Interface button On the next dialog box click the CRT 300 button then OK Align the computer and Cellcorder IR ports
16. e e ne E a E A EE E E TaN 4 4 1 Resistance Test Overview ccsccescceseessecsseceeeseeeeeeeeeeeeeeeeenseeneeees 5 4 2 Skewing Effecten e a e o E BR Sei e aa 6 PANEL CONTROLS AND INDICATORS ccceesseescesscesecesecesecesecaessaeeaeeenes 7 CRT 300 BASICS arosai ioe a e EE dev E ese 9 6 1 Power OMOTE eie E ER RO E E EDE 9 6 2 Mechanical Reset Switch ss sssesssssesesssrsersresersessreressesresreeesseseeses 9 6 3 Main Meni siit EE E T OEREN eeees 10 6 47 Using the Test Leads s2ccci ss inie i RE aa 10 6 5 Using the Modemi ra jc anid ira E A ar Benes ates 11 6 6 Charging the Cellcorder cccecccccsseesseeeceeeeeseceseesseeseeeeeeseeses 12 CELLCORDER DATA STORAGE cceescesscssecesecssecnsesaeceeeneseaeeeeeeeenaeens 13 7 1 Using the Memory Card sseesseeeessesesseesersreseressreresseserseeseesesses 13 A Memory Card Files sc a2 ccs ets aa a i 14 7 2 Clearing Temporary MeMory cccceeceeseecseesceesceeeeeteeeteenseenaes 14 7 3 Deleting a Filerna enen borate eA eo 14 SETTING UP THE CELLCORDER syrnet cuss nodes Sae erR E s 15 8 1 System Setup Thresholds sneeseeeenseeseeseeseesessreressrsersssseesesseese 15 8 2 System Setup Clear Memory ssssssssessessereeeseeeessreresserersresersesseeee 17 8 3 System Setup Display zeeer e asie oa 17 8 4 System Setup Sound srren anse O E E E meen 17 8 5 System Setup Modem c ceccceecceseceseeeeeceeeeseeeeeeeeeseeeeeeeereneens 17 8 6 System Setup Freq
17. example if site 003 of 006 is deleted site 006 becomes 003 of 005 You may use the BAS program or CRT 300 Previewer to sort the sites on location battery or string name 9 6 Selecting a Site for Test Before reading voltage or resistance you should select a site though this is not mandatory A site setup is not required for testing but is useful for managing many sites If a site is selected before testing the site information will be saved in the CDF file along with the readings To select a site at the Main Menu select Load Access Setup Data Press the Right Left Arrows to step to a site then press Select If the Active Site screen displays the correct site names press Continue to return to the Main Menu To select a different site press Load If a site has been selected and you want to take readings with no site selected press Clear Refer to System Setup Thresholds for a description of the Clear function NOTE To determine at any time what site is selected from the Main Menu press Shift Site To select a different site press Load To have no site selected not recommended press Clear To return to the Main Menu press Continue 24 Measuring Voltage and Resistance 10 Measuring Voltage and Resistance This section describes Cellcorder testing Before testing charge the Cellcorder and verify it is within calibration To easily confirm calibration read a known voltage using a known shunt as an intercell connector
18. memory will be erased card Continue YES NO CLEAR YES NO Figure 13 Data in Memory Screens If the Cellcorder is running and you want to clear temporary memory press Shift Mem At the All data will be erased warning press Yes 31 Measuring Voltage and Resistance 10 5 3 Loading a File This section describes how to load a data file into Cellcorder temporary memory You may load open a memory card file to append voltage or resistance readings to add SG and temperature readings from a hydrometer module or to send the file to a computer or PDA To load a file at the Main Menu select Load Access Cell Data Highlight a file name using the Arrows then press Select to load the cell data into temporary memory After the file loads the Main Menu appears Computer permanently Use the memory Cellcorder temporarily stores cell data files card like a stores cell data files Can read or write files to diskette Can read or write files the memory card to the memory card Figure 14 Memory Card as a Disk 10 5 4 Appending a File Only CDF files can be appended First load the file into memory Refer to Loading a File To append voltage or resistance readings at the Main Menu select Mode Voltage or Mode Resistance To add SG and temperature readings refer to Mode Select Specific Gravity Temperature In Voltage mode data for Cell 001 if available appears In Resistance mode you must complete screen selections before
19. no keys respond disconnect the unit from all voltages open the battery compartment and press the reset switch using a pointed object Do not use a pencil as graphite may get inside the unit 6 3 Main Menu The Main Menu options are Mode Setup Load and Status Press the F1 to F4 buttons below the options to select them Mode Displays the Voltage Resistance and Specific Gravity Temperature menus to measure voltage determine resistance or record specific gravity SG and temperature NOTE You must import SG and temperature readings from a separate instrument Setup Displays menus for voltage resistance SG and temperature threshold limits memory storage LCD contrast sound modem connection ripple frequency and date time Load Displays menus for accessing site setup or cell data files Status Summarizes overall voltage OV cell voltage cell resistance and intercell resistance readings as averages min max lists or violations Helps determine if retesting is needed 6 4 Using the Test Leads This section summarizes good test lead connection practices to help ensure the accuracy of readings For actual test lead connection refer to Measuring Voltage and Resistance WARNING Never let any Cellcorder metal surface touch a battery post or grounded rack while testing with the unit WARNING Do not attempt to read internal resistance of an open cell module while the battery is on line An open cell can be determined by
20. should select a site though not mandatory Refer to Selecting a Site for Test WARNING Do not attempt to read internal resistance of an open cell module while the battery is on line An open cell can be determined by the abnormally high voltage across it and the low voltage across all other cells modules NOTE When taking resistance readings a skewing effect of the cell voltages produces a small error Refer to Skewing Effect 26 Measuring Voltage and Resistance Connect the resistance test leads to the Cellcorder but not to the cell under test At the Main Menu select Mode Resistance then select how many intercell connections per cell will be read one to four Refer to Application Note CC 002 to determine the number If the test leads do not support intercell readings select Combine to have no uQ values displayed for Ricl to Ric4 Mode Select Intercell Type 1 Voltage 1 Single 4 Quad 2 Resistance 2 Dual 5 Combine 3 5 6 Temperature 3 Triple BACK Figure 10 Mode Select and Intercell Type Screens After selecting intercell type specify whether the battery is smaller or larger than 1000 ampere hours This affects the length of time the Cellcorder applies a load Select Amp Hour Rate WARNINGS No Vfloat readings 1 0 1000 AH exist Do you want 2 More than 1000 AH to take Vfloat readings now BACK YES HO Figure 11 Select Amp Hour and Float Warning Screens After you select amp hours if float voltage rea
21. the Main Menu select Setup Thresholds then choose Voltage Cell Resistance Intercell Resistance Specific Gravity or Temperature Use the Arrows to scroll the menu A series of screens appears for parameters that may be set Press the Arrows to change values Press Accept to display the next screen or return to the Thresholds menu NOTE On the Temperature screen select F Fahrenheit or C Celsius using the C F button before setting the high low temperatures The following table shows the ranges for each programmable entry Disabling a Threshold Setting any threshold value to zero or 32 F 0 C for temperature disables the threshold Voltage Voltage Threshold High ccceseeseesseesteereeees 00 000V to 19 999V Voltage Threshold LOW ccceeseesseesteeteeeteeees 00 000V to 19 999V Cell Resistance Cell Resistance Threshold High 008 00000pQ to 64999 LQ Cell Resistance Threshold Low ee8 00000pQ to 64999 LQ Intercell Resistance Ric 1 of 4 Intercell Res Threshold High 00000pQ to 24999 LQ Ric 2 of 4 Intercell Res Threshold High 00000pQ to 24999 LQ Ric 3 of 4 Intercell Res Threshold High 00000u2 to 24999 LO Ric 4 of 4 Intercell Res Threshold High 00000pQ to 24999 LQ Specific Gravity SG Specific Gravity Threshold High 0 ecceeeeseeeseeseeee 0 000 to 9 999 Specific Grav
22. the equipment If liquid does get into the equipment unplug it immediately and contact your nearest authorized service center or Alb r directly Ensure equipment is provided adequate ventilation Do not block equipment ventilation openings Do not exceed equipment voltage or power ratings or capabilities Do not let unauthorized persons operate the equipment The maximum voltage the Cellcorder can read is 20V Do not attempt to read Overall Volts OV The Cellcorder calculates OV based on cell voltage readings Never let any Cellcorder metal surfaces come in contact with a battery post or grounded rack while testing with the unit Do not attempt to read internal resistance of an open cell module while the battery is on line Do not perform any testing with the Cellcorder when the AC Power indicator is lit or when the charger module is connected to the Cellcorder Injury to personnel or damage to equipment could result Use of this product in a manner not specified could compromise the designed in safety of this product High voltage or current may be present in the equipment Only qualified personnel should perform the operations described in this manual What s New 2 What s New The Cellcorder CRT 300 battery cell voltage and resistance tester is the newest addition to the Alb r Cellcorder family The CRT 300 is lightweight stylish rugged and durable Special features include new user friendly operation Smart Media
23. the voltages of the remaining cells increase to make up the difference since the charger controls the overall voltage The skewing effect is particularly noticeable on small and weak cells For large batteries such as mini tank cells the effect is not as noticeable but there is still a small error in the voltage readings Panel Controls and Indicators 5 Panel Controls and Indicators This section describes the Cellcorder controls indicators and connectors Menu items that appear on the LCD display are described in the sections of the manual where they are used Top Panel Indicators Power AC cee Red On when Cellcorder battery charger is connected Battery Green On when charger is connected and battery is charging Off indicates fully charged battery Smart Media Card Yellow On when Cellcorder is accessing the Smart Media memory card for read or write Bee per nisus Emits audible feedback when enabled Top Panel Controls Fl Print 2 02 06 F1 selects the function on the LCD directly above Shift F1 selects Print which sends data to the printer via IR F27 Send seascnkecas F2 selects the function on the LCD directly above Shift F2 selects Send which sends data to the computer via modem or IR F3 Save ninni F3 selects the function on the LCD directly above Shift F3 selects Save which saves data to the memory card FAI Site 263 8sca F4 selects the function on the LCD directly above Shift F4 selects
24. while internal components cool down The fan may turn on Warnings indicate testing is halted if components get too hot 28 Measuring Voltage and Resistance Continue reading until all the cells are measured If the leads are incorrectly or poorly connected messages appear After testing is done remove the leads from the cell under test and press the Esc Escape key or Shift Start to return to the Main Menu To save refer to Saving the Readings 10 3 Mode Select Specific Gravity Temperature Specific gravity SG and temperature readings can be transferred from a compatible hydrometer data storage module in three ways 1 From the data module to Cellcorder via IR 2 from the module to computer via IR or 3 from the module to computer via RS 232 Select a cell data file before transferring data The optional hydrometer reads SG and temperature An optional data storage module which holds data for up to eight strings A to H is mounted on the hydrometer and has two IR ports One port interfaces with the hydrometer the other transfers data to the Cellcorder computer or PDA The module also accepts an RS 232 cable to transfer data to the computer When using RS 232 refer to the Battery Analysis System User s Guide When Mode SG Temperature is selected from the Main Menu the temperature displays in degrees Fahrenheit CF or Celsius C Select F or C by clicking C F under Setup Thresholds Temperature or under Load Access
25. 001 NOTE Uploaded temperature values are rounded to the nearest whole number On the Cellcorder to return to the Main Menu press Cancel then Back To save the file with the SG and Temperature data press Shift Save type the file name then press Save The data module powers off after about one minute of inactivity To delete data on a data module channel select the channel and press Del until the flashing LED goes out Refer to the data module and hydrometer manuals for additional instructions 10 3 2 Hydrometer Data to Computer Use the CRT 300 Previewer or BAS program to transfer SG and temperature data from the hydrometer data module to the computer via IR or RS 232 serial cable To transfer data refer to the CRT 300 Previewer User s Guide or the Battery Analysis System User s Guide 10 4 Overall Voltage OV Data The Cellcorder adds the cell voltages in a string and calculates overall voltage OV You may view OV using the Main Menu Status selection or the BAS program OV can be printed out using the IR thermal printer or printer attached to the computer The OV value cannot be manually entered 30 Measuring Voltage and Resistance 10 5 Saving the Readings After you finish taking voltage or resistance readings save them to a file on the memory card Saving lets you clear Cellcorder temporary memory and take new readings on another battery Use Microsoft Explorer to copy files from the memory card to the computer
26. 7013 c 1 of the DFARS and ii if the software is supplied to any unit or agency of the United States Government other than DOD the Government s rights in the software and its documentation will be as defined in Clause 51 227 19 c 2 of the FAR RESTRICTED RIGHTS LEGEND Use duplication or disclosure by the Government is subject to restrictions as set forth in subparagraph c 1 ii of the Rights in Technical Data and Computer Software clause at DFARS 252 227 7013 Alb rcorp 990 South Rogers Circle Suite 11 Boca Raton FL 33487 Information in this document is subject to change without notice Cellcorder CRT 300 User s Guide 4200 038 Book Revision 1 1 2003 Alb rcorp 990 South Rogers Circle Suite 11 Boca Raton FL 33487 This manual may not be copied in whole or in part without express written permission from Alb rcorp Microsoft Windows Microsoft Excel Microsoft Access and Microsoft Explorer are registered trademarks of Microsoft Corporation Pentium is a registered trademark of Intel Corp Smart Media is a registered trademark of Toshiba Corporation Cellcorder is a registered trademark of Alb rcorp Palm OS HotSync and Palm are registered trademarks of Palm Inc Printed in the United States of America iii iv BwWwWN ke Table of Contents SAFETY INFORMATION piei e ERRER AR A E 1 WHAT S NEW aanaeio niea E EEEE SE E AEE EEE Ti 2 SYSTEM REQUIREMENTS Sissit e t EA R E AES 3 GENERAL DESCRIPTION shrani
27. Cellcorder CRT 300 User s Guide Alber 990 South Rogers Circle Suite 11 Boca Raton FL 33487 Tel 561 997 2299 Fax 561 997 5588 www alber com Cellcorder CRT 300 User s Guide Alber 990 South Rogers Circle Suite 11 Boca Raton FL 33487 Tel 561 997 2299 Fax 561 997 5588 www alber com 1 WARRANTY AND LIMITATION OF LIABILITY LIMITED WARRANTY Alb rcorp warrants that the software product will perform in accordance with the accompanying written materials for a period of ninety 90 days from the date of receipt Some states and jurisdictions do not allow limitations on duration of an implied warranty so the above limitation may not apply to you To the extent allowed by applicable law implied warranties on the software product if any are limited to ninety 90 days CUSTOMER REMEDIES Alb rcorp s entire liability and your exclusive remedy shall be at Alb rcorp s option either return of the price paid or replacement of the software product that is returned to Alb rcorp with proof of purchase This Limited Warranty is void if failure of the software product has resulted from accident abuse or misapplication Any replacement software product will be warranted for the remainder of the original period or thirty 30 days whichever is longer Alb rcorp shall not be liable for any data or programs stored in or used in conjunction with this software product Without prejudice to the foregoing generality Alb rcorp shal
28. E Do not connect to the stainless steel bolt heads to make this measurement 78 Application Note CC 002 Make sure tips ony contact DUAL INTERCONNECTIONS Figures 3A and 3B show the typical intercell connections for dual post cells This type of interconnection requires that two readings be taken The first one shown should be with the intercell leads connected from Terminal Post A to Terminal Post C Take the second reading with the intercell leads connected from Terminal Post B to Terminal Post D The positive a red clip Cellcorder lead should remain connected as shown to the same terminal post for both measurements WW RED A B_Iic GLa Z N Bak Figure3A RED P BLACK YTN RF DUALINTERCONNECTIONS TRIPLE INTERCONNECTIONS Figures 4 and 5 show the typical intercell connections for triple post cells For cells arranged as in Fig 4 three readings are made The first one shown should be with the intercell leads connected from Terminal Post A to Terminal Post D Take the second reading with the intercell leads connected from Terminal Post B to Post E The third reading is with the intercell leads connected from Terminal Post C to Post F 79 Application Note CC 002 Fig 5 TRIPLE POST YRLA For VRLA cells or flooded cells configured as shown in Figure 5 four readings are made forming two X s Terminal Post
29. Setup Data OPT or HT or LT More Change select temp units and then selecting the site 10 3 1 Hydrometer Data to Cellcorder via IR To transfer SG and temperature data from the hydrometer to the Cellcorder using the IR data module do the following 1 To select a file to which SG and temperature readings will be added on the Cellcorder Main Menu select Load Access Cell Data Highlight a CDF file name then press Select 2 At the Main Menu select Mode SG Temperature then press Import 3 Power on the hydrometer data module by pressing the On button 29 Measuring Voltage and Resistance 4 10 11 12 On the data module press Sel to select the channel string A through H from which data will be transferred The module LEDs indicate memory status as follows Fast If the LED next to A through H is flashing fast that channel has data and is selected Steady If the LED is on that channel has data but is not selected Slow If the LED is flashing slowly the channel is selected but has no data Align the data module IR port with the IR port on the right side of the Cellcorder On the Cellcorder press Continue As data is received the Cellcorder displays cell numbers and the data module flashing LED stays lit When the maximum cell number is reached all readings have been loaded The data module LEDs resume flashing and the Cellcorder displays Storing data to EE then displays the SG and temperature for Cell
30. Site which displays the site selected POWELD ece roren Press and release to power on the unit Press and hold to power off Enter Arrows Five function key Enter plus four Arrow keys Press Enter after typing data such as password Press Up Down Left or Right arrows to navigate screens Testiin nAkeneaiests Press to initiate cell testing 1 abc Start Alphanumeric data entry Shift 1 selects Start which displays the Main Menu 2 def Time Alphanumeric data entry Shift 2 selects Time which sets the date format and time 3 ghi Mem Alphanumeric data entry Shift 3 selects Memory which clears stored data 4 jkl Hz Alphanumeric data entry Shift 4 selects Frequency Hz for 50Hz 60Hz ripple frequency 5 mno Alrm Alphanumeric data entry Shift 5 selects Alarm which sets threshold levels Panel Controls and Indicators 6 pqr Disp Alphanumeric data entry Shift 6 selects Display which adjusts LCD contrast TSt SEV n Alphanumeric data entry Shift 7 selects Service which accesses calibration default and password 8 vwx Mute Alphanumeric data entry Shift 8 selects Mute which sets the internal beeper on or off 9 yz blank Diag Alphanumeric data entry with blank space Shift 9 selects Diagnostics Shift eaaitiueedeceses teens Press Shift release Shift then press another key to select orange text on a key Shiftt key name Onsen
31. Smart Media card 8MB supplied and 16MB 32MB 64MB and 128MB 71 strings with 256 cells per megabyte 8MB size card can store 568 strings 10 years Fully IrDA compliant for PDA PC interface Physical IrDA compliant for printer interface V32bis 4 cell 8800mAh lithium ion 4 2V 8 hours 90 to 264VAC 5VDC 4 0A 47 to 63Hz 62 Environmental Temperature Range Operating Storage Humidity Range CRT 300 Specifications 32 F to 104 F 0 C to 40 C 20 F to 140 F 29 C to 60 C For extended periods lt 77 F lt 25 C 0 to 80 RH non condensing at 0 C to 31 C 0 to 50 RH non condensing at 32 C to 40 C Insulation Category I Pollution Degree 2 Altitude 0 to 2000 meters above sea level Accuracy Input Test Resistance Voltage Intercell Current Resolution Resolution Range Resolution 0 1 of reading 0 1 of reading 1 of reading 2V 60A 5uQ 1mV 2mQ 4V to6V 25A to35A 25uQ 3mV 3 3mQ 8V to 12V 15A to 20A 75uQ 6mV 5mQ 16V 5A 400UQ 10mV 20mQ Warranty One year limited warranty Ordering Information Cellcorder including software carrying case battery charger cables and clamps CRT 300 Optional Accessories Printer with IRDA interface Internal modem 2025 124 2025 031 2030 002 Smart Media card 128MB Note Specifications are subject to change without notice 63 Application Note CC 001 29 Appendix C Application Note CC 001
32. To return to the Main Menu press Cancel 41 Service Menu 13 3 Factory Defaults Resetting to factory defaults resets the calibration constants sets the password to 1234 resets threshold settings resets the values of any site in temporary memory and restores display settings WARNING The Cellcorder loses calibration when reset to factory default and must be recalibrated WARNING Unplug any test leads from the Cellcorder before initiating a firmware reset To reset the Cellcorder to factory settings at the Main Menu press Shift Serv password Enter Factory Defaults At the message prompt to restore to default settings press Yes 42 Battery Maintenance Schedule 14 Battery Maintenance Schedule The Cellcorder can easily take periodic maintenance readings An effective maintenance program that meets the recommendations of most battery manufacturers calls for the following measurements INTERVAL PARAMETER Quarterly Semi Annually Annually Cell Voltages X Intercell Resistance X Internal Resistance X Vented Cells Internal Resistance X Sealed Cells Specific Gravity X Temperature Profile X Capacity Every 3 to 5 years until signs of degradation Vented Cells then once every year Capacity Every year Sealed Cells Figure 21 Maintenance Schedule NOTE VRLA or sealed cells must be tested more often because of their shorter life expectancy and lower reliability U
33. all string data page CAUTION Delete cannot be undone however you can re install the backup database DB3_AlbJobDB PDB automatically stored on the computer during a HotSync operation Alber Mobile AOG Y ALL LOCATIONS 7 1 Location Battery2 Stringi Delete ALL Data Delete ALL String Data ot Figure 25 Delete All Data 18 3 About The About page displays the software version and copyright information 50 PDA Mobile Software User s Guide 19 Data Transfer to PDA via IR This section describes how to transfer cell data from a Cellcorder and specific gravity SG temperature readings from a hydrometer to the PDA via the IR infrared interface 19 1 File Transfer from Cellcorder to PDA Before transferring data to the PDA load the data in Cellcorder temporary memory press the Cellcorder Shift Send then make menu selections On the PDA Main Page press Cellcorder follow screen instructions then press Download to transfer Alber Mobile tits Y ALL LOCATIONS Location Battery1 Stringi LocationS BatteryS StringS LocationS BatteryS StringS oS Ba Download Cellcorder 1 Ensure Cellcorder is ON 2 Initialize Cellcorder IR 3 Align IR ports 4 Select Download Download Cancel Figure 26 Download Cellcorder The Cellcorder displays Sending data for Cell nnn during transfer Upon completion the PDA displays Cellcorder Download Complete Press OK to store the file On the Cellcorder return to the Ma
34. arge this reduction in capacity appears differently depending upon whether the resistance change is primarily metallic or electrochemical in nature 67 Application Note CC 001 METALLIC RESISTANCE This portion of the internal conduction path troubles most battery test experts It is here that deterioration of a cell can occur most rapidly and then will often go undetected between the yearly integrity tests or even less frequently the capacity tests The tear down of failed batteries with abnormal internal resistances has proven that the terminal posts and the internal straps and grids are most often the victims of corrosion poor welds or burns Where found con tact surfaces of a copper insert can corrode or loosen from its surrounding lead post The Cellcorder easily detects these types of problems Fig 5 clearly shows the loss of capacity due to a high internal metallic resistance The available voltage at the battery s terminals is reduced from the start of the discharge and continues to the end Fig 5 y TYPICAL DISCHARGE CURYE OPEN OF ACELL WITH A CIRCUIT METALLIC RESIST ANCE PROBLEM ELECTROCHEMICAL RESISTANCE Cell paste electrolyte and separators form the electrochemical part of cell internal resistance Long term increases in Rerecrrocnemica Can be caused by loss of active material or paste due to aging Short term changes also occur naturally during parts of the charge or discharge processes when the sp
35. aults to 256 L R and U D arrows DAT Battery installation date L R and U D arrows OPT Options The first screen sets temperature format U D arrows F or C The next sets ripple AC line frequency keypad The last sets date format HV LV High and low cell voltage Sets limits During L R and U D testing two beeps and reverse video indicate limits arrows are exceeded HR LR High and low internal cell resistance Sets limits L R and U D During testing two beeps and reverse video arrows indicate limits are exceeded HI1 High intercell resistance 1 2 3 4 Sets limits L R and U D HI2 During testing two beeps and reverse video arrows HI3 indicate limits are exceeded HI4 HT LT High and low cell temperature Sets limits During L R and U D testing two beeps and reverse video indicate limits arrows are exceeded HSG High and low specific gravity Sets limits During L R and U D LSG testing two beeps and reverse video indicate limits arrows are exceeded max maximum L R left right U D up down Figure 6 Definable Site Items 21 Setting Up and Editing a Site 9 2 Setting Up a Site Before Testing To create a new site at the Main Menu select Load Access Setup Data If the memory card has no sites the New Site screen appears If sites exist press New to display New Site To begin site setup highlight LOC with the Up Down Arrows To edit press Change Using the keypad type
36. ay more min max Ric SG and temperature values To return to the Main Menu press Back 11 3 Status Screen Faults To display faults values that exceed thresholds on the OV Status screen press Faults then select the menu item for which you want faults displayed volts internal cell resistance intercell resistance SG or temperature Press More to display all options To retest a displayed voltage or resistance reading that violates thresholds press Retest Typical fault screens for voltage resistance SG and temperature are shown below CELL c Temp HHH o HEE NEXT PREY CANCEL RETEST NEXT PREY CANCEL Figure 17 Typical Fault Screens 35 Status Screen The top portion of voltage and resistance fault screens indicates cell number and fault type Voltage Internal or Intercell The reading at fault is highlighted SG and temperature screens show cell number and highlight the problem SG or temperature value To display the next fault press Next or Prev Previous To return to the Main Menu press Cancel or Back 36 Diagnostics Menu 12 Diagnostics Menu Cellcorder warning and error messages indicate operation and connection status On power up the Cellcorder displays uploadable flash memory and boot memory versions If errors occur during use messages appear The only numeric error codes are for the Smart Media card Refer to Error Codes If the Cellcorder malfunctions use the Diagnostics descr
37. cation battery and string names model number and the install and read dates To display the page select Site Information from the Options menu All parameters are editable except Overall Voltage OV and Number of Cells The OV and Number of Cells change as cell data is added Site Information Location L Battery B String Model Overall V Cells Figure 34 String Site Information 55 PDA Mobile Software User s Guide 21 3 Thresholds To display the Threshold page for a string select Thresholds from the Options menu All thresholds are editable Setting a threshold to 0 zero or no value disables it Thresholds High Low Voltage 16 00 0 200 Resistance 60 Specific G Temp 0 Intercell R1 20 Intercell R2 20 Intercell R3 20 Intercell R4 Figure 35 String Thresholds 21 4 Add Edit Comments To display or edit comments for a string select Add Edit Comments from the Options menu Type comments on the Add Edit Comments page that appears Battery 1 String1 Add Edit Comments Figure 36 Add String Comments 56 PDA Mobile Software User s Guide 22 Printing To print string information from the PDA to an IRDA equipped printer select Print from the Options menu The Print Options page appears with all print options selected Select a box to check or uncheck an option Select Header s Site W Stats Thresholds w Comments Select Data I Voltage amp Intercell R1
38. ccept and agree to these terms you must return the full product with proof of purchase to Alb rcorp within thirty 30 days for a full refund Installation or use of this software product constitutes your acceptance of and agreement with the terms of this Software License Agreement LICENSORS All software on this media is licensed to you by Alb rcorp GRANT OF LICENSE You are granted the right to use the Alb rcorp Software on a single personal computer You may copy the software to use with this personal computer to any one hard disk drive of this personal computer and to the memory of this personal computer provided that you reproduce all copyright and trademark notices restricted rights legends and other proprietary markings RESTRICTIONS You may not sublicense rent or lease the Alb rcorp Software You may not reverse engineer decompile disassemble modify translate or create derivative works of the Software LIMITED WARRANTIES AND LIMITATION OF LIABILITY The limited warranties and limitation of liability in Section 1 of this file apply to are incorporated in and are made a part of this Software License Agreement EXPORT LAW ASSURANCES You acknowledge and agree that the Software is subject to restrictions and controls imposed by the United States Export Administration Act the Act and the regulations there under You agree and certify that neither the Software nor any direct product thereof is being or will be acquired s
39. cs A D Linearity cceeceseeseesecseeeneeeseeeeeeneeeereeeens 38 12 71 Voltawe Channel A sconces aie tevedesceeeleti geese 38 1257 22 Fest I Channel 33 3 see 0s cotedyce E 38 127 3 I r Channel 4 saeco cs testes icicle eats Modest ets escalates 39 E ASD PReterence te t 5 ceclc A E 39 12 8 Diagnostics Protection Circuit cccccesesseesceeseeeeeeeeeeeeeereerens 39 12 9 Diagnostics Modem cccceescescceseceseceseceeecaeecseeeseeeeeensenereearens 39 12 10 Diagnostics BUZZer 0 eeeceeccesceseceteceseceseeseecseeeeeeeeeeeeeeeresseens 39 12 11 Diagnostics Fas r rr ena r aE arara ar ernaia kasise ane 39 12 12 Diagnostics Temperature Sensors sseesessssseeesssrseesresersesseeee 39 12 13 Eror Code Sera a iets 5 sented sad gad se EE aSa AEE hse 40 13 SERVICE MENU r ne ar a A E E Aa 41 13 1 Entering the Password c cc ccsc 3 cceses riiin en 41 13 2 Changing the Password ssssesseesseseessesersreseesesseeressesresresersessee 41 13 3 Factory Defaullts 3 cccctsiisste ienn rinan eie 42 14 BATTERY MAINTENANCE SCHEDULE ccsccesecesecseeereeeeeeeeeeeeeeeens 43 15 UPGRADING THE FIRMWARE ccceccsessceeescsseeeseeceeessceeeseseeeeseaesaeea 44 15 1 Upgrading Using the Memory Catd ccceccesesseeseeeeeseeereeteees 44 15 2 Upgrading Using the IR Port ec ecceceeeceeseeeeeeeeeeeeeeeeeeereeeens 44 16 PDA MOBILE SOFTWARE acrin ninar e aR R 48 16 1 General Description PDA sssessss
40. d testing under controlled conditions is the only method with certainty of establishing a battery s actual capacity This is reflected in several national standards the latest of which was issued in 1995 However after many years of experience studies and experiments a wealth of information about battery behavior and measurements has been produced and some light has been shed on new tools that will help assess a battery s condition Fig 1 Metalic Resistance Classical CellModel Acid Resistance Capacitance between plates Leakage and other Resistance elernents Inductance of Leads and Structures As early as 1959 the equivalent circuits of cells and typical circuit values were published See Figure 1 These circuit models of a battery s cell are critical to understanding how its condition relates to cell internal parameters conduction paths and capacity THE BASICS RESISTANCE INDUCTANCE AND CAPACITANCE The models circuit elements are resistance capacitance and inductance Researchers have investigated battery parameters from DC through several thousand hertz and have made measurements in all units They tried to relate those to cell capacity often with mixed or conflicting results In almost all typical battery applications the inductance has no practical impact on battery performance because of its small magnitude from 0 05 to 0 2 microhenries On the other hand the actual capacitance of c
41. dings were taken the Resistance screen flashes Ready to Test If not a message asks if you want to take float voltage readings If you select Yes the Cellcorder switches to Voltage mode Insert the voltage probes into the Cellcorder and select the cell number to test Return to the Resistance menu when finished If you select No the Cellcorder takes voltage and resistance readings concurrently for each cell Voltage is read then the load is applied NOTE At any time to return to the Main Menu from the Resistance screen press Esc Escape or Shift Start The Cellcorder is ready to read resistance when Ready to Test is flashing Connect the three clip resistance probes to the cell and intercell under test If testing cells with single intercell connectors connect the probes as follows 1 Red clip to the positive post of the cell being tested 2 Red Black clip to the negative post of the cell being tested 3 Black clip to the positive post of the next cell 27 Measuring Voltage and Resistance If testing cells that require two to four intercell measurements refer to Application Note CC 002 Internal Resistance Measurement Procedures for probe connection diagrams NOTE The standard jaws supplied may not provide the best connection to some cell post designs If you encounter poor post connection contact Alb r for alternate or custom jaws at nominal cost The Resistance screen cell voltage Vc field displays Vc act or Vc m
42. dry out of electrolyte are all natural processes that push a cell to its end life This aging process is marked by increasing cell internal resistance and decreasing capacity It is generally agreed that below 80 actual capacity the cell s deterioration will accelerate rapidly and replacement is recommended The internal resistance increases slowly but toward the end of a cell s life it accelerates greatly Its end life value is normally about 25 or so above its initial value but can be as high as 50 69 Application Note CC 001 TEMPERATURE AND INTERNAL RESISTANCE Being aware of the effect of temperature on internal resistance is important Figure 7 for a typical AGM VRLA cell clearly shows rapid internal resistance and impedance increases below temperatures of about 45 F 8 Fig 7 N Normalized Internal Resistance Per Cent Vs Temperature of 77F Value a 3A 2A IA A IA 2A 3A 4A SA AA 7R RA IA 10M 11A 12A aA 1AM Degrees F REF 8 A In temperate climates VRLA cells in unconditioned temperature environments may show considerable internal resistance variation between quarterly measurements Recording of the ambient temperatures at the time of measurement will might save you further testing and false alarms Similarly cells chilled by air conditioning exhibit higher readings than their sheltered neighbors If possible try to r
43. e direct the air flow THE CELLCORDER The Cellcorder is invaluable in determining what a battery or cell s internal resistance is and in helping to identify abnormal conditions and normal aging While a battery or cell is on line it accurately and repetitively measures the internal resistance using DC techniques The AC filtering currents stray 60 hertz fields noise and normal float currents have virtually no effect on its readings The authors can t help but wonder what earlier researchers could have accomplished if they had access to microprocessor and solid state technology The microprocessor of the Cellcorder permits it to not only control measurements but to also precisely time the readings and performs calculations To boot it can tell whether a reading is valid and then records the results 70 Application Note CC 001 The battery manufacturers have customarily determined the internal resistance of cells using simple Ohms Law They usually measure the voltage differences and current during a battery discharge The Cellcorder does the same thing but very quickly and accurately Figure 8 reveals what happens when a battery is subjected to a load The instantaneous voltage drop when the load is applied or the instantaneous voltage recovery when the load is removed is due to the internal resistance The Cellcorder reads the current and the cell voltage just prior to removal of the load and then measures the recovered cell s
44. ecific gravity is altered or when the contents of the separators varies and or the chemical composition of the surfaces change Separator compression clogging or shorts and conditions like sulfation are frequently causes of abnormal increased electrochemical resistance however accelerated electrolyte dryout appears to be public enemy 1 when it comes to VRLA failures 68 Application Note CC 001 Figure 6 reveals how a battery with an electrochemical resistance problem behaves Its reduced capacity does not become apparent until much further into the discharge like running out of fuel On the other hand the metallic resistance problem can be viewed as pinching the fuel line In either case the worse the resistance the greater the shortfall between the cell s rated and actual capacity VOLTAGE Fig 6 TYPICAL DISCHARGE CURVE VOPEN OF A CELL WITH AN QROUIT ELECTROCHEMICAL RESISTANCE PROBLEM BATTERY AGING AND INTERNAL RESISTANCE Internal resistance provides a clue to aging The aging process of a battery s cells is based upon the rates at which their materials and construction deteriorate under design conditions For example the life of nearly all stationary cells is specified at 77 F under particular float charge conditions and discharges of stipulated depth and frequency Very slow corrosion of conduction paths the loosening of active materials from plates grid deformation and in the case of VRLA cells
45. ecords cell float voltage internal cell resistance and intercell connection resistance A compatible hydrometer can transfer specific gravity and temperature data via the IR port The self contained Cellcorder is comprised of a microprocessor load resistor display and rechargeable battery Voltmeter probes and a three clip resistance set are provided optional test leads are available from Alber The Cellcorder functions well even in high noise environments without the need to disconnect the battery from service A 60 amp DC load on 2V cells is used to calculate internal cell resistance and intercell resistance Circuitry rejects the 50Hz 60Hz ripple and associated harmonics often troublesome to AC based impedance and conductance meters The Cellcorder ships with an 8M memory card USB memory card reader writer resistance and voltage test leads carrying case charger module and Battery Analysis System BAS software An optional printer is available Data Memory and Communication The removable memory card stores virtually an unlimited amount of data The memory card IR port or internal modem transfers cell readings to a computer for analysis and report generation System Display The high contrast 128 x 64 pixel backlit graphical display shows menus instructions warnings and test results Power The Cellcorder is powered by a lithium ion rechargeable battery It does not operate on AC power A fully charged Cellcorder ca
46. ed battery does not affect data readings in memory WARNING Do not test any cells when the Cellcorder AC Power indicator is lit Injury to personnel or damage to equipment could result Before charging the Cellcorder disconnect any test leads from the unit Open the accessory compartment cover by loosening the two slotted screws Connect the charger module to the power connector inside the compartment then plug the module into 115VAC The Cellcorder Power AC and Battery LEDs should light The Battery LED indicates battery level only with the charger connected When the LED goes out the battery is fully charged When charging is complete unplug the charger from 115VAC then from the Cellcorder Replace the accessory compartment cover Before beginning testing cycle Cellcorder power off then on The life of the lithium ion battery depends on how well it is charged Do not store the Cellcorder in a discharged condition During use warnings indicate remaining test time when the battery is low At full discharge the unit turns off Data remains in memory and can be accessed after recharging the battery If you power on a unit needing recharge it will shut down without warning If you continue to use the Cellcorder in this state data could be lost To conserve battery life the Cellcorder shuts down if not used for ten minutes WARNING WARNING Battery has less Low battery detected than one hour run Power will shut down
47. eeeerenteeereens 30 10 5 Saving the Readings eienenn e ERR ER 31 10 5 1 Saving to the Memory Card o ce cecceseeseeseeereeeeeeeseeereeeens 31 10 5 2 Clearing Cellcorder MeMory ccceecceseesseeteeeeeeseeeeeeeeees 31 10 5 3 Loading a Biles cnc secad eke ntact encore ates 32 10 5 44 Appending a File cusna EREN 32 10 5 5 Storing Data for Multiple Strings 0 cc eeeeseeeeteeeees 32 10 6 Sending Readings via IR to a Computer oo cee eeeeeeteeeeteeeeees 32 10 7 Printing Test Results vsi c 03 ca ciobeccsd oan enn s erari 33 11 STATUS SCREEN eieuta eaa r aa e Eeen aeran aariat 35 Flt Status Screen Average a oct e eae o a ae eat 35 11 2 Status Screen Min Max ccceccesecssecsseeseeeseeeeeeeeeeeeeeeeeeteeeeenaees 35 113 Status Screen Faults ss ania 35 12 DIAGNOSTICS MENU ssscsssssneiesstssngesenecers cred ansureeendezseonpsrtuseencencestessins 37 12 1 Diagnostics Keypad 0 cccccceescescceseceseceeceeeceecseeeeeeeeeenseeerenrens 37 12 2 Diagnostics Display 0 ceeccescesecsecesecesecececeeceeeeseeseeeeeeeereerens 37 12 3 Diagnostics IR Port ccceeceescessceseceseceseeneecseeeseeeeeeeeeeeeenerensrens 37 12 4 Diagnostics Safety Relay cccecesccesecesecseeeseeeeeeeeeeeeeeereneresseens 37 12 5 Diagnostics Memory Card cccesccesecesececeeseeeseeeseeeeeeesenereneeens 38 12 6 Diagnostics Load Module ccccsccesessececeeseeeteeeseeeeeeeeeeereneens 38 12 7 Diagnosti
48. ells is surprisingly large as much as 1 7 Farads per 100 Amp Hours This cell characteristic is put to good use by charger manufacturers They depend on it to filter their charger output 65 Application Note CC 001 However little evidence has evolved that ties capacitance with the actual capacity of a cell It s worth noting that one researcher felt capacitive reactance obscures the predominant indicator of cell capacity elec trochemical resistance More so as the test frequency is increased Impedance and admittance measurements include both capacitance and inductance in their readings THE NATURE OF INTERNAL RESISTANCE At Alb r we have centered our efforts on cell internal resistance A refined cell model has been developed which subdivides the internal resistances of a cell as shown in Figure 2 into its metallic and electrochemical components These resistances do not change with test frequency Indeed researchers have concluded that a zero frequency DC or extremely low frequencies yield the best results when studying capacity relationships R rer winaPosr R strap R METALUG GRD R Grp TO FASTE E CELL VOLTAGE R paste R evectrowvte Pevectrocuemicat Recocmarog Fig 2 Internal Resistance Mod al Another group focusing on internal resistance is prestigious Nippon Telephone and Telegraph Their research and field personnel have shown that a major result of the lead acid battery deterio
49. em Vc act means Vc is the actual voltage being read Vc mem means the voltage at Vc was read earlier and is in memory Press the Test key While the progress indicator is on the screen you may press Stop to stop the test if required After the cell resistance or intercell resistance for Ricl appears move the probes to the next cell or intercell and press Test The cell or intercell Ric number advances when the leads are moved TEST PROGRESS 0x 100x Status STOP Figure 12 Resistance Test and Progress Indicator Screens If the cell requires two or more intercell resistance readings move the black red and black leads across the next intercell connection then press Test for each intercell measurement Refer to Application Note CC 002 for lead placement The screen displays the first Ric reading when Test is initially pressed and displays the next one after the leads have been moved and Test is pressed again In this case the cell number does not increment until the last intercell is read NOTE You can step to the next cell number using the Up Arrow but then you may have unread cell or intercell numbers The Arrows are primarily used to review readings upon test completion If you press Test before moving the probes to the next cell Readings exist Overwrite appears To read the same cell and intercells if applicable select Yes If not select No and move to the next cell If you press Test too soon Initializing appears
50. enerteaeees 58 25 DELETE STRING DATA Wu ccccececsessscecececeessssscecececeessaeceeeeecsensaeeeeeeeees 58 26 SERIAL ERRORS cccccccsessssscecececscesssaececececsesseeeeececsessnseaececeesesenees 59 27 APPENDIX A CELLCORDER PARTS LIST ccccccccccsesesssceeececeeserseaeees 61 28 APPENDIX B CRT 300 SPECIFICATIONS cc ccccccceesessceeececeesentseeees 62 29 APPENDIX C APPLICATION NOTE CC O01 o ccececsecssscecececeenenteeeees 64 30 APPENDIX D APPLICATION NOTE CC 002 ccccseessscccececeeserseeeees 77 31 APPENDIX E CONNECTION OPTIONS cccssccececeeeesesseceeececeenenseaeees 81 vii Table of Figures Figure 1 Data in Memory Message and Main Menu 9 Figure 2 Typical Battery Power Warnings csccsssseesceeeeeeeeeeeeenereres 12 Figure 3 Setup Menus onces cise 55000 yes do eeneg E EE oE 15 Figure 4 Threshold Limitsiinnereeniniiand ni r e hae eae 16 Figure 5 Setup Data Screens ssssseesesessssseseeieretssrsrstetrerstsssrsrsrrerssseseseee 19 Figure 6 Definable Site Items sseeeeseseesseseeeeserssrsrsrerrsretssssrsrsesssrsrerreree 21 Figure 7 Active Site Screen anoncon ioari ances aE estes E 23 Figure 8 Mode Select and Voltage Screens 0 0 0 cceeeeceesceeeeeeteeneeeeenereees 25 Figure 9 Voltage Screen with Stored Data cieeceseeceeeeeetetneeeeeeeaees 26 Figure 10 Mode Select and Intercell Type Screens 27 Figure 11 Select Amp Hour and Float Warning Screens
51. enon 28 V MEM ieee 28 voltage MEaASUTINg 0 0 eee 25 35 readings sssr 25 voltage mode eeee 25 voltage channel diagnostics 38
52. entralized database for analysis and report generation The modem can call out but cannot receive calls The centralized database approach allows one office or management team to monitor battery performance Letting the Cellcorder call and transfer data eliminates the test technician s having to extract and e mail or transfer data and saves time on the receiving side because data is imported automatically Additionally the central software can be set up to provide notification that data being is out of tolerance WARNING Do not test any cells with the accessory compartment cover removed Before connecting the modem unplug any test leads from the Cellcorder Open the accessory compartment cover by loosening the two slotted screws Connect the modem to a telephone line using the supplied handset cord not a telephone line cord Use a minimum 26AWG Telco cord Set modem settings under Setup Modem To verify modem and phone line operation select Shift Diagnostics Modem To transfer data press Shift Send then select 2 When transfer is complete unplug the modem cable from the Cellcorder and replace the accessory compartment cover 11 CRT 300 Basics 6 6 Charging the Cellcorder To ensure seven hours of testing charge the Cellcorder using the charger module until the green Battery LED goes out Charging may take seven hours If the battery wears down during testing do not use the charger module for power when testing cells A discharg
53. er appears To view additional columns of data slowly drag the horizontal scroll bar Battery1 Stringi Resist 5G Temp Cell Volt 6 788 6 789 6 789 6 789 6 789 6 789 6 789 6 789 930 970 974 974 971 972 972 971 000 0 a 0 00 0 00 0 00 0 00 0 00 000 o 0 00 0 deee Figure 28 View String Data 52 PDA Mobile Software User s Guide 20 2 Edit Cell Data On the Main Page select the string name To edit readings for a cell on the View String Data page select that cell number The Edit Cell box appears Battery 1 String1 Cell Volt Resist SG Temp 1 6788 980 1234 777 F 2 6 789 970 000 0 k Edit Cell 005 J Int R d 5G 1 23 Temp 7 Intercell R4 Figure 29 Edit Cell Data The figure above shows a typical page with Cell 5 selected Edit the readings and press OK To edit readings Press the stylus on the data to be edited then press the 123 button on the PDA Edit the number then press Done 20 3 Insert Readings On the Main Page select the string name On the View String Data page select the cell you want to insert a reading before or after then press Insert on the Edit Cell box On the Insert Readings box enter the new data select Insert Before or Insert After then press OK Dattnunl Ceainnl Insert Readings Intercell R1 Intercell R2 Intercell R3 Intercell R4 Insert before cell 004 O Insert after cell 004 Status Pending Figu
54. esistance Volts 3 5 G Temperature RESUME TESTING BACK CANCEL Figure 8 Mode Select and Voltage Screens 25 Measuring Voltage and Resistance Resume testing means no reading exists for the cell number Place the voltmeter probes onto the cell The Cellcorder reads the voltage and beeps when the reading is stored in temporary memory Move the leads to the next cell the Cellcorder increments to the next cell number Stored in memory indicates the cell number was previously read During testing you may review or retest previously read cells To return to a cell number press the Up Down Arrows or type a number and press Enter The screen displays Stored in Memory CELL Volts STORED IN MEMORY CANCEL RETEST Figure 9 Voltage Screen with Stored Data To test the cell again press Retest place the probes onto the cell and wait for the beep Lift the leads the Cellcorder steps to the next cell number If the next cell number was also previously read you can either retest or change the number using the Arrows or keypad After testing is done remove the leads from the cell under test and press Cancel and Back to return to the Main Menu To save refer to Saving the Readings 10 2 Mode Select Resistance Use the Resistance mode and three clip resistance probes to take internal cell resistance and intercell connection resistance readings on each cell 10 2 1 Taking Resistance Readings Before taking readings you
55. ess Continue At the message System ready to receive upgrade file Select file transfer method press Smart Media File transfer in progress appears and the frame number counts down When Upgrade successful System is running Version nn nnnnn appears press Continue to display the Main Menu 15 2 Upgrading Using the IR Port Download the HEX file from the Alb r Web site or an Alb r CD to Program Files Alber Alber Battery Analysis With Cellcorder power off to start in upgrade mode press Esct Power On At the message System is ready to clear Flash memory for new program to upgrade press Continue At the message System ready to receive upgrade file Select file transfer method press Infrared File transfer in progress appears The frame number does not count down yet On the computer desktop click the Battery Analysis System BAS icon to start the program On the menu bar click the Start the Cellcorder Interface button On the next box click the CRT 300 button then OK Align the computer and Cellcorder IR ports 44 Upgrading the Firmware On the CRT 300 Interface dialog box in the Firmware Update area click Load Update Select the HEX file then click Open On the Cellcorder screen the frame number counts down When Upgrade successful System is running Version nn nnnnn appears press Continue to display the Main Menu On the computer close the CRT 300 Interface box 45 Upgrading the Firmware 46 PDA Mobile So
56. eting a site 24 editing an existing site 23 linking after test 22 selecting for test 24 setting up a site 19 setting up before test 22 skewing effect eee 6 Smart Media See memory card sound setup ceeeeeeeeteereeeee 17 space key oerien t 22 specific gravity cee 29 specifications 62 63 Status button 10 STG described 0 00 21 stored in memory message 26 system requirements 3 system setup clear MemOry 0 006 17 dates yee nae eee 18 display eriein 17 frequency 02 2058 cece eee 18 MOdEM ecrini r 17 Soundin ii 17 system setup Menu 15 thresholds 15 Aina AEA EET 18 telco Connector essees 8 temperature eee 29 37 C F button 16 29 temperature sensors diagnostics Scat E EERE EA leeds 39 temporary memory clearing 14 test DULLON eee eeeeees 7 test I channel diagnostics 38 test key vs oe sash satis 28 testleads ei niiin 10 test leads connector 8 thresholds cell resistance 006 16 cell voltage c eee 16 default eee eceeeeeee 15 how to disable 0 16 intercell resistance 16 86 MENU eseese 16 SCUUP so cteciveds covnsdives cwenvesivese 15 specific gravity 16 temperature eee 16 time setup 0 0 eeeeeeteeereeeees 18 update Cellcorder firmware 44 UPG filenna nak 14 upgrading firmware 44 V AC ve ser
57. ftware User s Guide Cellcordere PDA Mobile Software User s Guide Alber 990 South Rogers Circle Suite 11 Boca Raton FL 33487 Tel 561 997 2299 Fax 561 997 5588 www alber com PDA Mobile Software User s Guide 16 PDA Mobile Software The Palm OS based CRT 300 Palm PDA Mobile Software program is available as a download for the optional PDA This manual describes program operation 16 1 General Description PDA The PDA Mobile Software which interfaces the PDA to the Cellcorder printer and DMA 35N hydrometer can store edit print and analyze battery test data Some PDA s with Windows Internet connection can e mail Cellcorder and hydrometer data files 16 2 System Requirements PDA The following are the minimum system requirements for the CRT 300 Palm PDA Mobile Software Palm OS 3 2 or later for standard operation IRDA file transfer Palm OS 4 0 or later and e mail software for enhanced file transfer options 17 Main Page File Database Power up the PDA then select the Alb r icon The Main Page lists strings of battery test data If there are several pages press the Up Down arrows on the screen to view additional string names Alber Mobile HAG Y ALLLOCATIONS Location Battery2 Stringi Location Batteryi Stringi Location Battery2 Strings Location Battery2 String Location Battery1 Stringi Location Battery String LocationS Battery1 Stringi Figure 22 Typical Main Page To sort files by date or
58. h and how fast Logically checks are done periodically At least quarterly check cells that have exhibited signs of abnormality either from inspection or an earlier capacity integrity or internal resistance test Since neither specific gravity nor visual checks can be done on sealed cells you would want to do much more frequent testing than on vented cells For that reason it s no surprise the P 1188 VRLA proposed Standard recommends internal measurements be taken quarterly On the other hand the standard for vented batteries 450 doesn t specify this type of check However it does call for annual connection resistance readings and you would want to take the internal resistances at the same time 74 Application Note CC 001 That s the nicest part of the Cellcorder its multimeter functions measure and record both the internal and connection resistances at the same time It saves you time and you don t even move the test leads for single post cells For detailed information request Cellcorder Application Note CC002 Intercell Resistance Measurement Procedures which covers single and multiple post cells measurements MANAGING THE CELLCORDER S DATA FILES As a testing program progresses the number of computer data files will increase rapidly as many as four yearly per battery string if the P 1188 guidelines are followed To quickly identify these type files and manage them with minimum errors through DOS or th
59. hipped transferred or exported directly or indirectly into any country or used for any purpose except as authorized by the Act and the regulations GOVERNMENT LICENSEE If you are acquiring the software on behalf of any unit or agency of the United States Government the provisions of Section 3 apply to are incorporated in and are made a part of this Software License Agreement GENERAL This Software License Agreement will be governed by the laws of the State of Florida except for that body of law dealing with conflicts of law Should you have any questions concerning this Software License Agreement or if you desire to contact Alb rcorp for any reason please contact Alb rcorp 990 South Rogers Circle Suite 11 Boca Raton FL 33487 email alber alber com 3 GOVERNMENT PROVISIONS The Government acknowledges the representations of the Alb rcorp software as Restricted Computer Software as the term is defined in Clause 52 227 19 of the Federal Acquisition Regulations FAR and is Commercial Computer Software as that term is defined in Clause 52 227 7013 a 1 of the Department of Defense Federal Acquisition Regulation Supplement DFARS The Government agrees that i if the software is supplied to the Department of Defense DOD the software is classified as Commercial Computer Software and the Government is acquiring only restricted rights in the software and its documentation as that term is defined in Clause 252 227
60. ibed ceeeecceees 21 LSG described eee 21 LT described iesiri 21 LV described 21 MAIN MCNU ee eeeeeeeeteeeeees 10 load ethene eins 10 84 SeU Pin E EE 10 Status eeun ei 10 memory card 8 13 31 card warning s es 14 diagnostics 0 eee 38 filOS vss bsee sd itch eis 14 TeAdeT aeieea 13 Smart Media LED 13 memory card LED 05 7 MiN MAaX SCIEN eee ees 35 MOD described 0 0 21 mode button 10 mode select resistance 0 0 eeeeeteeteeeeees 26 specific gravity 29 temperature ee eeeeeees 29 A 0 re 25 modei eree ea geste 11 diagnostics 0 eee 39 SOUP EETA EREA 17 multiple strings eee 32 opening a file eee 32 OPT described 21 ON nirien See overall voltage overall voltage cece 30 parts listessi 61 password Changing s es 41 default n0ck act een cee 41 enterin genien na 41 PDA add data cceeeeeeeeeee 58 Alber mobile button 49 all locations button 48 backup database 49 50 battery name 55 Cellcorder button 51 charger freq setting 49 comments option 56 D button eee 48 data transfer eee 51 data upload to PC 57 date format cee 49 delete data 0 54 delete string page 58 delete stringS ce 50 edit data eeeeeesseereees 53 edit NAMES eee 51 CILOTS ye n
61. ibed in this section to help determine the cause To display the menu press Shift Diag To view more menu items press the Up Down Arrows Diagnostics 1 Keypad 2 Display 3 IR Port 4 Safety Relay Y CANCEL Figure 18 Diagnostics Menu 1 of 3 12 1 Diagnostics Keypad To test key functionality select Diagnostics Keypad Press any key except Power and the screen indicates the key pressed If you press Shift press it again before continuing with other keys Do not press Esc twice or you will exit To return to the Diagnostics menu press Esc two times 12 2 Diagnostics Display To cause the LCD screen to display a series of letters and numbers select Diagnostics Display To return to the Diagnostics menu press Esc 12 3 Diagnostics IR Port To test the IR communication port with a computer or printer select Diagnostics IR Port then select PC Interface or Printer Interface Follow the on screen instructions After the test to return to the Diagnostics menu press Continue or Cancel This test requires a PC or printer with IR interface 12 4 Diagnostics Safety Relay WARNING Disconnect the Cellcorder test leads from any equipment before initiating this Safety Relay diagnostic If the diagnostic is enabled while the Cellcorder is connected to a voltage source the Cellcorder can be damaged 37 Diagnostics Menu Select Diagnostics Safety Relay to test the internal relay that protects Cellcorder circuitry The re
62. iccks cnn Date Cellcorder readings were taken 33 Measuring Voltage and Resistance Summary and Thresholds A summary of average minimum and maximum values for Voltige Cell voltage RES ecvisesssusedestes Cell resistance SG sheds sees Specific gravity Temp Temperature Int R1 2 3 4 Intercell resistance 1 2 3 and 4 Cell Data listed for each cell for Volt eee Cell voltage Res hhn Cell resistance Int RI ww Intercell resistance R1 Int R2 ww Intercell resistance R2 Int R3 we Intercell resistance R3 Int R4 wo Intercell resistance R4 OGen tarn Specific gravity Temp Temperature Set the thermal printer power switch to on If the Status LED is on connect the printer charger to charge the battery A flashing Status LED means paper out or high temperature Refer to the printer manual on the program CD CAUTION Charge the battery with printer power off The printer cannot operate from the charger Full charge time is about 16 hours minimum is one hour Do not leave the charger connected this will shorten battery life To send data from the Cellcorder to the printer press Shift Print On the Select Headers screen select the items you want printed site information statistics faults and thresholds Use the Arrows to highlight an item then press Enter to select or unselect it Press Next to display the Select Data screen Use the Arrow and Enter keys to select the data you want printed then pres
63. in Menu If you need to edit location battery or string names refer to Site Information 19 2 Data Transfer from Hydrometer to PDA To transfer hydrometer module SG and temperature readings to the PDA on the module select a string A to H On the PDA Main Page press Hydrometer follow screen instructions then press Download to transfer The hydrometer module LEDs go off during transfer Upon completion the PDA displays Hydrometer Download Complete You may edit location battery or string names on this page then press OK to store the file To edit location battery or string names Press the stylus on the text or number to be edited then press the ABC or 123 button on the PDA Edit the text or number then press Done 51 PDA Mobile Software User s Guide Alber Mobile OLE Y ALL LOCATIONS 5 1 Location Battery Stringi 779 LocationS BatteryS StringS 7 9 Location5S BatteryS StringS 7 fa Oc ion B gt j Download Hydrometer 1 Ensure module is ON 2 Select string A H 3 Align IR ports 4 Select Download Downoad Figure 27 Download Hydrometer 20 Viewing and Editing Readings PDA This section describes how to view edit insert and delete readings 20 1 View String Data To display string data on the Main Page use the stylus to select the string name The View String Data page displays data in tabular format To view a cell slowly drag the stylus along the vertical scroll bar until the cell numb
64. ity Threshold Low 0 ceeeeeeeseesteeneeees 0 000 to 9 999 Temperature Temperature Threshold High 32 0 F 0 C to 99 9 F 37 7 C Temperature Threshold Low 32 0 F 0 C to 99 9 F 37 7 C Figure 4 Threshold Limits You must use the Up Down Left Right Arrows to enter threshold values You cannot use the keypad to type numeric values After thresholds are set to return to the Main Menu from the Thresholds menu press Back twice NOTE You may also use Shift Alrm to access Threshold 16 Setting Up the Cellcorder 8 2 System Setup Clear Memory CAUTION After clearing Cellcorder memory you cannot recover the data Refer to Clearing Cell Data To clear data in Cellcorder temporary memory at the Main Menu select Setup Clear Memory The message appears Warning All data in temporary storage will be erased Continue To delete the data press Yes To not delete press No To return to the Main Menu from the System Setup menu press Back NOTE You may also use ShifttMem to access Memory 8 3 System Setup Display To adjust the Cellcorder LCD display at the Main Menu select Setup Display Adjust Contrast Use the Up Down Arrows to adjust contrast then press Accept To return to the Main Menu from the Display menu press Back twice NOTE You may also use Shift Disp to access Display 8 4 System Setup Sound To turn the Cellcorder beeper off or on at the Main
65. l not be liable for the loss or corruption of data or programs stored in or used in conjunction with this or any other software product nor shall Alb rcorp be liable for the cost of retrieving or replacing lost or corrupted data Alb rcorp s sole and exclusive liability for any and all losses and damages arising out of any cause whatsoever shall in no event exceed the purchase price of the software product purchased NO LIABILITY FOR CONSEQUENTIAL DAMAGES ALBERCORP SHALL NOT IN ANY CASE BE LIABLE FOR ANY DAMAGES INCLUDING SPECIAL INCIDENTAL INDIRECT EXEMPLARY COLLATERAL OR CONSEQUENTIAL ARISING FROM BREACH OF WARRANTY BREACH OF CONTRACT NEGLIGENCE OR UNDER ANY OTHER LEGAL THEORY ARISING FROM THE WARRANTY HEREIN STATED OR THE PURCHASE OF PRODUCT INCLUDING WITHOUT LIMITATION LOSS OF PROFITS USE OR GOODWILL Some states and countries do not allow the exclusion or limitation of incidental or consequential damages therefore the above exclusion or limitation may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary state to state and country to country 2 SOFTWARE LICENSE AGREEMENT THIS IS A LEGAL AGREEMENT PLEASE READ BEFORE INSTALLING SOFTWARE Any use of this media other than to review this Software License Agreement constitutes your acceptance of and agreement with the terms of this Software License Agreement with respect to the Alb rcorp Software If you do not a
66. lay starts clicking when this diagnostic is active To return to the Diagnostics menu press Cancel 12 5 Diagnostics Memory Card To test the input output I O to the Smart Media memory card select Diagnostics Memory Card When testing is successful the screen displays Memory Card IO Good To return to the Diagnostics menu press Escape 12 6 Diagnostics Load Module WARNING This diagnostic draws up to 60 Amps from the voltage current source Select Diagnostics Load Module to test the circuitry that applies a load current to the battery under test On the Select Load menu select the voltage range then connect the resistance load leads to the voltage source If the leads are not connected only the 1 to 2 volt range operates To return to the Diagnostics menu press Cancel Requires test leads and voltage source to test all conditions AC Power indicator must not be lit while test leads are connected 12 7 Diagnostics A D Linearity To display the readings from the analog to digital converter select Diagnostics A D Linearity Use this diagnostic only when instructed by Alb r technical support Menu selections are described below To return to the Diagnostics menu press Cancel 12 7 1 Voltage Channel Voltage Channel displays the voltage connected to the standard two lead set of voltage leads supplied with the unit This input is for the cell voltage readings Input voltage must not exceed 20 volts 12 7 2 Test Channel
67. lls of the same age Lastly try obtaining data on the same model cells of any age Over time data to the end life or 80 capacity level will be accumulated CAUTION Internal resistance data taken without the benefit of correlated known capacities is often referred to as as found comparative values This as found data could be used to set a baseline but be very cautious It is not unusual to find an entire string of cells of uniform internal resistances and normal appearance on float but with failing capacities In this situation we highly recommend at least a crude service load test be performed to lend some credence to the internal resistance measurements THE COURSE OF ACTION If you do not have end life or 80 baselines developed from significant samples of the same cells age etc you should use the following rough rules of thumb based upon Cellcorder user reports and in house experience If the internal resistance is 20 50 above the 100 baseline then the cell be load tested the sooner the better if it s towards the high end at 50 or above the baseline the cell be replaced Surprisingly the IEEE ANSI VRLA P 1188 proposed standard is more liberal in this matter It recommends that from 25 to about 43 the cell s manufacturer be contacted Above 43 a load test be done ASAP Actually the standard is expressed in the reciprocal of internal resistance conductance mhos 73 Application Note CC 001
68. m User s Guide 4 1 Resistance Test Overview In the Resistance mode the user connects the leads and initiates the test sequence The Cellcorder reads and records cell float voltage unless already stored in voltmeter mode Using the cell voltage the Cellcorder determines the correct range connects a fixed resistance across the cell and intercell under test and applies 60 Amps on 2V cells for a few seconds Test current changes from 5 to 60 Amps depending on the cell module voltage 1V to 16V During load condition the unit reads cell voltage current and intercell voltage drop and calculates internal cell and intercell resistances At test completion the Cellcorder displays the internal cell resistance Rc and the intercell resistance Ric The Cellcorder can transfer test results to a computer using the IR infrared communication port memory card or modem The Battery Analysis System program can analyze the data and create reports display data in bar graph format and generate standard and custom reports For operation of the Voltage Resistance and Specific Gravity Temperature modes refer to Measuring Voltage and Resistance General Description 4 2 Skewing Effect When resistance is read there is a skewing effect of the cell voltages that leads to a small error As the first half of the cells are resistance tested those voltages become depressed until the charger brings them back to normal float levels This means that
69. memory card To open the data file you want to link to a site at the Main Menu select Load Access Cell Data Highlight a CDF file name then press Select to load the data into memory After the data loads the Main Menu appears To confirm the file is not already linked to a site at the Main Menu press Shift Site The Active Site screen should not display location battery or string names If the file is linked names are displayed You can link the file to a different site at any time To return to the Main Menu press Continue 22 Setting Up and Editing a Site Active Site Loc BAT STG CONTINUE LOAD CLEAR Figure 7 Active Site Screen NOTE If a data file is associated with a site it can be linked to a different site by loading the site and saving the file To select the site you want linked to the file at the Main Menu select Load Access Setup Data Press the Right Left Arrows to step to the desired site then press Select If the Active Site screen displays the correct site names press Continue to return to the Main Menu To select a different site press Load To save the linked data file to the memory card press Shift Save At Enter File Name type the file name and press Save F2 If the file name exists a message prompts for overwrite After the file is saved the Main Menu appears You may confirm the site file correlation by pressing Shift Site NOTE To determine at any time what site is selected from
70. n Note CC 001 CLEAN UP is also important especially in preserving the jaws and clips of the test leads Wipe off all grease and then apply an acid neutralizing solution REFERENCES 1 ANSI IEEE 450 1995 IEEE Recommended Practice for Maintenance Testing and Replacement of Vented Lead Acid Batteries for Stationary Batteries ANSI New York NY 1995 2 ANSI IEEE PAR 1188 IEEE Recommended Practice for Maintenance Testing and Replacement of Valve Regulated Lead Acid Batteries for Stationary Batteries ANSI New York NY 1994 3 E Willihnganz and P Rohner Battery Impedance Farads Milliohms Microhenries AIEE 1959 4 S DeBardelaben Determining the End of Battery Life Intelec 86 Toronto Canada 5 S Misra T Noveske L Holden S Mraz Use of AC Impedance Conductance and DC Resistance for Determining the Reliability of VRLA Battery Systems Intelec 93 Paris France 6 Y Konya T Takeda K Takano M Kohno Et Al 4 Deterioration Estimating System for 200 AH Sealed Lead Acid Batteries Intelec 94 Vancouver B C 7 K Peters Ten Years Experience of VRLA Batteries in Telecommunications Service May 1994 8th Battery Conference amp Exhibition Solihull UK 8 Johnson Controls Impedance and Conductance Testing Application Note Form 41 7271 Aug 1994 Milwaukee WI and Alb r in house data 9 G Alber Are Internal Cell Parameter Measurements a Substitute o
71. n test for seven hours Isolated operation helps ensure safety A charger module included recharges the battery Float Voltage Readings The Cellcorder measures the voltage applied during full float operation The voltage range covers all cells or modules up to 20 volts Cell or module reading accuracy is to four full digits General Description Internal Cell Resistance Using a patented process the Cellcorder applies a momentary load and calculates internal cell resistance by determining instantaneous voltage drop and load current Cells floating on line or off line can be measured This method helps find weak potentially failing cells when comparing internal cell resistance of all like cells in the string Refer to Application Note CC 001 Intercell Resistance The Cellcorder measures the resistance between two electrically connected cell terminals The measurement consists of connector resistance and contact resistance at the points of connection to the cell terminals Auto Ranging The Cellcorder automatically selects the correct voltage range load resistor and test time Data Extraction and Analysis The memory card IR interface or modem can transfer data to a computer The BAS program analyzes data displays results in graph or tabulated formats and prints reports It also exports report files in ASCII Excel or comma delimited format so other programs can generate customized reports Refer to the Battery Analysis Syste
72. name press the D or N buttons To filter by location name press All Locations or other name on the screen then select a name from the drop down list After filtering you can again sort by date or name 48 PDA Mobile Software User s Guide The Palm PDA HotSync operation can back up the database to a computer The DB3_AlbJobDB PDB database can be loaded onto another PDA or the original PDA if the device requires a reset 18 Options Menu To display the Options menu on the Main Page press Alb r Mobile The drop down menu displays User Preferences Delete All Strings and About ZAJ Veuve VULGI ye JM Tye 7 10 Location Battery Stringi 7 10 Location Battery String 7 10 LocationS Battery1 Stringi gt t Figure 23 Options Menu 18 1 User Preferences Select User Preferences to define the temperature units F C date format USA Europe China and charger frequency 50Hz 60Hz associated with data uploaded to a computer To change a preference press the down arrow next to the item to change then select from the drop down menu User Preferences Temperature Units w Degrees F Date Format w USA fram dd yyyy ChargerFrequency w 60 Hz Figure 24 User Preferences 49 PDA Mobile Software User s Guide 18 2 Delete All Strings PDA Delete All Strings removes all the strings and battery test data stored in the PDA This action cannot be undone To delete all the strings press OK on the Delete
73. nd other parameters During testing the Cellcorder uses site settings for voltage and resistance thresholds A site setup is not required for testing but is useful for managing many sites Setting up a site lets you record details for a location and consistently use the same information for future testing The following sections describe navigating site screens setting up a site linking a file to a site editing a site and deleting a site To set up thresholds with no site selected refer to Setting Up the Cellcorder 9 1 Navigating the Site Menu To access any site screen first insert a memory card into the Cellcorder At the Main Menu select Load Access Setup Data If the memory card has no sites the New Site screen appears with Change Save and Cancel options a New Site v SELECT NEW CANCEL MORE CHANGE DELETE CHANGE SAVE CANCEL Figure 5 Setup Data Screens If sites exist Site 001 of XXX appears where XXX is the number of sites on the memory card To step through the sites press the Right Left Arrows The menu bar has Select New Cancel and More corresponding to keys F1 to F4 Pressing More displays Change Delete and Back Press Back to return to the previous menu items The left column lists items to which you may assign values To scroll the list press the Up Down Arrows Descriptions appear when an item is highlighted Edit some items using the keypad edit others using the arrow keys When items require names or n
74. nection resistances should be measured to aid in determining the cause and corrective actions HOW TO TAKE READINGS When taking intercell connection resistance readings it is important that a the test leads are connected properly Measurements should include the post to intercell connector resistance Always check your connections and connect only to posts not nuts bolts or straps See figs 1 5 This is the main area where connection problems occur and 77 Application Note CC 002 b the test probe tips fingers make a good connection piercing any grease lead oxide or crud coating the posts or straps This is the leading cause of error messages after pressing the test button Often jiggling the probe will lower the readings significantly and save you the heartache of unnecessarily reworking a connection Fig 1 SINGLE INTERCONNECTIONS SINGLE INTERCONNECTIONS Figure 1 shows how the Alb r Cellcorder should ideally be connected to obtain the proper measurement Note that ideally the reading includes both the intercell connector resistance and the post to intercell connection resistance Figure 2A shows the connection for VRLA cells such as the ABSOLYTE II batteries where the terminal post is accessible Figure 2B shows the connection for VRLA cells where the terminal post is not accessible In this type of cell the intercell to post connection resistance is included in the internal cell resistance measurement NOT
75. o display the Options menu and select Add Cellcorder Data or Add Hydrometer Data Follow screen instructions then press Download to transfer data When transfer is done press OK to store the new file Battery5 String5S Battery5 String5 Add Cellcorder Data Add Hydrometer Data 1 Ensure Cellcorder is ON 4 1 Ensure module is ON 2 Initialize Cellcorder IR 2 Select string A H s 3 Align IR ports 4 3 Align IR ports 4 Select Download 4 Select Download Mote All existing hydrometer data SG amp temperature will be overwritten Download Cancel Download Cancel Figure 39 Adding or Replacing Cellcorder Hydrometer Data Note All existing cellcorder data will be overwritten For help using the Cellcorder or hydrometer refer to File Transfer from Cellcorder to PDA or Data Transfer from Hydrometer to PDA 25 Delete String Data To delete one string on the Main Page select the string name On the View String Data page press the top bar to display the Options menu and select Delete String On the Delete String box press Delete to delete the string This action cannot be undone Battery 1 String1 Delete String Location Location Figure 40 Deleting String Data 58 PDA Mobile Software User s Guide 26 Serial Errors If the PDA detects an error during a data download from the hydrometer or Cellcorder the Serial Receive Error page appears Follow screen instructions and transfer the data again Albe
76. ochemical resistance change is a small part of total internal resistance as the stored energy drops from 100 to substantially lower levels of charge In the real testing world this is good news It means that a battery can be reliably tested by the Cellcorder at float open circuit voltage and even partially discharged THE BASELINE AND WHEN BEST TO GET IT The fantasy of a battery literate person is that complete capacity and internal resistance test data from day zero is available for analysis He seeks to determine the typical internal resistance of cells at 100 and 80 as well as the trend from 100 through 80 capacity 72 Application Note CC 001 The fantasy begins with the battery s installation An acceptance capacity test is conducted and the cells internal resistances measured The results should be fairly uniform and he would safeguard this data He knows it serves as the ideal baseline or reference per IEEE ANSI P 1188 for future internal resistance tests He will then be able to make cut and dry decisions about maintenance or cell replacement Unfortunately it s a fantasy in most environments because in the rush and tumult of getting a facility on line establishing a baseline usually has low priority As a result we are then left to getting data in the best ways possible The second best time to obtain a set of data is shortly after capacities have been determined on the same model ce
77. on eee 16 29 CCO koria es 64 CCOO iaaiiai 77 CCE Eene a 14 CDP Mence cnc 14 24 appending 0 0 eee 32 deleting 14 importing into ADF 31 linking oe ee eeeeeeeeees 22 CEL described 21 cell cell capacity selection 27 celsius button 16 29 central database for modem 11 change button eee 22 Charger neinn ei 12 INdICAOP cesses inpe 12 Clear buttone eee eters 15 clear memory setup 17 Clearing data eects 14 clearing data from memory 31 clearing temporary memory 14 connection options 4 81 83 oro 01 0 ee 7 DAT described eee 21 data appending from a file 32 clearing from Cellcorder 14 clearing from memory 31 deleting a CDF file 14 loading a file eee 32 SAVING cade chee S 31 saving to memory card 31 sending to a computer 32 STOLA Ean Kieren 13 storing for multiple strings 32 date Setup iicscesesiehes ceed 18 deleting a file eee 14 deleting a site eee 24 deleting characters 22 diagnostics A D linearity eee 38 BUZZER nasta ns 39 diagnostics menu 37 display 0 eeeeeeeeeseeeeees 37 faik sess a a a 39 IR poriniti a 37 keypad eceeeeeeeeeeees 37 load module eee 38 Memory Card eee 38 Modem 39 protection circuit 39 safety relay eseese 37 temperature sensors 39 display diagnostics
78. on the Cellcorder must not be lit CAUTION Do not insert or remove the memory card when the Cellcorder Smart Media Card LED is lit WINDOWS 2000 CAUTION When using Windows 2000 memory card removal from some manufacturer s drives may require your doing the following 1 Double click the My Computer icon on the Windows desktop Right click the reader writer drive icon and select Eject from the pop up menu 3 After the message It is now safe to remove the media from the drive appears remove the memory card Failure to follow this procedure could result in lost data See your drive manual to determine if this or other procedures apply 13 Cellcorder Data Storage 7 1 1 Memory Card Files Setup data for all sites on a memory card is stored in the CLC300 CCF configuration file The Cellcorder accesses this CCF file when reading or saving site setup information CDF data files contain Cellcorder cell readings these files are imported by the BAS program into an existing ADF accumulated data file or viewed separately using the CRT 300 Previewer program The UPG file on the memory card is for Cellcorder firmware updates CAUTION It is strongly recommended that you use only one memory card If you use two or more cards each card can contain a Site 001 Site 002 and so on because each card will contain a CCF configuration file 7 2 Clearing Temporary Memory To clear cell data in temporary memory refer to System Se
79. ostics Buzzer Tests the beeper that provides audible feedback for keystrokes and alarm conditions To return to the Diagnostics menu press Continue 12 11 Diagnostics Fan Tests the Cellcorder fan which cycles on to prevent overheating To return to the Diagnostics menu press Continue 12 12 Diagnostics Temperature Sensors Displays temperatures of the Cellcorder circuit board Load Temperature and regulator Ambient Temperature When the load temperature rises due to continual testing the fan turns on If the load temperature exceeds a set limit load testing circuitry is disabled and a warning appears To return to the Diagnostics menu press Cancel 39 Diagnostics Menu 12 13 Error Codes Memory card error messages display text such as card not detected or out of memory or numeric error codes Determine if the problem is the memory card or the card drive CAUTION Do not insert or remove the memory card when the Cellcorder Smart Media Card LED is lit Remove the troublesome card and if available insert a known good card If the Cellcorder reads the card the problem is the first memory card Attempt to read the defective memory card using the card drive attached to the computer If neither the Cellcorder nor the computer can read the card the card is defective or data on the card is corrupted If the computer reads the data successfully copy the data to another memory card and see if the Cellcorder can
80. r Supplement to Capacity Testing Sep 1994 NE Utilities Battery Conference Albany N Y 76 Application Note CC 002 30 Appendix D Application Note CC 002 Internal Resistance Measurement Procedures This document is available at www alber com INTRODUCTION Intercell resistance problems account for a great many battery system failures In UPS or other high current applications the failures can lead to explosions and fires that are not only costly but also represent safety hazards Most battery manufacturers unfortunately do not supply baseline resistance values so presently users must establish their own values The recommended procedures for establishing base lines are New systems read all the resistance values after installation and calculate the average value Older systems disassemble 10 sets of intercell connections burnish neutralize and clean them reapply corrosion inhibiting compound reconnect retorque and then calculate the average of the new readings Intercell resistance measurements should be taken once a year of all cells IEEE 450 1995 and forthcoming IEEE VRLA maintenance recommendations Any connection that is 20 or greater than the baseline or installation value requires corrective action The importance of these measurements is illustrated by the new VRLA standard that recommends quarterly sampling 25 of the intercell connection re sistances If an upward trend is detected all con
81. r Mobile tits Y ALLLOCATIONS 5717 Location Battery Stringi 779 Location5 Battery StringS 7 9 LocationS BatteryS StringS Information D Serial Receive Error Please check both devices are ON and IR ports are aligned Figure 41 Serial Receive Errors 59 PDA Mobile Software User s Guide 60 Cellcorder Parts List 27 Appendix A Cellcorder Parts List One each of the following CRT 300 Cellcorder Unit 1000 058 Serial No Charger Module for Cellcorder 4000 033 Memory Card 8MB 2030 001 Memory Card Reader 2025 032 Voltage Lead Cable Set 2 Leads 1100 222 Resistance Test Cable 3 Leads 1100 221 Cellcorder CRT 300 User s Guide this manual 4200 038 Battery Analysis System BAS and Previewer software 2027 014 BAS Manual 4200 002 Carrying Case 3800 028 Carrying strap 3800 029 Warranty Card Checked By Date 61 CRT 300 Specifications 28 Appendix B CRT 300 Specifications Physical Dimensions Weight Keypad Display Type Viewing Area Resolution Viewing Angle Backlight Memory Type Supported Sizes Storage Capability Data Retention Communication Infrared Internal Modem Battery Type Voltage Charge Time AC Adaptor Input Voltage Output Voltage Output Current Frequency 12 H x 7 W x 3 D 305mm x 178mm x 76mm 3 4 pounds 1 5Kg Rubber keys with polyurethane coating LCD STN Reflective 2 619 x 1 309 Graphics LCD 128 x 64 40 White EL
82. r key until Release power button appears Powering off the Cellcorder does not remove readings from memory ata AE Prora ih CELLCORDER temporary storage CRT 300 Do you want to save to memory card YES NO CLEAR MODE SETUP LOAD STATUS Figure 1 Data in Memory Message and Main Menu At power up a system message may appear Data is present in temporary storage Do you want to save to memory card To go to the Main Menu press No To save cell readings to the memory card insert the card and press Yes If you press No or Yes data remains in Cellcorder temporary memory To clear the data from memory without saving press Clear all readings in temporary memory will be lost Shift Symbol Note Press Shift on the keypad to display the shift symbol on the top right of the screen Some commands require that you press and release the Shift key then press another key with orange text For example to display the Main Menu press Shift Start The Shift symbol on the screen confirms Shift is enabled Escape Key Note In many cases the Esc key behaves like the Cancel or Back key 6 2 Mechanical Reset Switch WARNING Do not reset the Cellcorder when the AC Power indicator is lit Before resetting disconnect the Cellcorder test leads from any equipment Disconnect the leads connected to the internal Cellcorder battery CRT 300 Basics A reset switch is located in the battery compartment under the batteries If the CRT 300 locks up
83. ration mechanism is an increased internal resistance A 500 microsecond duration pulse technique is used to measure cell internal resistance Test results lead them to conclude that battery deterioration capacity can be estimated within 10 by internal resistance measure Note that Capacity vs Normalized Rinternat curve shown in Figure 3 is somewhat curved Some feel the relationship between most cell internal parameters and capacity is not a simple straight line as has been described in recent times but rather a more complex curvi linear function 66 Application Note CC 001 ne a een een ee Fig 3 CAPACITY amp INTERNAL RESISTANCE ESTIMATED FROM PULSE DISCHARGES Capacity Ratio 1a B3 1 o LL B 14a 14 LE Internal Resistance Ratio Unit Value Equal to R at 90 Capacity IMTERHAL Part of this belief that a straight line cannot describe a capacity relationship is rooted in the differences exhibited during battery discharges from cells with metallic vs electrochemical resistance problems The typical discharge curve of a cell at 100 capacity is shown in Figure 4 VOLTAGE FIG 4 Vo ren TYPICAL DISC HARGE CURVE OF A 100 CAPACITY CELL A battery s capacity is adversely affected by an increased internal resistance Obviously the power is dissipated internally P x Rivrernat and is not available where it is really needed at the load Thus actual capacity is diminished However during disch
84. re 30 Insert Readings 53 PDA Mobile Software User s Guide 20 4 Delete Readings On the Main Page select the string name On the View String Data page select the cell you want to delete then press Delete on the Edit Cell box On the Delete Cell box press OK to delete the readings Battery5 String5S Cell Volt Resist SG Temp 1 6 788 980 1 183 066 3 2 6 789 970 1 183 066 3 3 6789 974 1 183 066 3 4 6 739 974 1 231 066 3 Delete Cell 005 Are you sure d Status Pending Figure 31 Delete Cell Readings 21 Analyzing Cell Data On the Main Page select the string name To display the Options menu press the title bar on the View String Data page 1 Site Information 9 Thresholds 3 Add Edit Comments 5 Upload to PC 6 Add Hydrometer Data 7 Add Cellcorder Data 8 Delete String Figure 32 String Options Menu 54 PDA Mobile Software User s Guide 21 1 Stats Statistics To display a summary of string data select Stats from the Options menu or press the Stats button on the View String Data page The Stats page appears Voltage 6 Resist SG 1 Terp Int R1 Int R2 Int R3 Int R4 Cells Figure 33 Stats Page The Stats Statistics page displays average and minimum maximum values for cell voltage cell internal resistance SG temperature intercells 1 to 4 and the number of cells and OV 21 2 Site Information Use the string Site Information page to edit lo
85. read it If not remove the memory card from the Cellcorder Power down and restart the Cellcorder Insert the memory card and attempt to read it If the error message still appears the problem may be in the Cellcorder and you should contact the factory for assistance 40 Service Menu 13 Service Menu The password protected Service Menu has the Calibration Factory Defaults and Change Password options This menu is not used during normal use To display the Service Menu at the Main Menu press Shift Serv The password screen appears 13 1 Entering the Password The Cellcorder factory set password is 1234 If the password is unknown contact Alb r for a password based on the randomly generated four numbers following Service Code Enter password rarer a Service code HHH CANCEL Figure 19 Password Screen After you type the password press Enter to display the Service Menu 13 2 Changing the Password You may change the password to any four digit number At the Main Menu press Shift Serv type your current password press Enter and from the Service Menu select Change Password At Enter New Password type the new four digit password but do not press Enter Type the new password again in the Confirm New Password area then press Accept Enter new password Confirm new password ACCEPT CANCEL Figure 20 Change Password Screen If New Password and Confirm Password agree the Service Menu appears
86. rough Windows File Manager a file naming system can be important Try to include in the filenames eight characters as many descriptors as possible to reflect the data s date location and battery Thus filename 941 WPB1A DAT would describe the first test data in 1994 for location WPB s battery 1 string A Whether you use numbers or characters the important thing is to make the filename as recognizable as possible while avoiding duplicate filenames This helps immensely in finding files and to avoid overwriting deleting or copying wrong files especially when using operating systems before version MSDOS 6 SAFEGUARDING THE CELLCORDER By far the most common cause of damage to the Cellcorder is from grossly excessive input voltages particularly when taking UPS cell readings AWARENESS is the most important factor in avoiding these kind of problems Before any testing begins take five minutes to survey the battery bank to make sure that cells are not misnumbered the intertier cable routing is unmistakable the main battery terminals and other spanable high voltage points are identified and temporarily covered Also before making a measurement that includes a cable routed through a tray to another tier use a voltmeter to identify the other end Make sure no potentially damaging voltage is present POWER UP the Cellcorder before connecting it to a battery This activates additional protective circuitry 75 Applicatio
87. s A to E then B to D and B to F then C to E In all triple post strap measurements the positive a red clip Cellcorder lead should remain connected as shown to the same terminal post for all readings 80 Connection Options 31 Appendix E Connection Options For the latest connection options see the Alb r Web site at www alber com or contact your local Alb r sales representative Combired Leods No Interce NOTE Reference Drawing No CCM 304 A423 Rev A1 for additional information on Spike Probe Leods 127 Probes No Intercell For further information on which Cellcorder leods ore best suited to your individual requirements contact your local ALBER representative or ALBERCORP drectiy at Phone 61 997 2299 Fox 561 997 5588 990 S Rogers Circle Suite 11 Boco Raton FL 33487 ALL ALBERCORP PRODUCTS ARE ENGINEERED DESIGNED AND MANUFACTURED IN THE USA 81 Index A D linearity diagnostics 38 A D reference diagnostics 39 ADF file wo eee 14 22 32 importing CDF into 31 amp hours selection 27 appending a file 32 AITOW KOYS cseeseeesseeseeeseeseees 7 average SCreen 0 eeeeeeeseeeeees 35 BAT described cesses 21 battery battery LED 7 12 battery level indicator 12 charg etnan a 12 low warning message 12 maintenance schedule 43 warning Message s s 12 eepitr masen earna 7 buzzer diagnostics 39 C F butt
88. s Next Select Header s Select Data 3 O Voltage O Icki O Site OStats O Resistance O I O svG m cRe cl O Faults O Thresholds O Temp NEXT CANCEL NEXT BACK CANCEL Figure 15 Print Options Align the IR ports and press Continue The Status LED flashes while data is being received When printing is done the Cellcorder Main Menu appears 34 Status Screen 11 Status Screen When data is in Cellcorder memory the Status screen displays the number of cells and the Overall Voltage OV Options display averages min max values and threshold violations faults STATUS STATUS Average STATUS Total of cells S G have data OU HHH HH P Rici un AVG MIN MAH FAULTS BACK MORE MIN MAX FAULTS BACK AVG MORE FAULTS BACK Temp iH Figure 16 Typical Status Screens To display the OV Status screen at the Main Menu press Status The Cellcorder displays the number of cells that contain data and the calculated OV of those cells To return to the Main Menu press Back 11 1 Status Screen Average On the OV Status screen press Avg Average to display the average cell voltage Vc cell resistance Rc and intercell resistance Ric Press More to display more average Ric specific gravity SG and temperature values To return to the Main Menu press Back 11 2 Status Screen Min Max On the OV Status screen press Min Max to display the minimum and maximum values for Vc Rc and Ric Press More to displ
89. se Cellcorder resistance measurements in conjunction with baseline data on the batteries being maintained Obtain cell resistance baseline data from the battery manufacturer or Alb r or acquire it with a capacity test Take Cellcorder readings according to the Maintenance Schedule table the resistance readings dictate which battery string should be subjected to capacity testing If one or more cells exhibit cell resistance 30 to 40 higher than the average or baseline value then capacity test those cells using a single cell tester such as the Alb r SCT 200 If most cells are above the normal expected readings then capacity test the entire string 43 Upgrading the Firmware 15 Upgrading the Firmware You can upgrade Cellcorder firmware using the memory card or the IR ports on the computer and Cellcorder Alb r publishes upgrades to the Web at www alber com Upgrading using the memory card is much faster than IR WARNING Do not continue until you have the HEX upgrade file ready You will be clearing the current firmware 15 1 Upgrading Using the Memory Card Download the HEX file from the Alb r Web site or an Alb r CD to Program Files Alber Alber Battery Analysis then use Windows Explorer to copy the file to the memory card With Cellcorder power off insert the memory card into the Cellcorder To start in upgrade mode press EsctPower On At the message System is ready to clear Flash memory for new program to upgrade pr
90. seeeeeeeees 27 Figure 12 Resistance Test and Progress Indicator Screens eeeeeeees 28 Figure 13 Data in Memory Screens scescesceesceeeeeeteceeecnereecneeeeeeaeeaees 31 Figure 14 Memory Card as a Disko ee ceeeceeeeeceeeeceseceeesecneeeecneeeeeeneeaees 32 Figure Ts Print Options ss 05 aisha Anette eR eee aay 34 Figure 16 Typical Status Screens cceeeceeseeccesecreeeeceeeerceeeeeeaeeaeeaeeneesees 35 Figure 17 Typical Fault Sereen Suini nosenie ea e a aean 35 Figure 18 Diagnostics Menu 1 Of 3 esesesssseseeieersersrrrrerersersrsesssrse 37 Figure 19 Password Screen 23s sien he a e a n 41 Figure 20 Change Password Screen sesessesesssesereeererssssrseserersesesseseerreree 41 Figure 21 Maintenance Schedule sessseeeesesesseesieeerrerssssrsrserersessssrsrerreree 43 Fi re 22 Typical Main Pages i 2 divee cee ie hn neh s ht 48 Figure 23 Options Menu sv eee aie et ann neat esos 49 Figure 24 User Preference Snin nin Anes aha Reh ater dint 49 Figure 25 Delete All Data iis tated iene tien ean ieee eine ee 50 Figure 26 Download CellcorderT seessesresessssssseserrserseresssseseerrsesrrsesesesecsens 51 Figure 27 Download Hydrometer ccescecesceesceseeeeeseceeeeecnereecaeeeeeaeenees 52 Figure 28 View String Data ccecesecssesseesecneseeceseeeeesecaeesecnevseeaeeeeeaeeaees 52 Figure 29 Edit Cell Data cini senin e a e n a 53 Figure 30 Insert Readings e ssseessesess
91. sesiseeerererssestsrrretsssstseserersessssseseseee 53 Figure 31 Delete Cell Readings ssseseseseeeesesesesiserererssrsesrserersesssrsrerreree 54 Figure 32 String Options Menu eesssessseieiesesssesrsererersssrsrsrersesssrsreereree 54 Figure 33 Stats Pages wes 4 aiaee ia e e aE E a 55 Figure 34 String Site Information esesessesseeieesssrsisrerrsressrsrsrsererersseseseee 55 Figure 35 String Thresholds mosses aae iiei ia 56 Figure 36 Add String Comments cccscssccseesceseeeceseceeesecneeereaeeeeeaeenees 56 Figure 37 Print Options Pages icscicccsccsccsecsgeccsecte ceseteguceviavuveescetaeectiesscesteeeds 57 Figure 38 Upload File to PC cescssccesesecosvenenerencnenenseneveneoncesenereeennes Sl Figure 39 Adding or Replacing Cellcorder Hydrometer Data 58 Figure 40 Deleting String Data ec eeesescesceeeeeceececesneneseceueeceseneseetenes 58 Figure 41 Serial Receive Brit ors icssnvesscorccvheita eisacecse nee aden een ty 59 1 Safety Information Safety Information You must read and understand the following safety precautions and those printed elsewhere in this manual before using the Cellcorder Except as explained in this manual do not attempt to service Alber equipment yourself Opening the equipment may expose you to dangerous voltages Refer servicing beyond that described in this manual to authorized personnel Do not allow liquids or moisture to get into
92. sholds can be set or changed outside of site setup Refer to Setting Up a Site The unit indicates an out of tolerance reading by sounding two beeps and displaying the reading in reverse video Site Not Selected If a site is not selected you can set up thresholds using the System Setup menu to warn if readings exceed tolerances The settings remain in Cellcorder memory until changed cleared to default zero values or a site is selected Site Selected Ifa site is selected you can change the thresholds using the System Setup menu but the changes affect only the Cellcorder and not the site file The settings remain in Cellcorder memory until changed cleared to default values or another site is selected Default Thresholds If a site is selected you can quit the site settings and return to default thresholds for voltage resistance temperature and SG This does not affect the site file To clear thresholds to zero from the Main Menu press Shift Site to display the site battery and string names of the site currently selected To quit the site settings press Clear This clears site settings but not thresholds The Cellcorder displays Do you want to clear all thresholds settings to default To clear Cellcorder thresholds press Yes To return to the Main Menu press Continue or to select another site press Load Setting Up the Cellcorder To set up Cellcorder not site file voltage resistance temperature and SG thresholds at
93. ssssseseessesersreseesessreresseseeseesersesses 48 16 2 System Requirements PDA ssssssssssseeessesersresesessteresreseesreserseeses 48 vi 17 MAIN PAGE FILE DATABASE e cccocsessesnccccesceessesnceecescecssssececescecns 48 18 OPTIONS MENU e Succ cueeoecottentek ecasev ine AE see aeeviteseoues 49 18 1 User Preferencess ccccccesssssssssccccssovssesscccccesvsnsscneccscssessseenesees 49 18 2 Delete All Strings PDA nenn n e E 50 183 Abote a e E E N 50 19 DATA TRANSFER TO PDA VIA IR ccccesssccccceceessnseceeeeecsensseeeeeeeens 51 19 1 File Transfer from Cellcorder to PDA scccccescceceeeeeererresseerrrre 51 19 2 Data Transfer from Hydrometer to PDA ssssessseeessseserseeserseesee 51 20 VIEWING AND EDITING READINGS PDA s snssssesssessssssseersrrrsssesssee 52 20 1 Vaews String Dataene Geseatiaeeeutenentectans 52 202 Edit Cell Datavcnd aka a a a aa 53 20 3 Insert Read E S a a r a a a eae 53 20 4 Delete Readings a aaeeea eea a ses enea A 54 21 ANALYZING CELL DATA r a r ea E EES 54 A A E e IE E eS E T E 55 2V2 Site Information ereenn e eaa a e etea 55 PA OEE E EKES TEI e EEEE E A BETETE SEAE AT EEEE A 56 21 4 Add Edit Comments eeeseeseeeeeeeessensessesssrreessssserrerssssessrrreessesse 56 22 PRINTING eae A n a a a A 57 23 FILE TRANSFER FROM PDA TO PC ou ccccscsccccecsesesseceeececsensstsceeeeeens 57 24 ADDING OR REPLACING STRING DATA cccscccsccecseserseceeecece
94. taint als Alphanumeric data entry Special characters ESC secs Bdvcsauvesnssess Escape key Press to exit certain screens Hold and press Power On Esc Power On to start in firmware upgrade mode Left Panel Connectors Test Leads Connector for test leads that connect to the cell under test Do not connect or use when Cellcorder AC LED is lit Memory Card Port for inserting the memory card May insert remove with power on or off but the Smart Media Card yellow LED must not be lit Right Panel Connectors Infrared Port A port for communicating with a computer or printer via infrared IR light signal Bottom Panel Controls Battery Compartment Mechanical Reset Switch located under the battery pack Press to reset the Cellcorder Bottom Panel Connectors Accessory Compartment Teleoiscnicnctick eh A modular jack for communicating with a remote computer via telephone POWET esid ssceecticeacs A 5VDC input jack for connecting the Cellcorder battery charger module CRT 300 Basics 6 CRT 300 Basics This section describes new CRT 300 features including the power up sequence main menu mechanical reset test leads and modem connection 6 1 Power On Off To power on the Cellcorder press the green Power key The LCD screen displays the Alb r logo the System Initializing screen with version level and the Cellcorder Main Menu To power off the Cellcorder press and hold the Powe
95. the location name and press Save To change a name or number during setup highlight the item press Change type the correction and press Save Press the Down Arrow to highlight BAT press Change type the name and press Save Continue this process for all items in the list Note that some items use Accept instead of Save After assigning all values press Save Site NNN of XXX appears NNN is this site number XXX is the number of sites on the memory card To return to the Main Menu press Cancel twice If while setting up the site you inadvertently return to the Main Menu refer to Editing an Existing Site Space Key and Deleting Characters Use 9 on the keypad to type spaces in location battery string or model names To delete characters highlight the character and press Delete F1 You cannot use the space key with file names 9 3 Linking a File to a Site After Testing Linking a CDF file to a site embeds site setup into the CDF file This is useful when transferring data to the computer because the software can set up anew ADF battery file if one does not exist Also because site setup is part of the CDF file the file can be viewed using the CRT 300 Previewer If cell readings were taken with no site selected or saved to a CDF file not associated with a site you can link the file to a defined site or create a new site then link the file as follows If the readings are only in Cellcorder memory first save them to the
96. the Main Menu press Shift Site To select a different site press Load To have no site selected press Clear To return to the Main Menu press Continue 9 4 Editing an Existing Site To edit an existing site whether associated with a CDF data file or not at the Main Menu select Load Access Setup Data Press the Right Left Arrows to step to the site to edit then press More To edit an item highlight the item then press Change Using the keypad or Up Down Arrows type the new data and press Save or Accept To edit another item highlight the item press Change edit then Save or Accept When editing is done you may select the site by pressing Select then Continue or return to the Main Menu by pressing Back then Cancel twice 23 Setting Up and Editing a Site 9 5 Deleting a Site To delete a site at the Main Menu select Load Access Setup Data Using the Right Left Arrows step to the site to delete To delete the site press More Delete At the warning press Delete The site deletes and the number of sites decrements by 1 Press Back then Cancel twice to return to the Main Menu If the deleted site was the active site press Shift Site to display the Active Site screen Press Load and select a new site or press Clear to clear the deleted site and have no site selected Refer to System Setup Thresholds for a description of the Clear function NOTE When a site is deleted the last site shifts to fill the deleted site For
97. tup Clear Memory Usually you would not clear data from memory until saving it to the memory card Data cleared from memory is lost but can be retrieved from the memory card if it was saved Save needed data to the memory card and a computer You can further analyze cell readings using a computer that has the BAS program installed 7 3 Deleting a File You can delete a CDF cell data file from a memory card in two ways 1 Insert the card into the computer drive and delete the file using Windows Explorer or 2 Insert the card into the Cellcorder and delete the file as follows To delete a CDF file using the Cellcorder at the Main Menu press Load Access Cell Data Using the Up Down Arrows highlight the file to delete To delete the file press Delete At the warning press Delete When Data File Deleted appears press Continue To return to the Main Menu press Cancel Setting Up the Cellcorder 8 Setting Up the Cellcorder To display Cellcorder test and system options at the Main Menu press Setup Options are available for Thresholds Clear Memory Display Sound Modem Frequency Date Time To scroll the menu press the Down Up Arrows The following sections describe the options System Setup System Setup System Setup 1 Thresholds 4 Sound a Date Time a 2 Clear Memory 5 Modem 3 Display y 6 Frequency y BACK BACK BACK Figure 3 Setup Menus 8 1 System Setup Thresholds Cellcorder voltage and resistance thre
98. uency cccssccessccessscsssssensessssseeesssveceesneeons 18 8 7 System Setup Date Time ccceeccesceesececeeseeeseeeeeeseeeeeeeerenrens 18 SETTING UP AND EDITING A SITE eeeeecceecesecssecesecnsecaecaecaeeeseseneeees 19 9 1 Navigating the Site Menu ce ecceeceeseceeceeeceneceseceseeeeeeeeneeses 19 9 2 Setting Up a Site Before Testing cecceceesseeseeseeeseeereeseeseeees 22 9 3 Linking a File to a Site After Testing cceeceseeseeeesteeeteeees 22 9 4 Editing an Existing Site cc eeeeeesceeceesceeeceeecsecssecseeeeesseeees 23 95 gt Deleting a Site s c2 35 sedissocestien ese ceseessacd oxhcaaecceeine ahadtns toeene eeteegenbes 24 9 6 Selecting a Site for Test cc ceccesecscecsseeneeeeeeeeeeeseeeeesereneeeneensees 24 MEASURING VOLTAGE AND RESISTANCE ceseseseeseeereeeeeeeeeeeeeeeeees 25 10 1 Mode Select Voltage cccecceeccescceseceseceseceeecseeceeeseeeeeeneenerenrens 25 10 1 1 Taking Voltage Readings 00 ccccceseeseescecseeereeeeeeeeeeereeeeens 25 10 2 Mode Select Resistance ccccecccsssesseceseceeeeeeeeseeeseeseeeeeeeerensrens 26 10 2 1 Taking Resistance Readings ccccescsseeseesseeeeeeeeeseeeeees 26 10 3 Mode Select Specific Gravity Temperature cesses 29 10 3 1 Hydrometer Data to Cellcorder via IR sses 29 v 10 3 2 Hydrometer Data to Computer cecceceeseeseeteeeseeeeeeeeees 30 10 4 Overall Voltage OV Data ceeececceseeseereeeeeeeeees
99. umbers note that each alphanumeric keypad key types up to four characters a number and three letters The space character is on the 9 key The cursor advances after pressing a key or you may use the Right Arrow To type a name for example press a key then wait or press the Right Arrow to step to the next space NOTE On certain screens the cursor advances two seconds after an alphanumeric key is pressed 19 Setting Up and Editing a Site Location battery and string names have a set number of characters and other parameters have minimum maximum values When High Low Temperature and High Low SG summary thresholds are exceeded this is indicated with two beeps and reverse video and printed in the Thresholds section on the test printout The following table lists editable items and the keys to use up down left right arrows alphanumeric keypad to edit them After editing an item on an existing site some screens such as thresholds display Accept while some such as battery name display Save Pressing Accept or Save saves the change to the site file 20 Setting Up and Editing a Site Item Description Edit Text Using LOC Location name 39 characters max L R arrows keypad BAT Battery name 18 characters max L R arrows keypad STG String name 15 characters max L R arrows keypad MOD Model number of battery 39 characters max L R arrows keypad CEL Total number of cells Def
100. voltage The resultant resistance is simply Riwrernat AV I CELL VOLTAGE 02 281 V2 2 088 2 253 V 2061 4 76 AMPS unas N V2 yav LOAD CURRENT e 325SECONDS m R intemal Av 375 Microhms Fig 8 Measuring Internal Resistance THE MOMENTARY TEST DISCHARGE This is a feature worth your time to understand It is in part what distinguishes the Cellcorder from most instruments presently on the market and will help provide readings in which you can be confident For rated cell capacities of less than 1000 amp hours the discharge is short only three to four seconds in the order of 20 to 75 amps For larger capacities the duration is close to 10 seconds To prove a point about safety and the effects of short term high currents we performed the following experiment We imagined an internal conductor corroded down to the size of a dot We found that passing the Cellcorder s test current through a skinny wire 27 inches of 20 gauge wire caused no damage nor barely heated it Try it The reason is that very little energy is involved It amounts to only a maximum of 5 watts per 1000 microhms and lasts only seconds In an actual test within milliseconds of starting the Cellcorder senses the current level If there is a very high internal resistance the current will be low and the discharge will be instantaneously terminated Thus a cell with an exceptionally corroded internal conductor will not be further

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