A&T Qulon-12m User manual

Lead acid battery
capacity indicator
Qulon-12m
User's manual
2005
А&T

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Thank you for purchasing. Your lead acid battery ca-
pacity indicator Qulon-12m is destined for fast battery capac-
ity estimation. With the help of the device, you can test new or
used 12-volt lead acid batteries. This will help you to con-
demn defective batteries or batteries that have lost capacity.
With Qulon-12m, you will always keep your battery systems in
perfect working order.
Qulon-12m is designed for years of reliable work and
does not need any service.
Please read this manual! It contains significant in-
structions for using battery capacity indicator. Following this
manual, you will keep device working and your batteries
ready to take critical loads.
Keep this manual! In contains important safety pre-
cautions and warranty information.

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Contents
Introduction 4
1. Safety precautions 5
2. General description 6
3. Battery capacity estimation 7
3.1. What is battery capacity 7
3.1.1. Dependence between battery capacity and
discharge current 7
3.1.2. Battery capacity and battery state of charge 8
3.1.3. Temperature dependencies 8
3.1.4. New batteries 9
3.2. Battery capacity estimation with Qulon-12m 9
3.2.1. Device placement 9
3.2.2. Battery preparation 10
3.2.3. Connection to a battery 10
3.2.4. Battery state of charge 11
3.2.5. Battery capacity estimation 12
3.3. Qulon’s screen during battery capacity estimation13
3.3.1. Screen under “save by default” mode 13
3.3.2. Screen under “save by command” mode 15
4. Alarm messages 15
5. Memory 17
5.1. Memory organisation 17
5.2. Two save modes 18
5.3. Main menu 19
5.3.1. Close group 20
5.3.2. Records 21
5.3.3. Clear memory 22
5.3.4. Options 23
6. Adjusting Qulon 23
6.1. Options menu 24
6.2. Save mode 25

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6.2.1. Save by default 25
6.2.2. Save by command 25
6.3. Calibrate (coefficient adjustment) 26
6.4. Filtration 27
6.5. Language 28
7. Calibrating Qulon (coefficient determination) 29
7.1. Coefficient from the producer’s site 30
7.2. Measured discharge method 31
7.3. Method of average 33
7.4. Method of maximum 33
7.5. Method of battery history 34
8 Appendix: test cable checking 35
9. Specifications 36
Warranty 37

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Introduction
The life of lead acid batteries is limited to several
years and while working batteries loose capacity. When the
battery capacity becomes unacceptably small, battery needs
to be replaced. It is exceptionally important to determine
correct time of battery replacement. If a battery is replaced
too early – the owner of a battery looses money. If a battery is
replaced too late, the loss could be even larger.
Qulon-12m - lead acid battery capacity indicator is a
device for battery capacity estimation. With Qulon, one can
sort 12-volt batteries by their capacity and reject batteries that
have lost capacity.
Memory for keeping test results helps user during
testing large amount of batteries.
The battery capacity estimation is based on the de-
pendence between battery capacity and battery ability to con-
duct electric current. Battery capacity indicator sends a test
pulse to a battery and analyses the battery answer. Qulon-
12m utilises the most up-to-date method of battery capacity
estimation taking into account the multifrequency battery re-
sponse to test pulses.
Different battery producers use different technologies
and battery designs. Therefore, the dependence between test
pulse form and value and battery answer form and value
could be slightly different. That is why Qulon-12m is not a
high precision device for capacity measurement. It estimates
battery capacity basing on electrical measurement and

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some algorithm saved in Qulon’s microprocessor.
Qulon-12m is calibrated on factory. Using this calibra-
tion, you can estimate the capacity of any 12-volt lead acid
battery. Experienced user can reduce capacity estimation
error by device recalibration basing on the battery with known
capacity.
1. Safety precautions
Unpack Qulon-12m and check if there are any trans-
port damages. If any, appeal to your dealer or the transport
company.
Attention! Lead acid battery under test is a source
of possible danger. Battery terminals shorted with any metal
detail could cause burn or fire. Please adhere to battery
maintenance and service rules.
If battery under test is a part of high voltage battery
system and battery test is conducted without battery disas-
sembly be especially careful. Do not connect test clamps to
several 12-volt batteries connected in series. If such case,
device will not switch on. If summary voltage exceeds 400
volts device could be damaged.
Qulon-12m is a complicated device. Do not try to dis-
assemble it. There are parts that need service inside. The
device should be repaired only by certified personal.

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Attention! Do not use device with back lid opened.
2. General description
There is a LCD display in the center of Qulon’s front
panel. It is used to show ampere-hour capacity, battery volt-
age and additional information: adjustment coefficient, num-
ber of recorded measurements and current croup of records.
Qulon has memory for recording results of battery tests. The
maximum number of recorded results is 200. User is free to
separate recorded results to as many as 26 groups.
If it is impossible to estimate battery capacity because
of some reasons, alarms are shown at the display.
There are two control buttons on the front panel to the
left of display.
Right panel of Qulon is the place for test cable con-
nector. Qulon is supplied with special test cables that use
four-wire (Kelvin) connection. This type of connection is used
in order to diminish contact resistance influence on the devise
results.
There is a connection diagram under the back lid of
the device.

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3. Battery capacity estimation
3.1. What is battery capacity
Battery capacity is an electrical charge (quantity of
electricity) that battery can deliver under specified conditions.
Usually battery capacity is expressed in ampere-hours (A*h or
Ah). Capacity equals to discharge current (in amperes) multi-
plied by discharge time (in hours). Battery producers rate
nominal battery capacity for some standard conditions. Usu-
ally (but not necessary), these conditions are: 20-hour dis-
charge time, 20oC discharge temperature and 1.75 V final
battery voltage (voltage limit at which discharge is considered
to be complete).
3.1.1. Dependence between battery capacity and
discharge current
Charge that a battery can deliver depends on the dis-
charge current (discharge time). If discharge current grows
(discharge time decreases), the battery capacity decreases.
This dependence is an individual property of a specific bat-
tery. The dependence between relative battery capacity and
discharge time for LCL-12V33AP battery is given in the table
below.
Discharge time,
hours
Relative capacity, %
0,1 37
0,3 48

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Discharge time,
hours
Relative capacity, %
0,7 53
1,9 76
4,2 84
9,2 92
20 100
Qulon-12m always shows capacity for 20-hour dis-
charge time. If you discharge your battery during smaller time,
the capacity will reduce.
3.1.2. Battery capacity and battery state of charge
We need to distinguish capacity and state of charge.
Capacity is the quantity of electricity that a fully charged bat-
tery can deliver. State of charge is a characteristic giving in-
formation on the degree to which the capacity is filled. For
example 33Ah battery can contain 33 A*h if a battery is fully
charged and 10 A*h if the battery charge is not full.
Qulon-12m estimates capacity of fully charged battery
and can’ be used to determine state of charge.
3.1.3. Temperature dependencies
While testing battery under low or high tem-
perature, dependence of battery capacity from the tempera-
ture should be taken into account. Qulon-12m always shows
the capacity that a battery could deliver during next discharge
under the same condition. That is why if you get estimated
capacity under plus 20oC as large as 20 A*h

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you should not be surprised if the same battery will deliver
only 10 A*h during discharge under minus 20oC.
Factory calibration of Qulon-12m is conducted for use
under room temperature (about 20oC). Therefore, in order to
get most precise results of battery capacity estimation, keep
batteries under room temperature before test for the time
needed for temperature equalising.
3.1.4. New batteries
The majority of lead acid batteries increase capacity
after their first discharge-charge cycles. That is why while
testing absolutely new batteries (the batteries that never were
charged or discharged) you could get estimated capacity less
then rated (may be by 10 or 15 %). This is usual – the battery
will increase capacity after several cycles (or several months
under float charge).
3.2. Battery capacity estimation with Qu-
lon-12m
3.2.1. Device placement
Qulon-12m can work in any position horizontal or ver-
tical.
To avoid device errors do not use it near the sources
of large electromagnetic noise. .

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3.2.2. Battery preparation
Correct estimation of battery capacity can be achieved
for fully charged batteries only. Therefore, the battery should
be fully charged before test.
Normally you need do disconnect battery circuit before
test. During test, the battery should be not connected to
charger or load. If a battery has been charging or a battery
was connected to some devices with automatic charger (e.g.
UPS), 15-20 minute pause should be made.
If battery terminals are dirty or oxidized – clean them.
3.2.3. Connection to a battery
Battery capacity indicator Qulon-12m is supplied with
special test cables that use four-wire (Kelvin) connection to a
battery. Two halves of one (red or black) clamps are insulated
from each other.
Verify that clamp halves do not have other connection
with each other except battery terminal.
Observe polarity when connecting to a battery. Con-
nect red clamp to positive battery terminal and black clamp to
negative terminal. Qulon has reverse polarity protection –
device will not switch on if you mistake.
Attention! Applying voltage between clamp halves is
not allowed.
Capacity estimation is correct only in case if

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device clamps have secure and reliable connection directly to
battery terminals. Connect test clamps directly to battery ter-
minals. Never connect clamps to wires or nuts that have con-
nection with the terminal. Do not connect clamp to a terminal
by touching it with a side surface of a clamp.
Fig. 1. Connecting clamp to a battery terminal
If the contact is not good, Qulon sends an appropriate
message to the screen (see section 4). When such message
appears, disconnect clamps from terminals, clean terminals
and connect clamps once more.
Attention! Qulon feeds from the battery under test. To
avoid battery discharge disconnect device from the battery
after test.
3.2.4. Battery state of charge
Qulon-12m estimates capacity for fully charged bat-
teries only. The battery under test should have voltage not
less then 12.6 V.
If a battery is deeply discharged (voltage less the 9 V)
– device will not switch on. .
Correct Not correct Not correct

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If a battery is not fully charged (voltage is more then 9
V and less then 12.6 V), device shows a message “Voltage
low” and battery voltage at the screen. In this case, discon-
nect clamps from the battery and charge the battery in full
according to the battery manual.
If Qulon is connected to a battery with voltage larger
then 14 V, a “High voltage” warning and battery voltage would
be shown on the screen.
If a battery voltage is between 12.6 volt and 14 volt
Qulon shows a battery voltage on the screen and begins the
process of capacity estimation.
Attention! Qulon feeds from the battery under test.
That is why the battery voltage shown on the screen can dif-
fer from the open circuit voltage measured by multimeter.
3.2.5. Battery capacity estimation
If a battery voltage is between 12.6 volt and14 volt
Qulon automatically starts battery capacity estimation.
Capacity estimation needs time. The value appears on
the screen after 1-2 seconds (4-5 seconds if additional filter-
ing is applied – see section 6.4). Please wait until capacity
value appears.
After capacity is estimated, Qulon shows the ampere-
hour value of the battery and switches on the screen light for
10 seconds.

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3.3. Qulon’s screen during battery capacity
estimation
If battery capacity estimation was successful, the ca-
pacity value is shown on the screen.
This result can be saved in memory. Qulon-12m has
two saving regimes (save modes): saving by default (result is
saved immediately after it appears) and saving by command
(one needs to push button for saving). Detailed description of
both saving options is made in section 5.2.
The screen view is shown on the following figures de-
pending on chosen regime.
3.3.1. Screen under “save by default” mode
Figure 2 shows screen view for the case when “save
by default” mode is chosen.
Left part of the screen contains icons describing
button functions.
Menu enter – press upper button to enter menu (see
section 5).
Delete result – press lower button to delete just saved
result – you will be asked for delete confirmation.
The centre of the screen is occupied by estimated
capacity and battery voltage. If it was not possible to estimate
capacity, the alarm message is sent to this screen zone (see
section 4). .

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Battery capacity – measured in ampere-hours.
Battery voltage – measured in volts.
Right part of the screen (the zone of inversion) con-
tains additional information.
Fig.2 Screen under “save by default” mode
Coefficient – the multiplier (calibration coefficient)
used to estimate capacity (see section 6.4).
Current group – the group to which just received test
result was saved (memory organisation is described in sec-
tion 6.2).
Number inside group – the number of just received
test result inside current group.
Memory cells free – total number of test results that
can be saved in memory (not more then 200).
Coefficient
Menu
ente
r
Delete result Battery volt-
age
Number
inside group
Memory
cells free
Current
group
Battery capac-
ity

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3.3.2. Screen under “save by command” mode
Figure 3 shows screen view for the case when “save
by command” mode is chosen.
When this mode is used, just received test result is not
saved. There is no battery name (group and number inside
group) on the screen. The function of the lower button is
changed.
Save result – press lower button to save just received
test result –you will be requested for save confirmation.
Fig. 3 Screen under “save by command” mode
4. Alarm messages
Sometimes (mainly if the battery is not properly pre-
pared for testing), Qulon-12m fails to estimate capacity. If this
happens, alarm message appears on the screen describing
the reason for the fail. .
Save result

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All alarm messages with their possible causes and
recommended user actions are listed in the following table.
Message Possible cause Recommended actions
Contact Bad contact be-
tween any of test
clamps and bat-
tery terminal
Disconnect clamps,
clean terminals and
connect clamps once
more
Capacity
low
Battery capacity is below 0.5 Ah, Qulon
can’t estimate it
Capacity
high
Battery capacity is too high (may larger
then 350 Ah), Qulon can’t estimate it
Voltage
low
Battery is dis-
charged
Charge battery in full
and try once more
Noise Large noise –
capacity estima-
tion is not possi-
ble
If a battery is con-
nected to a charger,
disconnect it. If you are
working in a room with
high level of electro-
magnetic noise change
the place or switch to
additional filtering
Voltage
high
Battery voltage is
too high
Ensure that the battery
is disconnected from
the charger

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5. Memory
5.1. Memory organisation
Battery capacity indicator Qulon-12m has memory for
200 test results. For user’s convenience, test results can be
split to groups. Maximum number of groups is 26, each group
is identified with a letter of Latin alphabet – from A to Z. A
user arbitrarily manages the quantity of results inside group.
Each test result recorded is identified with a name that
consists of a group name and a number inside group. If the
whole memory were empty, the first test result recorded
would be named A-1. Next test result recorded will have a
name A-2 and so on. User can close current group at any
time. In this case, the next test result recorded will be the first
in the next group, which would be named in the alphabet or-
der (e.g. B-1).
The following memory operations are possible.
A) Saving of test result just received (“save by com-
mand” mode);
B) Erasing of test result just saved (“save by default”
mode);
C) Closing current group (next group opens automati-
cally), if current group is not “Z”;
D) Erasing all saved test results from memory.
The following memory operations are impossible.

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A) Saving test result to arbitrary chosen group or arbi-
trary chosen number in the current group;
B) Erasing of part of saved test results from memory;
C) Recording test result to a closed group;
D) Opening closed group.
All memory operations are made with the help of main
menu.
5.2. Two save modes
Qulon-12m has two save modes: “save by default” and
“save by command”.
Under “save by default” mode just received test result
is saved automatically. It can be erased by pressing lower
button.
Under “save by command” mode just received test re-
sult is not saved automatically. It can be saved by pressing
lower button.
User can choose save mode with the help of options
menu. Chosen mode is valid for next tests until it is changed.
Under both modes saving is performed only if:
A. Battery capacity estimation was successful or
B. Qulon sent one of messages: “capacity low”,
”capacity high”, ”voltage low”, and “voltage high”.
If other messages appear, test result is not saved.

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In “A” case (see above), the following information is
saved: estimated capacity, calibration coefficient (for current
test), battery voltage, group name and number inside group.
In “B” case, the appropriate message is saved instead
of estimated capacity.
If there are 200 test results saved in memory, a mes-
sage “memory full” is displayed. After this message, saving is
impossible. During next test, the number of free cells in mem-
ory in the right bottom corner of the screen is “0”. User should
clean all memory in order to start saving test results again.
5.3. Main menu
After the battery capacity was estimated or alarm
message shown, the user can come into the main menu by
pressing the upper button.
If “save by default” mode is on user will be advised to
erase just received test result. The user can agree (and the
result will be erased) or disagree (and the result will be kept in
memory) before entering menu.
Main menu has four items. The view of main menu is
shown on figure 4.
Pressing lower button brings cursor to next line.
Pressing upper button enters the menu item specified by cur-
sor.
First three menu items serve for memory operations,
the last one – for device adjustment.