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West Mountain Radio Battery Box Technical information

1. 7 E emm 2973 Voag 11 1 Cole 3 User entered voltage or use Detect button Program determined number of cells Capacity Ah 1 00 Weight of battery for optional Ragone Plot r Zeller Uli ZZ NoAnpllier User entered Capacity Ah IER to convert from mAh divide by 1000 Test Type Discharge Unique user entered Test Name Cutoff Voltage user entered or determined by Detect button Test Amps Graph Ampere gt Test Type user selection This section varies with selected test type El Copeety Check Pass Fal Pass Theechokt 500 gt Profile Profile defaults to lt Auto Check gt which causes the program to automatically recommend appropriate test discharge current and cutoff voltage from the user entered Battery Type and Capacity It then reads battery s fully charged voltage and makes a cell count estimate and recommends a test cutoff voltage and discharge current With this profile you only need to provide the basic information to run a test and the software will do the rest All you need to supply is the Test Name the Battery Type chemistry and provide the batteries rated Capacity West Mountain Radio 19 Operating Manual The user can manually override any parameter and run a test or save those custom settings as a Profile To add and save a new profile use your mouse to highlight lt Auto Check gt Then type in
2. NOTE You will notice that the test graph tabs come up in the order that you select the next test If you would like to re arrange the order you may click on the tab with your left mouse button holding it down and drag the tab over to a new location When a test is completed on a CBA you may start testing another battery while the other CBAs are running Disconnect the battery and click Test gt New A prompt will appear asking if you wish to append your graph or start with a new one Only tests of they same type can be appended to the current graph Connect the next battery and type in the test info and start the test Do this procedure in order as indicated for best results NOTE if you are in the process of connecting another battery and starting a new test when a test completes it will pop up a notice that a test is completed and switch the tab to the completed graph If this happens simply close the completed test notice window and finish starting the new test Even though the tab corresponding to the new test has switched to a completed test you may still start the one you were trying to start where you expected Congratulations you have a multiple channel battery analyzer system completely setup and running West Mountain Radio 60 Operating Manual Testing From Script This section explains how to configure your CBA software to run tests from a command line or scripting language Firstly if using multipl
3. To Aroen Fos Arnpitters Melee 02 tunes Gah Mendes Ki Max Time This field should be greater than the typical charge time for your selected battery Graph Minutes is only one available graph type for this Test Type Graph Temperature An extended license will allow you to graph the temperature of your charging battery West Mountain Radio 26 Operating Manual Power Profile CBAIV Only This test is extremely useful for characterizing different power supplies solar cells and batteries The voltage current relationship is extremely useful and the data gathered will allow your power supply to operate at optimum power output and efficiency This test continuously increases the load by the Current Increment while the voltage is graphed vs current or vs power Using a voltage vs power graph the peak power output of a battery or power supply can be accurately measured Information about the Battery section Amplifier section and Cutoff Voltage can be found in the Test Configuration section of the Help New Test CBA 123 Profile lt Auto Check gt Battery Battery Type Li poly v sl Cels 3 Detect _ S Voltage 11 1 Weight 1 000 kg Capacity Ah 1 00 Test Test Name Amplifier No Amplifier Cutoff Y 18 40 E O One Amplifier Two Amplifiers Test Type Power Profile x E Four Amplifiers Current Increment 1 00 a E Cutoff Current 20 00
4. N lO CBA IV Computerized Battery Analyzer West Mountain www westmountainradio com 1020 Spring City Drive Waukesha WI 53186 262 522 6503 sales westmountainradio com 2015 West Mountain Radio All rights reserved All trademarks are the property of their respective owners Introduction Thank you for choosing the West Mountain Radio CBA It takes the guesswork out of using batteries and it will help you learn about batteries The CBA is much more than a simple battery voltage tester or a battery load tester The CBA will test virtually any type or size of battery any chemistry or number of cells up to 55 volts Now anyone can do scientific tests of their batteries for a reasonable price By itself the CBA is capable of tests up to a maximum of either 40 amps or 150 watts for short periods of time For continuous operation suggested values are 20 amps or 100 watts whichever is higher With an optional amplifier tests can be done at 500 watts Up to four amplifiers can be used for a total test power of 2000 watts The CBA not only tests the total amount of energy stored in a battery capacity in amp hours but it graphically displays and charts the voltage versus time using a constant current load Graphs may be displayed saved and printed and the axis parameters can be changed at anytime Multiple test graphs of the same battery or multiple batteries may be compared or overlaid a very useful featu
5. West Mountain Radio 67 Operating Manual temperature if used temperature will also be graphed during hands free test test and saved to file open n specifies the temperature to stop the test to prevent test from running if external temperature is too high AmpHrs If performaing a hands free Watthrs test test this specifies the Minutes graphing format to be used Ragone Ragone graphing only works Amos for discharge tests Amps and Watts Watts are only available for PowerProfile tests n For a hands free test specifies the number of CBA Amplifiers connected to the system If this is not specified it is assumed 0 Serial For multiple CBA users this is necessary to specify which CBA unit to use amplifiers West Mountain Radio 68 Operating Manual Hands Free Testing An external software program or script can initiate a hands free test by executing the software with the test command line options For example C Program Files CBA WMRCBA2 exe test discharge 2 cutoff 10 5 open result bt2 The software will remain open and run the test until the test has completed For most tests it is completed when battery voltage has dropped below cutoff voltage For multiple discharge test test will complete after the specified duration has expired or the cutoff voltage is reached which ever happens first When the test is complete the software will clo
6. Profile lt Auto Check gt Battery Battery Type Li poly N Voltage 11 1 Cells 3 s lt Capacity Ah 11 00 Weight 11 000 kg Test Test Name Amplifier No Amplifier Cutolf Vs 8 d A One Amplifier Two Amplifiers Test Type w Four Amplifiers Resistance Graph Ca C West Mountain Radio 33 Operating Manual Resistance In this field specify your desired Resistance in Ohms Using the battery specifications enter a safe value that will not exceed the limitations of the battery you are testing Graph For a Constant Resistance test you may view your graphical results in Amp Hours Watt Hours or minutes This can be changed at any time during the test or after it is completed and also when opening a saved file To do this right click on the graph area and choose Chart Properties Or select Test gt Chart Properties Charge Discharge Test This test can be performed by selecting Charge Discharge as your Test Type This option will not be displayed on the pull down unless the WMR CBA Charger Interface board is connected to your computer via USB You can verify this by looking for this device in Windows Manager under the section labeled Custom USB Devices For more detail s see CBA Charger Interface Information about the Battery section Amplifier section and Cutoff Voltage can be found in the Test Configuration section of the Help West Moun
7. One way to keep track of tests is by using a unique number for each battery If you re testing the same batteries over and over you may wish to include the cycle number as part of the test name You might also wish to make the date or time part of the name so that it will be visible on a graph when viewed at a later date This version of the software does allow putting notes on a graph with date and time or you could make that information part of the test name Be certain to choose test and file names that allow you to keep track of the test data in a way that is satisfactory for your needs To start a new test from a blank screen click the New Test document Icon below File This will bring up small window asking which CBA you wish to use If you are unable to distinguish between the different CBA s select on and click Identify Choose your desired CBA and a New Test window will appear along with a tabbed blank graph window behind it Connect the battery and select a test profile or correctly fill in the parameters and start the test Continue until all of your batteries are being tested or all the CBAs are in use In a given time the first test will complete and the corresponding tabbed graph will pop up over the others a completed test window will pop up and the software will beep your computer speaker until you save the test and disconnect the discharged battery West Mountain Radio 59 Operating Manual
8. when the temperature gets above a user specified limit After the recovery time expiries the test resumes until the test is stopped or the voltage cutoff is reached Capacity Check This feature allows you to verify that your battery capacity correlates to the manufacturer claimed battery capacity Ensure the capacity window on the new test prompt matches the battery to be tested This information is usually found on a sticker on the battery If you are unable to find the battery capacity contact the battery manufacturer The default Threshold is 80 and has a range of 50 to 100 of the specified capacity A2200 mAh battery must supply at least 2 2 Ah 80 1 76 Ah before the voltage drops below the cutoff voltage A pass and fail results are indicated in the legend and the status bar A vertical dotted line on the graph indicates the Ah required to pass West Mountain Radio 25 Operating Manual Charge Monitor The Charge Monitor test will show the voltage of a battery over time as it is charged This option provides a recording multi meter that gives precise measurements and visually displays that information Information about the Battery section Amplifier section and Cutoff Voltage can be found in the Test Configuration section of the Help Profle Aao Oath Battery Daten Tee Loy Vehage 197 S Cm 3 gt Detect J Capacty fidt 1 00 Weg 100 kg Te Toit Ham Tern Gong No Ampa Qay San One Asch en me EERE
9. Firmware Calibration Date License Type 3 0 127 5 26 2011 7 52 00PM Extended 41 64 1 1 0001 12 00 00 AM Update Identify Select the connected CBA that your license is valid for and click License Add License Key Licensee Battery Man CBA Serial H 10299 Cancel e License Key YV7_35_929 SH_O7V CBA Name My super CBA West Mountain Radio 47 Operating Manual Enter your registration information exactly as shown in the email Licensee CBA serial and the License key You may optionally enter a CBA Name It is suggested if you plan to use multiple CBAs in the future Clicking Identify will flash the selected CBA s green LED for a few seconds The default name contains the serial number preceded by CBA If you expect to need multiple CBAs running on one computer choose a name to identify this one from the multiple CBAs you might have now or in the future If you are prompted to do so close the program after registering your license and then restart your CBA software Congratulations on purchasing your Extended License You are now ready to begin using the Extended Features West Mountain Radio 48 Operating Manual Extended Software Features This section covers the advanced features available only with an Extended License These features will be grayed out unless you have purchased a License and registered your license by entering you
10. an appropriate name for a new custom profile The program will ask you if you want to save it as a new profile or update the information for the existing lt Auto Check gt information After saving a profile or profiles you may recall them by typing in part of the profile name or selecting it from the drop down menu NOTE if you select a saved profile and change the settings the program will ask you if you would like to save those changes to the existing profile or create and save a new profile Profile has changed Profile 1S No name_new has changed Choose one of the following options Update existing profile Create a new profile named My new profile If you no longer need a profile you may highlight it and use the Delete button to the top right of the New Test window Battery Type The Battery Type drop down selection must be chosen correctly in order for the software to recommend how to test that particular type of battery Select the type of battery you are about to test NOTE If you have an unusual type of battery that is not on the list it is recommended you select Other Custom and then manually set the test parameters If you are unsure about any parameters review the battery specifications or contact the battery manufacturer or contact West Mountain Radio West Mountain Radio 20 Operating Manual Voltage This is the rated average pack or cell voltage
11. causes blindness or severe scarring injuries Never use a standard lead acid battery without proper ventilation West Mountain Radio 5 Operating Manual Sealed lead acid batteries such as gelled or AGM absorbed glass mat types are much safer Automotive and marine types are not as safe and should be used in protective ventilated housings Never make the last connection to a lead acid battery causing a spark on the terminal Always connect the load or charger last and at a safe distance away from the battery NiCad NiMh and Alkaline Safety Warnings These batteries can be dangerous also If they are shorted out or charged or discharged at too high a rate they can overheat and explode A single D size NiCad cell can actually melt a 10 penny nail don t try this Lithium Safety Warnings Reprinted with permission of the Academy of Model Aeronautics Words in bold and were added by West Mountain Radio Lithium Battery Fires Lithium batteries are becoming very popular for powering the control and power systems in our models This is true because of their very high energy density amp hrs wt ratio compared to NiCads or other batteries With high energy comes increased risk in their use The principal risk is FIRE which can result from improper charging crash damage or shorting the batteries All vendors of these batteries warn their customers of this danger and recommend extreme caution in their use In spite
12. contact West Mountain Radio for support West Mountain Radio 75 Operating Manual Computer System Requirements Basic Requirements e APC with a Pentium 233 or better e At least an 800 X 600 graphics card and display monitor e Windows 98SE ME NT 2000 XP Vista Windows 7 32 or 64 bit e An available USB port Recommended e AMD or Pentium 1 2 GHz better e Better than 800 X 600 graphics card and display monitor e Windows XP Vista or Windows 7 e 1 GB or more RAM e An available USB port For graph and label printing e Any Windows compatible laser or ink jet color or black and white printer e Avery 5160 labels are required for label printing West Mountain Radio 76 Operating Manual Support If you cannot find the answer to a question about using the CBA here in this manual and help files you may get help several other ways Web Support http www westmountainradio com supportcba htm Email support westmountainradio com Phone 262 522 6503 x32 Fax 262 522 6504 Mail West Mountain Radio 1020 Spring City Drive Waukesha WI 53186 USA If you have a problem with your computer or USB port contact the computer manufacturer If you have a problem with your computer s Windows operating system contact the computer manufacturer if Windows came pre installed when you purchased the computer If you purchased a copy of Windows and put it in your computer you should contact Microsoft
13. directly If you have a problem with a battery or a product you are using with it contact that manufacturer or supplier West Mountain Radio 77 Operating Manual Cc CBA Charger Interface 55 CBA Testing From Script c ccccssscccceessscecceetsseeeceeeteseeeeeetenecee 61 Charge DISCHANRGC oriasi aana aAA aA ARAA 34 Charge Monitor TeSt ccccccscccccesesscecceerseceeeeetesecceeeeessneeeeeeseaes 25 Constant Power Test 31 Constant Hesisiance anini innra ninien ir EARNE ERNE 32 D Discharge EE 23 Duty Cycle Tesi 34uekgesieeekEssiideeeessZdZ eekRE ees 28 E Extended FOatures siccncsevevsgeesindedscansncdcdecebedcesdensrteeaetedenestenac 49 F Firmware Updates iy icc sagicacaanaataceasasaadsactannnciadasnaviaduanaadaddtenaatdee 69 G Getting State EE 7 l ugeet E 1 L LICENSING ME 47 M Multi CBA Setup A Operation 57 Multiple Discharge Test 30 P Power Protile TeSt cceccnieniiien i n eege 26 Program Features censon aAa AEE 13 S EE EEA E EA 3 Saving And Prini ecn 41 SUP POM eege a aa A ea aE 75 System Heouirements 73 T Temperature Probe Cotton 67 Test Configuratio ssrin EEN 19 Test EXaMple iioii ariaa a a aaa 37 Troubleshooting ririnui iaaa aE 71 West Mountain Radio 78 Operating Manual Specifications One model for all testing ranges Maximum continuous discharge rate 100 watts Maximum limited term discharge rate with lt 3500 ma hour battery 1
14. is complete An LED will suffice These inputs can handle up to 12V e OUT A and OUT B These outputs are shorted relays closed when the software is starting a charge cycle The purpose of this is to connect to a push button on a charging unit where the push button might control the start stop of the charger e Powerpole When a Charge Discharge test is not running or during the Discharge cycle of a Charge Discharge test these poles will be open During a Charge cycle these Powerpole will close short and the WMR Charger Interface and the CBA Software can read the current drawn by the battery from the charger unit e Green LED This is lit when the CBA software has connected to the WMR Charging Interface board NOTE There is a green power LED also e Yellow LED This is lit when the CBA software is currently performing a Charge Discharge test It will go dark when test is complete e Red LED This is lit when the CBA software is currently in a charging phase of a Charge Discharge test the Powerpole are closed and the charging unit is connected to the battery When starting a charging cycle the CBA software will close both the OUT A and OUT B relays and leave them closed for the duration of the cycle If this is not compatible with your charging unit or need more flexible options contact WMR and we can add support for your charging unit West Mountain Radio 55 Operating Manual While performing a char
15. set Never attempt to charge Lithium cells with a charger which is not specifically designed for charging Lithium cells Never use chargers designed for Nickel Cadmium batteries 5 Use charging systems that monitor and control the charge state of each cell in the pack Unbalanced cells can lead to disaster if it permits overcharge of a single cell in the pack If the batteries show any sign of swelling discontinue charging and remove them to a safe place outside as they could erupt into flames 6 Most important NEVER PLUG IN A BATTERY AND LEAVE IT TO CHARGE DISCHARGE UNATTENDED OVERNIGHT Serious fires have resulted from this practice 7 Do not attempt to make your own battery packs from individual cells These batteries CANNOT be handled and charged casually such as has been the practice for years with other types of batteries The consequence of this practice can be very serious resulting in major property damage and or personal harm West Mountain Radio 7 Operating Manual Again Primary Safety Considerations e Never discharge a battery at a higher discharge rate than it is designed for e Never use a battery that has poorly insulated or frayed wiring or exposed metal parts e Never connect a battery with reverse polarity Never test a battery near flammable materials e Never allow a battery reach a temperature that causes it to get so hot that it may be too hot to touch Recharge your batteries imm
16. with open this command sets the battery information This is only used for informational purposes and does not affect the test parameters If this is not specified random data may be saved to the file Type is battery type and the following strings are allowed e Alkaline Carbon Zinc Lead Acid LiFePO4 Li ion Li poly NiCd NiMH e Other Example 4Ah 6 Cell 13 2V battery 5 5 pounds battery 4 6 13 2 5 5 Lead Acid West Mountain Radio 66 Operating Manual TI aa Specify the cutoff voltage If using a hands free test this parameter is required if not specified the program will not run atest The test is completed when the battery goes below this voltage Example test discharge 1 cutoff 10 5 Specify which test results file to open If a hands free test mode was initiated with test command line option then test results are saved to this file when finished D y Example open test bt2 When using test for hands free test and saving results to a file specified by open this option sets the title of this set of data when appending to the file This parameter is optional If user does not specify a title software will ue TEST If titale is already used in a specified file test name will be appended with an incremental number ex TEST 2 will become TEST 3 Example test discharge 1 open test bt2 title Test XRF200
17. you may adjust the discharge current in 1 mA increments but only within a 10 mA measurement window You may not see a change unless you are on the cusp of switching to the next 12 bit data level This feature is useful to calibrate at especially low discharge rates below 500 mA Do not use this option without complete understanding Calibrate Current Offset Current Drive Offset m H e Cancel Voltage Calibrate is grayed out and only available with an Extended License See the section of the manual on Extended Software Features Help Contents Index Search This gives you access to these files directly from the program instead of from the CD ROM or our web page About CBA Displays the current software version West Mountain Radio 18 Operating Manual Test Configuration To begin testing your battery click File gt New or the button You will notice that the New Test window defaults to the Profile lt Auto Check gt and is in the auto check mode With this profile you only need to provide the basic information to run a test and the software will do the rest All you need to supply is the Test Name the Battery Type chemistry and provide the batteries rated Capacity Test Profile in lt Auto Check gt mode Profle lt AuioCheck gt User entered Battery Type Chemistry Battery Battery Type Lipo
18. 25 watts Maximum limited term discharge rate with lt 1000 ma hour battery 150 watts 0 3 amp accuracy typically better than 10 ma 3 40 amp accuracy typically better than 45 ma 0 5 volt accuracy typically better than 005 volts 5 15 volt accuracy typically better than 01 volts 10 60 volt accuracy typically better than 05 volts Maximum operating voltage 55 Volts 48 Volt Lead Acid Telecom supported Maximum discharge rate 40 amps Battery dependent 100 watt continuous Minimum discharge voltage to maintain 30 amps 9Volts Battery dependent Minimum Voltage for a 40 amp discharge 2 volts at completion of test Battery dependant Minimum discharge rate 0 01 Amps Residual current drain battery connected while not in use lt 003 amps 12 volts High performance micro controller with built in USB interface and 12 bit A D conversion USB powered the CBA does not use the battery being tested to run the CBA or the fan System ready and Test in progress LED indicators viewable from across a room CBA internal over temperature sensing and protection Graph printing on any standard color or B amp W printer Battery test label printing on standard 05160 stick on labels Dimensions 3 5 H x 2 8 W x 3 6 D Weight 16 oz West Mountain Radio 79 Operating Manual CBA IV Warranty CBA IV is warranted against failure due to defects in workmanship or materials for one year after th
19. Ze Gi D i 5 8 Ore rpili sntered Capacity Ah O Tredan ert fram mAh divide by 1000 7 Ze Sab O Four Ample el he Unique user entered Test Name e BR Gu Ee Cutoff Voltage also determined Grach f he using the Detect Button SE Test type user selection _ Recommended Test Amps After clicking Suggest Button Graph x scaling type can be anged duringfafter or from a saved file ab After starting the program click the E button or to go File gt New Notice that the Profile is set to the default selection Leave it like this as we will use the to help test this battery We are testing a lithium polymer battery so let s select Li Poly in Battery Type At this time you may plug in this battery Be careful to make a solid connection with the correct polarity You will notice that when you plugged in the battery that the CBA panel on the right shows the voltage At this time either click the Detect button or correctly fill in all the necessary fields Using the Detect button will change the Cells to 3 and the nominal Voltage to 11 1 average voltage for a three cell Li Poly pack The program will also set the Test Cutoff V Make sure that this is all correct West Mountain Radio 37 Operating Manual Type in or scroll to the rated capacity for the battery in this case 2 2 Ah The sticker reads 2200 mAh Capacity This is converted t
20. alid or missing parameters 2 could not find CBA 3 parameters are vaild but the power requirements would damage CBA Reduce desired test current or reduce test voltage 4 test stopped because internal temperature too high 5 test stopped because temperature probe too high 100 Critical error contact WMR 101 Critical error contact WMR West Mountain Radio 63 Operating Manual This parameter should be given before other parameters The following command line options are required to use test cutoff discharge performs a test with constant current draw from the battery amps specifies the desired current Example 1 5 Amp Test cutoff at 10 5V test discharge 1 5 cutoff 10 5 power performs a test with constant power draw from the battery watts specifies the desired power draw Example 50 Watt test cutoff at 10 5V test power 50 cutoff 10 5 resistance performs a test with constant resistance load on the battery ohms specifies the desired load Example 5 Ohm test cutoff at 10 5V test resistance 5 cutoff 10 5 multiple performs a test with multiple setpoints of constant current draw n specifies the number of constant current setpoints tn specifies the duration in seconds to draw this current an specifies the desired current draw for this setpoint The test will complete regardless of cutoff voltage when all setpoint durations have completed Test will als
21. average of a discharge cycle of a battery not the fully charged voltage which is actually measured by the CBA when a battery is first connected In the lt Auto Check gt mode this is automatically calculated from the user provided battery type information and from the CBA s reading of the fully charged battery voltage Double check that this voltage is correct before starting a test NOTE Manually changing this will also change the battery cell count Cells This represents the number of series cells estimated to be in your pack Using the Detect button will let the software estimate this for you Double check that the number of cells is correct before starting a test Detect Button Clicking here will fill in Voltage and Cutoff V based on the current CBA reading Additionally using the Battery Type the number of cells will be estimated Capacity The Capacity Ah is the rated capacity of the battery in Ah Ampere Hours This must be typed in or selected in order for the software to recommend an appropriate discharge rate Normally this information is on a sticker on the battery otherwise contact the manufacturer If the capacity is in mAh milliampere Hours divide by 1000 to convert to Ah Weight The Weight of the battery is optional information not needed to run a test It is saved with the file and is needed to plot a Ragone graph but only with the Extended version software upgrade West M
22. ay a new test the test type will be grayed out NOTE If you open a previously saved file with previous test tests on it you may add more tests to it With the File gt Overlay menu choice you may open additional test files and those graphs will automatically be overlaid over the test graphs that are already on the screen If you try and save an over lay screen with multiple test files on it you will be asked if you if you would like to overwrite erase the last file opened and replace it Be careful to choose what you would like West Mountain Radio 43 Operating Manual Printing Test Graphs Since the CBA is able to save a file with multiple overlaid graphs we have provided the option to print in either color or black and white For B amp W printing we provide unique tick marks on each graph to identify each graph trace with a corresponding legend key For color printing each graph has its own color You must select B amp W if you wish to print on a black and white printer Go to Tools gt Preferences and select B amp W if you would like each graph plot uniquely identified with a B amp W legend keys After selecting color or B amp W go to File gt Print Setup and then the printer that you would like to use While you are there you would normally select portrait mode for the print out To select black and K Preferences EJ white printing select Tools gt Preferences Temperatu
23. consequential loss of any kind e For any business losses loss of revenue income profits or anticipated savings loss of contracts or business relationships loss of reputation or goodwill or loss or corruption of information or data By using this product you agree to the limitations of liability set forth in this disclaimer are reasonable CBA Operating Requirements e Never connect a battery with the polarity reversed e Always connect the USB cable BEFORE connecting the battery e Never connect a battery to the CBA that is connected to something else e Contact West Mountain Radio for support before connecting to a USB hub e Operate the CBA in a cool dry location e Never allow metal parts or wiring of the battery come in contact with the metal heat sink e Never allow the cooling fan to be blocked or jammed e Do not ignore the warnings that the software may give you e The CBA can get hot Do not touch the metal heat sink while or shortly after conducting a high power test Lead Acid Battery Safety Warnings There may not be a consideration while testing lead acid batteries but there certainly is while charging lead acid batteries These batteries especially automotive and marine types give off explosive hydrogen gas when charged A nearby or internal spark or flame can cause a lead acid battery to explode sending liquid acid and lead shrapnel in all directions This is particularly dangerous and frequently
24. dentifies what test or tests are contained in the saved file Note Changing the file name will not change the test name of the graphs on the screen The first time you save a file you will get a window requesting confirmation of the file name and directory Subsequent saves File gt Save or click Li will save the file but will not ask again for file name or directory t Me Teei ee tte Saks t o 8808 UBI2TOFR danad Sove es DEJV aneao Ge er 6008 UB12TOFA deer D 2 n OB Jom SES Hess me 43D Slam d My Seen lag das omens J se e D emp bd vu Gan D o 3 piw bo Gren W s 5 on 5 Gs 5 a wen Ges are d s d ds s EE ZE 9 d dree y x2 GE Wy rese d gt F a e CS s idy Weizen L Gees ane 3 Seel E E If you attempt to close the program or the test that is on the screen you will be asked if you would like to save that test or tests to a file West Mountain Radio 42 Operating Manual If you attempt to start another test with a test on the screen the program will give you the following choices Selecting New Test will prompt for a test to be appended or to start a new graph New Test hi Oo you want to add anaw test to the current test documert NOTE If you wish Bel or create a ren test document to save multiple tests in the same file they MUST be New Ti New Document Gace Lecter T e oam Tost Type Discharge Constant Power If you attempt to overl
25. e The test was set for 30 seconds on and 30 seconds off at a 4 amp load Move the cursor to the graph until you see the test name displayed Step 2 right click and select Add Note note Properties Duty cycle test with UB1270FR 30 sec on 30 sec off at 4 amps Font Microsoft Sans Serif Spt m Location Fore Color M 0 Back Color TI OO Alpha 255 20 px Rounding 0 s The note properties screen besides letting you type the note lets you select the location of the start of the sentence relative to where you clicked Set the pixels in the px box and the direction of offset with the Location check boxes You may also change font style and size with the selections to the left West Mountain Radio 51 Operating Manual KEE SCC DEE EE LETN PELET TETIT The final note is shown on the graph NOTE If you have a number of graphs overlaid notes are helpful in identifying different tests and graph features West Mountain Radio 52 Operating Manual Temperature Graphing ZE Wort Mountain Rato CHa H jog De pe lech the Rain 15 2800 1 Ab patty Vet 26 Ah ALAA Fetes t The test will be stopped when the temperature is above the specified threshold or a Recovery Time can be specified When the battery reaches the threshold temperature the test will stop for the given recovery time and then resume To see the results over time for ba
26. e test to remove that graph trace You may also select properties and change the graph style but only if the test was done and saved on Version 2 or later of the software BP open Allows you to open any saved file Old test files from the previous version 1 of CBA software may be opened by changing Files of type from bt2 to bt When you open and display an old style bt1 file when you save it will be converted to the new bt2 and saved in the new format Close Will close the file displayed on the screen and prompt you to save it Led Save Saves the test document graph currently displayed on the screen West Mountain Radio 14 Operating Manual Save As Allows you to save a test under a new file name as a copy or to save the same file in a different folder location Export Converts the test file to CSV Comma Separated Values comma separated file format and allows you to save it for data manipulation with a spreadsheet program such as Excel or with a text viewer i Print Print Preview and Print Labels For a discussion of printing functions refer to the help section on printing Recent files A convenient way to open files that you were recently using from a list of the last eight files Exit Closes the program and will prompt you to save a file of the tests on the screen Test Menu New Test Opens a New Test window This new test can be appended to the curr
27. e CBA s you should first ensure that you can connect to multiple CBA s while the program is in normal operation If you have a CBAIV this capability is built in If you are unsure start the CBA software and select Tools and then CBA Devices CBA Serial U Femme Calbsation Date lcerae Type 1 30127 SCC ZEIEN EMended DEE Once here begin plugging in your devices and if more than one shows up similar to what is pictured above in the window please read the help section Multi CBA Returning to your scripting language or commandline it is very important that all commands are carefully reviewed before they are run These commandline parameters are for expert users only USE EXTREME CAUTION and please review the Safety section of this help manual West Mountain Radio 61 Operating Manual CBA Software Command Line Options Items in italics are dynamic value to be specified by user See Table on following page West Mountain Radio 62 Operating Manual Command Parameters Comments test discharge amps Initiate a hands free power watts test A hands free resistance ohms test will open the multiple _ n t7 a7 tn an software to perform duty amps ton toff a test and when profile increment the test is complete cutoffcurrent the software will automatically close The software will return the following result codes when test is complete 0 test run completely 1 inv
28. e date of purchase from West Mountain Radio Warranty does not cover damage caused by abuse accident misuse dal el or abnormal usage failure to follow instructions NEG el installation alteration lightning or other incidence of excessive voltage or current If failure occurs within this period return the CBA IV or accessory to West Mountain Radio at your shipping expense The device or accessory will be repaired or replaced at our option without charge and returned to you at our shipping expense Repaired or replaced items are warranted for the remainder of the original warranty period You will be charged for repair or replacement of the CBA IV or accessory made after the expiration of the warranty period West Mountain Radio shall have no liability or responsibility to customer or any other person or entity with respect to any liability loss or damage caused directly or indirectly by use or performance of the products or arising out of any breach of this warranty including but not limited to any damages resulting from inconvenience loss of time data property revenue or profit or any indirect special incidental or consequential damages even if West Mountain Radio has been advised of such damages Except as provided herein West Mountain Radio makes no express warranties and any implied warranties including fitness for a particular purpose are limited in duration to the stated duration provided herein www westmountainradi
29. e program and its features West Mountain Radio CBA Top Menu Bar File Test Tcols Window Help Eile Test Tools Help See descriptions later in this section SKS at DI KS Help Help program version and hardware serial information Stop Stops the test in progress Changes to a pause button when test is running Start Starts the new test Changes to a pause button when test is running Properties Allows you to change the test name and graph style Print Prints the graph on the screen See Saving and Printing Save Saves the test on the screen See Saving and Printing Open Opens a existing test file saved in your PC New Test in current document Opens a new test to overlay the currently displayed test File Menu RS New Starts a new test document This will initialize a new blank graph Overlay Will allow you to open a saved test document and allow you to overlay the tests in that file over the test graph or graphs already on the screen as long as they are the same type Once you have a series of graphs for battery comparison on the screen you may save those under an existing or new file name West Mountain Radio 13 Operating Manual SC1300NiMH 1 3 5 NiMH cells 1 3 LC1OOONIMH 1 2 A NiMH cells 1 0 NOTE If you have test graphs on the screen that you wish to remove you may right click on the graph trace and select Delet
30. ection of the Help New Test CBA 1 Extended Profile lt Auto Check gt Battery Battery Type Li poly N Sl Cels P E ra a x Weight 1 000 kg Voltage 11 1 Capacity Ah 11 00 Test Amplifier No Amplifier Cutoff 8 O Dne Amplifier Two Amplifiers Four Amplifiers Test Name Test Type Test Amps Period On 60 0 Period Off 30 0 Graph AmpHrs Cancel Test Amps In this field specify your desired discharge rate Using the battery specifications enter a safe discharge rate that will not exceed the limitations of the battery you are testing West Mountain Radio 29 Operating Manual Period On This is the number of seconds the battery will be discharged at the given rate Period Off The load will drop to zero amps during an off period and will last for the number of seconds specified here The duty cycle will be Pon Pon Poff Graph For a Duty Cycle test you may view your graphical results in Amp Hours Watt Hours or minutes This can be changed at any time during the test or after it is completed and also when opening a saved file To do this right click on the graph area and choose Chart Properties Or select Test gt Chart Properties Note When graphing in Amphr or Watthr the cycle will not be apparent and therefore it is suggested to display in minutes West Mountain Radio 30 Operating Manual Multiple Disc
31. ediately with an appropriate battery charger after you have completed your test Some types do not like to sit discharged for extended periods of time Never test or charge your batteries while unattended e Have a fire extinguisher nearby Your CBA has been supplied with a 25 amp fuse installed to give better protection from an inadvertent reverse polarity connection shorting the heat sink to the battery or having external connections that cause ground loop shorts A fuse is partial protection as the fuse does not always blow as quickly as the FET It depends on the voltage and source impedance but ultimately time We are installing a 25 amp fuse to give added protection and we have included a spare 40 amp fuse packed separately Do not use the 40 amp fuse unless you plan test a single Lithium cells in excess of 25 amps Because of both the CBA s 100 to 150 watt maximum power limit and its ability to regulate current at low voltages the only battery that can be fully tested in excess of 25 amps is a single Lithium cell The practical maximum discharge rate to maintain constant current regulation with a Nickel cell down to a 9 volt cutoff is approximately 25 amps Anything over 4 volts will exceed the long term power limit of 100 watts power volts times amps West Mountain Radio 8 Operating Manual Getting Started We strongly suggest that reading this entire manual and help file for a full understanding of the CBA and so
32. emp 78 1 F To the right there is an example of the readings displayed while testing a single cell Lithium at 22 amps Note the readings displayed and that the en virtual fan is running and virtual LEDs are lit as the LEDs on your CBA will have also West Mountain Radio 38 Operating Manual It is near the start of a test and the Voltage is at 3 80 V at 22 amps Note that the Current is not exactly at 22 amps but 22 04 this is normal The current will fluctuate perhaps 1 as the CBA is constantly adjusting The AmpHr will steadily increase as the discharge continues and the power in Watts will decrease as the battery voltage drops If you have a temperature probe connected and on the battery that reading be shown here also The test will stop when one of the specified limits is reached the voltage of the battery dropping to the pre set Test Cutoff V the optional temperature probe sensing that the user set over temperature limit has been reached or if operating at the limits of the hardware 150 watts or 40 amps the CBA itself overheats due to lack of cooling or high room ambient temperature WARNING Never run a test unattended Even thought we have included many safety features unexpected things could happen that could cause a battery explosion or fire Also certain types of computer lock ups could cause the CBA to over discharge the battery West Mountain Radio 39 Operating Ma
33. ently open graph or file P stort G El Properties These will be grayed out unless you have filled out a New Test window and selected OK instead of Start If available you may start a test or stop a test in progress Properties will allow you to change the test name before starting a test or graph type at any time West Mountain Radio 15 Operating Manual Chart Properties Allows you to change the graph scaling or put a title on the graph Tip You do not normally want to change the graph scaling as the automatic scaling works very well Tools menu Preferences Lets you customize certain settings for the program such as Temperature Units allowing you to pick either degrees C or F Save window size and position causes the program to come back with the same window the next time you open it Stop test when battery temperature reaches Print charts in black and white is for setting it to code the graphs for identity when not color coded Anti Alias chart text smoothens the text graphics E Preferences X Temparature Units OK Degrees Fahrerhet Degrees Celsius f Save window sze and position C Stop test when battery temperature reaches 2 deg TT Print charts in black and white C AntAkss chart t t C ArtiAias chat graphics L l Anti Alias chart graphics text smoothens the graph graphics Lab Calibrate Tools Lab Calib
34. er the voltage without good reason as most batteries can be damaged due to over discharge Lead and lithium chemistries are particularly susceptible to this type of damage It is commonly believed that nickel cells actually benefit from discharge to 0 volts if they are then quickly re charged However a pack of nickel cells should never discharged to near zero volts as a pack of cells could become unbalanced and damaged The software will give a warning before starting a test if you have lowered the test cutoff voltage below recommendations West Mountain Radio 22 Operating Manual Test Type Normally you would leave this set to discharge A Discharge Test provides a regulated constant current discharge The other test option featured in the standard version is Charge Monitor which uses the CBA as a recording voltmeter to chart voltage vs time for evaluation of a charger A CBAIV enables another standard test for power supply characterization Power Profile With an Extended License more tests become available like Constant Resistance Constant Power Multiple Discharge and Duty Cycle AWMR CBA Charger Interface board allows you to perform a Charge Discharge Test WARNING Never hook the CBA to a battery that has something else connected that is not totally ground isolated To test a charger in the charge monitor mode the charger must be totally electrically isolated from the computer ground CBA Amplifiers Notice the amplifier
35. ery and the CBA may be HOT 2 Aa E v er ee 11 When the test is complete go to the File menu and save the file if you wish to keep it NOTE The file name will default to the test name but you may change it to another name if you wish If you close the program or try to run another test you will be asked if you wish to save the completed test already on the screen 12 If you wish to run another test start at step 4 of these instructions Click the button or Test gt New When starting the new test toyou will be asked if you would like to save the previous test and start a new test or add that test to the graph on the screen West Mountain Radio 11 Operating Manual After running a discharge test on a battery the battery should be recharged Most batteries are rated for many recharge cycles depending on the battery type and on the discharge rates sometimes 1000 s of cycles Most batteries should not be left at their fully discharged cutoff voltages but should be stored in a partially charged state for maximum battery life This completes the getting started section Read this entire manual and help files for a full understanding of battery testing with a CBA West Mountain Radio 12 Operating Manual Program Features The installation and basic operation is covered in the Getting Started section of this manual help This section gives a detailed explanation of using th
36. es For technical information on a battery refer to the Battery Manufacturers website to get detailed information on the rating of the battery Most battery labels have limited information but the manufacturer s website may have more detailed information General Information on batteries is also available on the West Mountain Radio CD Select Battery Information and FAQ s Primary Safety Considerations e Never discharge a battery at a higher discharge rate than it is designed for e Never use a battery that has poorly insulated or frayed wiring or exposed metal parts e Never connect a battery with reverse polarity e Never test a battery near flammable materials e Never allow a battery reach a temperature that causes it to get so hot that it may be too hot to touch e Recharge your batteries immediately with an appropriate battery charger after you have completed your test Some types do not like to sit discharged for extended periods of time e Never test or charge your batteries while unattended e Have a fire extinguisher nearby Liability Disclaimer West Mountain Radio will not be liable to you whether under the law of contract the law of torts or otherwise in relation to the contents of or use of or otherwise in connection with the CBA product e To the extent that the product may cause any bodily or equipment damage West Mountain Radio 4 Operating Manual e For any indirect special or
37. est Mountain Radio 49 Operating Manual 1 Start a test at the intended current for the battery you are planning to test with the wiring you are planning to use for your test set up Record the voltage that the software reads V_CBA Record the voltage that your voltmeter reads V_Battery at the calibration point 4 Record the average Current I shown by the software while the voltages are being measured 5 Stop the test and go to Tools gt Lab Calibrate gt Voltage Calibrate In the calibrate voltage window click Reset to clear any previous calibration and then enter readings you have recorded Press Calculate and the calculated resistance will be valid for all future tests with this CBA until it is reset The voltage readings graphed and displayed will be corrected accordingly Press OK to save the calibration settings for future tests with this CBA If you change the test setup in any way you should re calibrate the setup or reset the calibration Calibrate Voltage Drop LA Amps V_Battery 12 04 Volts Cancel V_CBA 12 01 Volts i d E 0007 gen West Mountain Radio 50 Operating Manual Graph Notes af 3 E Froo det Add Mote Odette Test f Adding notes is a feature that may be used for additional notes and observations and many other purposes The test below is a graph of a duty cycle test using Voltage vs Tim
38. ftware operation 1 2 3 From the CD ROM opening screen click on Software and Hardware Installation Follow the instructions on the screen to complete both the hardware and software installations Connect the CBA to your computer s USB port using the supplied cable before connecting a battery NOTE If Windows says Found new Hardware you did not complete the previous step Start the West Mountain Radio CBA program NOTE For a CBAIII the green LED will come on when the program starts For CBAIV the LED will light as soon as the drivers are installed The software should start with a New Test screen in the Auto Check profile In the New test window select the Battery Type chemistry and select or type in the Capacity Ah New Test CBA 1 Multi Profile lt Auto Check gt Battery Battery Type Li poly v Cells 3 z S Weight 1 000 kg Voltage 117 a a Capacity Ah 1 00 Test Test Name snp ies ZE No Amplifier Cutoff V 8 One Amplifier Two Amplifiers Test Type Discharge A a Four Amplifiers Test Amps 0 50 sg Graph Minutes v Capacity Check Threshold 80 0 West Mountain Radio 9 Operating Manual NOTE To convert mAh milliampere hours to Ah Ampere hours divide by 1000 If the capacity rating is not printed on the battery contact the manufacturer or visit their web page 5 Con
39. ging cycle the CBA software will look for a high on either IN A or IN B to signify a charge complete If this is not compatible with your charging unit or need more flexible options contact WMR and we can add support for your charging unit Typical Setup The CBA and battery are both connected in parallel to the indicated Powerpole connector When the test is in Discharge the relay on the Charger Interface board is open and creates an open circuit Similarly during charge mode the CBA acts as an open circuit while the Charger Interface board relay is closed and the battery is charged Here is a setup diagram West Mountain Radio CBA Charger Interface Top View Multi CBA Upgrade This section explains how to configure a multiple CBA testing setup The CBA software provides support for up to 12 CBAs on one computer An Extended License is still required for specialized testing To purchase an Extended License visit West Mountain Radio Licensing Requirements Multiple CBAIII setups require a Multi CBA License West Mountain Radio 56 Operating Manual Multiple CBAIV setups DO NOT require any additional licenses Computer system requirements e CBAIII and CBAIV only CBA and CBAII not supported e Desktop computer laptop computers not supported e At least a 400 watt PC power supply e Available PCI slots for additional USB connections 1 PCI slot per 4 CBA s e Pentium 2 GHz or better e Running other applica
40. harge Extended Software Battery applications that experience different current loads such as a variable number of motors running can be tested using this test Allowing for up to five different current loads for varying durations this test allows realistic testing and real time analysis of performance under a highly variable load When entering the load use the battery specifications to enter a safe discharge rate that will not exceed the limitations of the battery you are testing Information about the Battery section Amplifier section and Cutoff Voltage can be found in the Test Configuration section of the Help New Test CBA 1 Extended Profile lt Auto Check gt Battery Battery Type Voltage Capacity h Test Test Name Cutoff Y Test Type Li poly 11 1 1 00 8 40 Multiple Discharge a Y Si v a v y ES y EN E a Y a E vv Cells 3 E Weight 1 000 kg Amplifier No Amplifier One Amplifier Two Amplifiers Four Amplifiers Seconds Seconds Seconds Seconds OKAIRA Seconds West Mountain Radio 31 Operating Manual Constant Power Extended Software You may also run a test with constant power instead of constant current With this test the current will be constantly increased as the battery voltage decreases over time Useful for batteries that are used in systems that require consistent power Information ab
41. he Help New Test CBA 1 Multi Profile lt Auto Check gt Battery Battery Type Li poly bi Voltage 11 1 Cels 3 Capacity h 1 DO Weight 1 000 kg Test e Test Name Sieg L m No Amplifier Cutoff H One Amplifier Two Amplifiers Test Type Discharge gt S Four Amplifiers TestAmps 0 50 E Graph Minutes v Capacity Check Threshold 80 0 West Mountain Radio 24 Operating Manual Tests Amps In this field specify your desired discharge rate Using the battery specifications enter a safe discharge rate that will not exceed the limitations of the battery you are testing If you would like to have the CBA software make a suggestion on a typical discharge rate you may click the Suggest button Graph For a Discharge test you may view your graphical results in Amp Hours Watt Hours minutes or with an Extended License Ragone This can be changed at any time during the test or after it is completed and also when opening a saved file To do this right click on the graph area and choose Chart Properties Or select Test gt Chart Properties Graph Temperature This is an Extended License feature allowing you to graph the battery temperature side by side with the battery data A Voltage vs Time graph is recommended for this option Recovery Time This setting is enabled with an Extended License and allows the test to pause and the battery to Recover
42. her plugged directly into the computer or into the cards not a combination of both Before installing a Multi CBA system you should have already installed and run a stand alone system with one CBA You should also have studied the rest of the help files and become familiar with the operation using one CBA Go to Help gt About CBA and check that you have our CBA software version 2 1 0 14 or later If you have an earlier version visit our web page and download and install the latest version update Setup If more than one CBA is connected with out a valid Multi CBA license or CBAIV connected the program will not start Licensing and new hardware can be obtained from West Mountain Radio No Multi CBA License is required for CBAIV For further instructions on license entry see Licensing NOTE Do NOT unplug the USB cables with the program running West Mountain Radio 58 Operating Manual Testing Multiple Batteries It is necessary that you are already familiar with testing batteries one at a time with a single CBA If not go back and read this help manual for using the CBA system for battery analysis It is very important to correctly keep track of your tests especially with multiple CBA s Our software deliberately requires a test name for each test By default it uses that name for the file name when you save the completed test file However you may change that file name when you save the test if you wish
43. isch 4 Temp 6 Lami Aod zella A Ah 4 OOA 10808 LEIDIER Sectarpe arre Termeratire 10608 UE1270 act 4 Tarp Tarpwatire D DI i HREF t prere ee geseag L zerasg L PATI EE Select the file names from the directory list with the tests that you need labels for or use the Select All button for all files and tests a At this point you can check print oon Fcc me ee preview to see what labels you will fr eener tee get The program will print a label E Choos Libels te Pret ebe for each test in each file no matter GE i g how many each file contains G L t Note You are selecting file names ingat Files may have multiple tests in WIE Ted Fid otete be them and one label will be printed for each test in the selected files FER Lee of pase Bowe lent ter Adr ch iegre it e Pa Note You may turn a partial sheet around in your printer if you are printing a few labels and wish to use up a partial sheet West Mountain Radio 46 Operating Manual Licensing To purchase an Extended license follow the instructions on West Mountain Radio Your License information will be sent by email NOTE This information is case sensitive After receiving the information start the program and connect the CBA that matches your License information Click on the connected icon at the bottom right Running KR 9 or go to Tools gt CBA Devices CBA Devices CBA Serial
44. multiple discharge and constant resistance The results can be graphed as Voltage vs Amp hours Watt hours Minutes or Ragone depending on the type of test Ragone graphs require the weight of the battery batteries to be accurate A CBAIV enables another test Power Profile This type of test is very useful for power supply testing or solar cell analysis The resulting graph displays Voltage vs Amps or Watts The Extended Software version also adds the ability to graph the battery temperature with CBAIII and CBAIV when the optional temp probe is connected An additional lab calibration feature makes it possible to compensate for test lead resistance giving accurate readings at the battery terminals The Extended software is only necessary when using a CBA III and a CBA Amplifier When using CBA IV with an amplifier either software license will provide provisions for operation with one to four amplifiers for testing at high discharge rates or doing destructive testing We hope that you enjoy using the CBA and find it useful You will learn valuable information about the batteries that you test West Mountain Radio 3 Operating Manual Computerized Battery Analyzer Software Safety Precautions The West Mountain Radio CBA is inherently safe but the batteries it tests are not Anything that stores energy is potentially dangerous Some types of batteries are safer than others but they are all capable of causing explosions or fir
45. nect the battery with very short solid low resistance connections using the proper connectors and polarity WARNING BE CERTAIN THAT YOU HAVE THE POLARITY CORRECT FOR STANDARD CONVENTION RED TO RED BLACK TO BLACK AND PLUS TO PLUS MINUS TO MINUS 6 The battery voltage will display the resting fully charged battery voltage on the right side of the screen Click the Detect button if you would like the software to suggest some baseline settings after you have selected the chemistry type If the number of cells or average pack voltage is not correct check that you have entered the proper battery type If you are sure the average pack voltage or cell count is incorrect change the software estimate to the correct value in either the Voltage or Cells 7 The discharge current in the Test Amps can also be suggested by the software by clicking Suggest This calculation is based on the battery capacity and chemistry type If you would like to run a test at different discharge rate change the Test Amps window WARNING DO NOT CHOOSE A HIGHER DISCHARGE RATE THAN THE BATTERY IS CAPABLE OF SEE THE BATTERY MANUFACTURE S SPECS NOTE If the no load battery Voltage multiplied times the Test Amps selected Volts x Amps Watts exceeds the wattage rating of the CBA or the default recommended maximum discharge rate for a given battery type our software will prompt you to lower the discharge current before s
46. nual The graph of our completed test is shown below E aert Mountain Resi CHA tI Jaa Sebo Dt SW Pipot sch IZARO LIA Se Arehn Test Data During the test all variables are displayed Voltage Initial voltage was 12 6 volts end voltage was 8 4volts Amp Hr the rated capacity of this battery is 2 2 Ah and the test measured 2 347 Ah This is a 1 hour 1C discharge Most lithium batteries are rated at 2 hour 5C discharge Even at this higher rate the capacity of this battery is better than its ratings Test Complete West Mountain Radio 40 Operating Manual After completing this test we have several options for starting another test e We could save this file by selecting File gt Save or Save As and name and save the file in the default My Documents CBA directory or the directory of our choice e We could also select Test gt New and the program will ask you if you want to append a new test on the previous test or start a new test document If you have a similar battery you would like to compare you would select append otherwise select a new test after saving West Mountain Radio 41 Operating Manual Saving and Printing Saving After a test completes go to File gt Save or click bel The name in the Test Name box will be suggested as the default name or you may edit and pick a different file name It is important that you choose a name that i
47. o Ah by dividing by 1000 Again the program can automatically recommend the discharge rate by clicking the Suggest button The program will suggest settings for a one hour discharge for most battery types Enter the Weight of the battery if you are interested in a Ragone graph which adds weight as a variable in the graph Next enter a meaningful test name that may include which battery you are testing the date the cycle information or other useful information The CBA standard software version has selections of Discharge A constant current discharge which is the most common way to evaluate battery capacity and Charge Monitor which monitors the battery voltage as you charge it Make ye sure the Graph Type is set to Discharge NOTE You may optionally change the discharge rate Test Amps or cutoff Voltage however the program will ask you if you are sure if you have a chosen higher discharge rate or a lower cutoff voltage before allowing you to start the test Current 22 04 Make sure that all the information displayed in the New Test Box is correct If necessary fix the AmpHr S gent entries before starting the test Watts Press the Start button at the bottom 83 77 of the test box and start the test NOTE Selecting OK will close the test box and display the graph allowing you to check or change advanced variables You may then start the test by selecting in the main menu T
48. o com West Mountain 1020 Spring City Drive Waukesha WI 53186 IO A tel 262 522 6503 fax 262 522 6504 West Mountain Radio 80 Operating Manual
49. o complete prematurely if the cutoff voltage is hit to stop this affect set cutoff voltage to 0 BE AWARE THAT CBA AMPLIFIERS DRAW A SMALL OFFSET CURRENT EVEN WHEN DISABLED That means when using multiple discharge setpoints if you have a setpoint with 0 load current there may still be a small offset current IF you are using a CBAAmplifier Example 10A for 30 seconds 30A for 5 seconds OA for 20 seconds 5A for 120 seconds test multiple 4 30 10 5 30 20 0 120 5 cutoff 10 5 West Mountain Radio 64 Operating Manual duty performs a test at specified amps load current load is applied for ton seconds and not applied for toff seconds ton and oft cannot be fractional numbers Test is automatically stopped when voltage drops below cutoff voltage profile performs a tests with load beginning at zero and increasing every 8 seconds by the specified increment until the cutoffcurrent value is reached or the battery voltage falls below the cutoff parameter Example 2A increment with 20 A cutoffcurrent and 8 5V cutoff test profile 2 20 cutoff 8 5 The following command line options are optional and can also be used with test battery open title battery temperature graph amplifiers West Mountain Radio 65 Operating Manual Command Parameters Comments capacity cells voltage weight type battery when performing a hands free test with test and saving results to a file
50. of this many fires have occurred as a result of the use of Lithium Polymer batteries resulting in loss of models automobiles and other property Homes and garages and workshops have also burned A lithium battery fire is very hot several thousand degrees and is an excellent initiator for ancillary resulting fires Fire occurs due to contact between Lithium and oxygen in the air It does not need any other source of ignition or fuel to start and burns almost explosively West Mountain Radio 6 Operating Manual These batteries must be used in a manner that precludes ancillary fire The following is recommended 1 Store and charge discharge in a fireproof container never in your model 2 Charge discharge in a protected area devoid of combustibles Always stand watch over the charging discharging process Never leave the charging process unattended 3 In the event of damage from crashes etc carefully remove to a safe place for at least a half hour to observe Physically damaged cells could erupt into flame and after sufficient time to ensure safety should be discarded in accordance with the instructions which came with the batteries Never attempt to charge discharge a cell with physical damage regardless of how slight 4 Always use chargers designed for the specific purpose preferably having a fixed setting for your particular pack Many fires occur in using selectable adjustable chargers improperly
51. ountain Radio 21 Operating Manual Test Name This is a required field and a test can not be started without a test name You should choose a name which identifies the battery and the current test so that you may identify the test perhaps years or months later It is suggested that depending on your testing application a naming convention be adopted Note that the software automatically records the battery chemistry Ah rating and the discharge rate with every battery test A saved file may contain multiple tests If you wish to take advantage of saving files with multiple tests in them you may wish to include the date and or time in the test name so you may identify a test among a series of tests of the same battery Test Cutoff Voltage The program will automatically recommend the Test Cutoff V the voltage where the test and discharge stops that is appropriate for the chemistry you have selected in the Battery Type NOTE 100 discharge is never 0 volts for any type of battery There is an industry standard for each chemistry Lead Acid batteries 1 775 volts per cell nickel 0 9 volts per cell and lithium 2 8 volts per cell The 100 discharge voltages may vary slightly between different manufacturers and may be dependent on temperature It is recommended to verify this voltage from battery manufacturers specifications NOTE You may manually change the cutoff voltage for any reason but do so with caution Do not low
52. out the Battery section Amplifier section and Cutoff Voltage can be found in the Test Configuration section of the Help New Test CBA 1 Extended Profile lt Auto Check gt Battery Battery Type Li poly v S cj ES ES ze Weight 1 000 kg Voltage 11 ot Capacity Ah 11 00 Test Amplifier No Amplifier EAE Dne Ampifier Test Name Two Amplifiers Test Type Four Amplifiers AmpHrs C SS Watts In this field specify your desired Power in Watts Using the battery specifications enter a safe value that will not exceed the limitations of the battery you are testing Also note that the CBA without amplifiers has a power limitation of 150 Watts West Mountain Radio 32 Operating Manual Graph For a Constant Power test you may view your graphical results in Amp Hours Watt Hours or minutes This can be changed at any time during the test or after it is completed and also when opening a saved file To do this right click on the graph area and choose Chart Properties Or select Test gt Chart Properties Constant Resistance Extended Software This test simulates a constant load on a battery As the voltage decreases the current also decreases In this test the load is specified in ohms Information about the Battery section Amplifier section and Cutoff Voltage can be found in the Test Configuration section of the Help New Test CBA 1 Extended
53. r name CBA serial number and license key in the Tools gt CBA Devices window We recommend that you are familiar with the standard operation before learning about and using the Extended features The New Test window will have several additional features Now that you have your Extended License registered you will see Extended on the New Test screen along with the CBA name you may have chosen New Test CBA 1 Extended Profile lt Auto Check gt The Extended software includes all the features included with the standard version and adds four new test types Duty Cycle Test Constant Power Multiple Discharge and Constant Resistance Voltage Calibrate This calibration feature accounts for resistance in the leads between the battery terminals and the Powerpole connector on the CBA Each CBA has its own stored Voltage Current and Temperature calibration so if you have multiple CBA s you can easily designate each one for a specific setup If you believe your CBA is not reading correctly check these settings first If you need accurate voltage measurements use the following instructions for the voltage calibration procedure For maximum accuracy and safety always use very secure connections with very low resistance Put a high accuracy voltmeter across the point you wish to read calibrated voltage perhaps across a cell for single cell testing or at the connector supplied with a battery pack W
54. rate gives you the option of calibration of temperature discharge current The Extended software version also has test lead resistance compensation to calibrate voltage West Mountain Radio 16 Operating Manual These are advanced options and should only be used by technically competent users having access to laboratory calibration standards Temperature Calibrate The optional temperature probe may be calibrated at room temperature by comparing it to a room temp thermometer For highest accuracy place a lab grade thermometer and the CBA temperature probe placed in water heated to the temperature of interest for testing dr Calibrate Temperature Probe To calibrate the CBA s temperature probe please enter the present temperature Typical room temperature is about 20 C Degrees C 53 3 Degrees F 127 9 In the standard version of the software the temperature is displayed and the temperature may be used as a safety feature to automatically stop a test at a user set maximum battery temperature West Mountain Radio 17 Operating Manual Current Calibrate An advanced option that only functions below 3 Amps If you have a need for the most precise measurements and you have access to a lab quality ammeter that has known NBS traceable calibration you may wish to use this option This option allows a calibration offset to center the CBA s calibration within a 12 bit window In other words
55. re The battery test data can be printed on a color or black and white printer or print convenient test labels to put directly on the tested batteries The optional external temperature probe provides automatic over temperature test cutoff The CBA is ruggedly built and supplied with 13 gauge high grade wire and Powerpole connectors for the battery connection It is small with a high performance cooling system and quiet fan It is provided with LED indicators visible from across a room that display communication and test status Powerpole is a registered trademark of Anderson Power Products West Mountain Radio 2 Operating Manual The software supplied with the CBA is easy to use and intuitive It provides automatic sensing of the battery cell count a safety check of the test rate and recommends a minimum safe discharge voltage It is designed to protect both the CBA and the batteries being tested There are user editable and recallable battery test profiles Capacity discharge tests may be viewed in Amp Hours Watt Hours or minutes The charge monitor test charts and records the voltage rise during a charge One of the standard features is a lab calibrate current adjustment to improve the accuracy for testing at very low discharge rates or for critical applications The optional Extended Software license provides all the features of the standard version but adds four different types of tests duty cycle constant power
56. re Unts ea Degrees Fahrenhet and then select print Degrees Celsus cence charts in black and white Save window size and postion See print preview Stop text when battery temperature reaches 33 deg below to see an Print charts in black andawhte example of the tick C Se ae chart tex marks different marks C Ap Ae chart graphics identify different graph oie CTTI WT KEE ER West Mountain Radio 44 Operating Manual Go to File gt Print You may select the number of copies you would like and you will be given another opportunity to select the printer t rere EE nen LOL T E If you wish you may go to File gt Print Preview window to see how it will look before printing If it is OK press Print at the top of the preview window If it is not OK close that window and go back to correct your printer setup West Mountain Radio 45 Operating Manual Printing Battery Labels A convenient way to save test information is right on the battery so we have given you a label printing utility that prints labels to place directly on the battery that was tested In order to print labels for the batteries you have tested select print labels from the file menu and have Avery 5160 standard address labels loaded in your printer E ect Mountain Hadis CHA il Jom fest Toch me Ha cen F a w 1808 LEIFR dachaga erg Lami Acid calle 20 Ah 2008 10608 LE D
57. s Graph x West Mountain Radio 27 Operating Manual Current Increment The test begins with a load of zero amps and increases the load on the battery or power supply every eight seconds until the Cutoff Voltage or the Cutoff Current is reached or the CBA becomes Current Limited because the 150 Watt max power rating has been reached If the CBA is Current Limited in a Power Profile test the test will end Cutoff Current Using the battery specifications enter a Cutoff Current that will not exceed the limitations of the battery you are testing When the load becomes greater than this value the test will end For example a current increment of 1 5 and a cutoff current of 12 will graph 9 points test begins at zero amps if the Voltage does not fall below the cutoff Graph Data for this test type can be displayed in Voltage vs Amps or Watts By graphing in Watts the maximum power output is represented by the right most data point West Mountain Radio 28 Operating Manual Duty Cycle Extended Software The duty cycle test is particularly valuable when attempting to evaluate the performance of a battery in an application which typically involves a cyclic or variable duty cycle This new test is much more exact and repeatable than pausing a test or starting and stopping multiple tests Information about the Battery section Amplifier section and Cutoff Voltage can be found in the Test Configuration s
58. s a noticeable thermal lag with our thermistor type probe The CBA may be set for automatic over temperature cutoff Place the probe on the battery Go to Tools Preferences and check the check box next to Stop test when battery reaches deg Fill in a temperature appropriate for your battery 60 degrees C or less should be safe for most batteries WARNING DO NOT continue a test if the Temp indication reaches or exceeds the maximum temperature specification for the battery being tested West Mountain Radio 71 Operating Manual Firmware Updates Some CBA devices have the capability to be updated with new firmware To perform this update open the list of CBA devices by selecting Tools and then CBA Devices from the menu Select the CBA you wish to update and if this CBA device has the capability to be updated the Update button will be available Clicking Update will bring you to the Update CBA Firmware window From this window you can choose which firmware to update using the pull down labeled File Pressing the Update button will cause the firmware to be sent to the CBA The Device and Status section of the window will show a status during the update process After new firmware is sent to the device the Status section will say Success when the CBA is ready to be used again CHA Devices CBA Send S Femeae Colteatern Oste Lomor Tyce 30027 5 26 2011 75200PM_ M West Moun
59. se and return an error code to the external software program or script A batch file is present in the executable directory that shows a working of example of calling the EXE and handling the returning error level West Mountain Radio 69 Operating Manual Temperature Probe Temperature Graphing Extended Version Ifyou have purchased an Extended License and the temperature probe accessory you will have the option of graphing an external temperature and allow for stopping a test if an external temperature hits a user specified threshold Simply click the Graph Temperature radio button when setting up a test If you are doing a standard discharge you will also have a recovery Time check box and time box Recovery time allows you to continue a given length of time after the discharge is complete to see any overshoot in the temperature rise Plug the probe s two pin connector in to the right most pins closest to the LEDs of the available pins in the cover slot It does NOT make any difference which way it goes in as long as it is plugged in to the far right two pins The extra pins are for future options If you are using this software with a CBAII Do NOT remove the blue jumper CBAIII and CBAIV do not have this jumper Let the probe sit in a location away from any heat source for enough time to allow it to acclimate to room temperature Have a good thermometer near by if you wish for more accurate calibration If yo
60. selection buttons are now available allowing use of one to four CBA Amplifiers You must be careful NOT to check these buttons if your test setup does not include properly connected and active amplifiers If your test does include amplifiers ensure they are connected and turned on and YOU MUST check the appropriate button so that the software sets and records the current correctly The amplifiers have a current gain of 10X and a power rating of 500 watts each The software reduces the CBA current draw to the corresponding level and records the current and power that would be measured at the battery terminals The New Test header includes the CBA serial number and name and indicates that the software is registered to run the Extended features enabled West Mountain Radio 23 Operating Manual Tests Discharge Test This is a classic test for measuring and analyzing battery capacity Using a constant current discharge the battery voltage lowers until the cutoff voltage is reached and the test stops Optionally using a temperature probe the battery temperature can be monitored and kept within safe levels The Extended License enables users to not only graph temperature but also when the temperature limit is reached have a recovery time for the battery temperature to lower and the test may then continue Information about the Battery section Amplifier section and Cutoff Voltage can be found in the Test Configuration section of t
61. tain Radio 34 Operating Manual New Test CBA 1 Multi Profile lt Auto Check gt Battery Battery Type Li poly v Voltage 11 1 5 Cells 3 E Capacity Ah 0 10 Weight 11 000 kg Test Test Name Aigo No Amplifier Cutoff Y 18 40 s O One Amplifier Two Amplifiers Test Type Charge Discharge Four Amplifiers TestAmps 2 00 Maximum Y 17210 ES Graph Minutes C Graph Current Cycles 4 s First Discharge a Recovery 10 seconds Ca The test alternates between charge and discharge cycles Discharging is accomplished with a WMR CBA Ill or CBA IV Charging is accomplished by having a the WMR CBA Charger Interface board control an off the shelf charging unit that the customer will provide When using Charge Discharge test the software will disable the Test Name field Instead the software will create test names Charge n and Discharge n automatically where n is the cycle number and increments automatically Test Amps During a discharge cycle this is the load the CBA will draw from the battery under test Using the battery specifications enter a safe discharge rate that will not exceed the limitations of the battery you are testing West Mountain Radio 35 Operating Manual Maximum V During a charge cycle if the read voltage goes above this the CBA software will stop the charge cycle Graph For a Charge Discharge test you ma
62. tain Radio 72 Operating Manual Update CBA Firmware Device CBA4 555 Rev1 Fw v4 1 WARNING DO NOT unplug your CBAIV during a firmware update Update CBA Firmware Device Loading File CBAIV firraware version 4 1 After this is finished your updated CBA is now ready to use West Mountain Radio 73 Operating Manual Troubleshooting If the CBA program indicates No CBA units available when opening a new test window and or the CBA green LED or virtual LEDs are not on when a CBA is connected and the program is running you may not have correctly completed the Windows CBA USB driver installation Re boot your computer Plug the CBA back in Repeat our hardware installation instructions and try it again If it still doesn t work open Device Manager In Windows 7 this can be done by opening Control Panel selecting System and Maintenance selecting System and then selecting Device Manager From the device manager scroll down to Universal Serial Buss Controllers and expand that list If you do not fine CBA in Universal Serial Buss Controllers try looking in the section labeled Other Devices If the CBA is found in either of those sections right click on it and select Remove Device Then disconnect and reconnect the CBA back into the PC If this doesn t cause the CBA software to see the CBA hardware contact West Mountain Radio CBA Charger Interface is not connec
63. tarting a test The CBA will run tests at up to 150 watts for short periods of time with a battery that has a rated capacity of 1 Amp Hr or less up to 125 watts below 3 5 Amp Hrs and 100 watts for any capacity battery 8 Type ina Test Name for the test that positively identifies the test for future reference perhaps write a number on your battery and use that number or a unique description of the battery and the test 9 Press the Start button in the New Test window Optionally press OK and use the Sp button or selecting Test gt Start If you have the settings correct you will see the graph appear and auto scale The red LED on the CBA will come on and the fan will start The virtual LED and fan on the right panel will start also The Current will ramp up to the Test Rate value and the voltage will start to record on the graph West Mountain Radio 10 Operating Manual 10 The test will continue until the test Cutoff V is reached At that point the test will automatically stop and the program will beep and display Test Complete Everything will return to the stopped condition ready for another test or for you to save the file Disconnect the battery at this time WARNING Do not ever leave a battery connected after a test completes Leaving a battery in a discharged state for prolonged period of time could over discharge and damage the battery CAUTION The batt
64. ting Have the CBA software running and try reconnecting the USB cable to your Charger Interface Board CBA does not indicate voltage The battery may not be connected or it is completely dead Otherwise you may have a damaged CBA please contact us for support CBA gets too hot and shuts itself off The CBA has an internal temperature monitor is programmed to protect it from overheating when operated at maximum ratings and at normal room temperature Make sure that the fan is running during a test nothing is blocking the cooling inlet and that it is being operated in a cool location Do not use it in direct sunlight or on near a heat source such as too near the battery being tested Do not attempt to conduct successive high current tests without letting the CBA cool down and shut off its fan between tests West Mountain Radio 74 Operating Manual Some CBA Menu selections are grayed out and do not work These are typically the optional features available only with the Extended License Visit www westmountainradio com to purchase an Extended License No load drawn from CBA during test or test runs but battery voltage never decreases The usual cause for this is the safety fuse in the CBA has blown If you remove the red lid from the bottom of the CBA you will see the automotive fuse connected to the PCB Verify this fuse is okay If the fuse is not okay replace it If the fuse is okay but the CBA is still not drawing power
65. tions not recommended when in use e Internal USB ports root hub required external hubs will not work We recommend that the computer be dedicated for testing batteries Do not expect to run other applications while testing batteries Do not connect or disconnect USB devices while testing batteries This section is specific to Multi CBA operation only Refer to the rest of this help documentation for complete instructions to operate each CBA Connection and Installation You may plug multiple CBA s directly into the USB ports of a desktop computer Do not use a laptop computer or expect a laptop computer to work If you wish to have more CBAs than you have available USB ports you may add internal USB PCI bus cards supplied and supported by West Mountain Radio Do not use attempt or expect to use ANY make or model external USB hub The internal USB PCI bus cards we supply are installed in your computer as any PCI card To install the driver files connect to the Internet so that the Windows plug amp play system will automatically install the drivers from Windows Update If you cannot put the computer on line you may request the driver installation files from us Each card has four ports available at the back of the card slot It does not matter which CBA is plugged into which port on which West Mountain Radio 57 Operating Manual USB card or computer USB ports but it is recommended that the CBA s are all eit
66. ttery temperature cool down and voltage recovery you need to use a Voltage vs minutes graph not Amphrs or Watthrs NOTE If you have the optional temperature probe you can select Graph Temperature for most of the test types but not all This will overlay a second graph on each test screen with the temperature You must have a temperature probe connected to the CBA and calibrated with the sensor in intimate contact with the center of the battery for proper readings Ragone Graph type Extended Software An additional graph type is available with the Extended software that allows you to compare radically different type and size batteries on the basis of power density power to weight This graphing type is particularly useful when selecting a battery to power a device that is weight sensitive such as small electric vehicles and mobile devices West Mountain Radio 53 Operating Manual E ss ener egen ADT i NOTE This graph can only be displayed if a test was started and save with the correct weight of the tested battery in the new test window If you are not familiar with Ragone plotting see http en wikipedia org wiki Ragone_plot West Mountain Radio 54 Operating Manual CBA Charger Interface Charge Discharge Test The WMR Charger Interface board has the following inputs and outputs e IN A and IN B These should connect to a signal on the charging unit that indicates charging
67. u do not have a good thermometer handy set it to any room temperature reference For laboratory quality measurements you may wish to calibrate it near the temperature of interest by submersing the probe in hot water near 140 degrees F and immerse a high accuracy thermometer in the water with the CBA probe With a temperature probe connected to the CBA go to Tools Lab Calibrate Calibrate Temperature Probe and enter in either degrees C or F your reference temperature reading and then click OK to save that calibration Note As long as you do not change to a different CBA or temperature probe you should not have to calibrate the probe again To use the probe attach it in close physical contact with the center of the battery or battery pack that you are testing Hold it in place with the probe s magnet most round cells are magnetic or with tape or a rubber band for better contact and more accurate readings thermal compound may be used Be certain it stays in close contact with the battery during your test The CBA temperature readings are West Mountain Radio 70 Operating Manual quite accurate over the range that a battery may be operated at however the readings will be incorrect if the probe is not in close contact with the battery or there is air moving over it Unlike an instant response IR thermometer other types of thermometers take a considerable amount of time to display their temperature reading There i
68. y view your graphical results in Amp Hours Watt Hours or minutes This can be changed at any time during the test or after it is completed and also when opening a saved file To do this right click on the graph area and choose Chart Properties Or select Test gt Chart Properties Graph Current If checked the CBA software will also graph current as a separate plot during the charge and discharge cycle Cycles This specifies how many cycles to perform A cycle is either a charge or a discharge To perform both charge and discharge this is 2 cycles First This specifies what cycle should be performed first a charge or discharge Recovery Configure the delay in seconds between cycles During this delay the charger unit is disabled and the CBA will stop discharging from the battery During this delay the CBA software will continue to graph voltage West Mountain Radio 36 Operating Manual Test Example Testing a battery The following example will lead you through testing a 3 cell 3S 11 1 volt lithium polymer battery New Test CBA 123 Test Profile in lt Auto Check gt mode Prolie lt dulo Check gt __ User entered Battery Type Chemistry Bailen gts Earley Type S Voltage determined from clicking Vdtage Detect button Copeebi ht 100 Weigh 1000 3 ko Program determined number of Cells Weight of battery optional for Ragone Plot Test TestNeme Test

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