Alber Cellcorder CRT-300 User manual

`
CellcorderCRT-300
User's Guide
7775 West Oakland Park Blvd
Sunrise, FL 33351
Tel: [phone] Fax: [phone]
www.alber.com
4200-038R2.1

CellcorderCRT-300
User's Guide
7775 West Oakland Park Blvd
Sunrise, FL 33351
Tel: [phone] Fax: [phone]
www.alber.com

i
1. WARRANTY AND LIMITATION OF LIABILITY
LIMITED WARRANTY
Albércorp warrants that the software product will perform in accordance with the
accompanying written materials for a period of ninety (90) days from the date of
receipt. Some states and jurisdictions do not allow limitations on duration of an
implied warranty, so the above limitation may not apply to you. To the extent
allowed by applicable law, implied warranties on the software product, if any, are
limited to ninety (90) days.
CUSTOMER REMEDIES
Albércorp's entire liability and your exclusive remedy shall be, at Albércorp's option,
either return of the price paid, or replacement of the software product that is returned
to Albércorp with proof of purchase. This Limited Warranty is void if failure of the
software product has resulted from accident, abuse or misapplication. Any
replacement software product will be warranted for the remainder of the original
period or thirty (30) days, whichever is longer.
Albércorp shall not be liable for any data or programs stored in or used in
conjunction with this software product. Without prejudice to the foregoing generality,
Albércorp shall not be liable for the loss or corruption of data or programs stored in
or used in conjunction with this or any other software product, nor shall Albércorp be
liable for the cost of retrieving or replacing lost or corrupted data.
Albércorp's sole and exclusive liability, for any and all losses and damages arising
out of any cause whatsoever, shall in no event exceed the purchase price of the
software product purchased.
NO LIABILITY FOR CONSEQUENTIAL DAMAGES.
ALBÉRCORP SHALL NOT IN ANY CASE BE LIABLE FOR ANY DAMAGES,
INCLUDING SPECIAL, INCIDENTAL, INDIRECT, EXEMPLARY,
COLLATERAL OR CONSEQUENTIAL, ARISING FROM BREACH OF
WARRANTY, BREACH OF CONTRACT, NEGLIGENCE OR UNDER ANY
OTHER LEGAL THEORY ARISING FROM THE WARRANTY HEREIN
STATED OR THE PURCHASE OF PRODUCT, INCLUDING, WITHOUT
LIMITATION, LOSS OF PROFITS, USE OR GOODWILL.
Some states and countries do not allow the exclusion or limitation of incidental or
consequential damages; therefore, the above exclusion or limitation may not apply to
you. This warranty gives you specific legal rights, and you may also have other rights
which vary state to state and country to country.

ii
2. SOFTWARE LICENSE AGREEMENT
THIS IS A LEGAL AGREEMENT. PLEASE READ BEFORE INSTALLING
SOFTWARE.
Any use of this media other than to review this Software License Agreement
constitutes your acceptance of and agreement with the terms of this Software License
Agreement with respect to the Albércorp Software. If you do not accept and agree to
these terms, you must return the full product with proof of purchase to Albércorp
within thirty (30) days for a full refund. Installation or use of this software product
constitutes your acceptance of and agreement with the terms of this Software License
Agreement.
LICENSORS. All software on this media is licensed to you by Albércorp.
GRANT OF LICENSE. You are granted the right to use the Albércorp Software on a
single personal computer. You may copy the software to use with this personal
computer to any one hard disk drive of this personal computer and to the memory of
this personal computer, provided that you reproduce all copyright and trademark
notices, restricted rights legends, and other proprietary markings.
RESTRICTIONS. You may not sublicense, rent or lease the Albércorp Software.
You may not reverse engineer, decompile, disassemble, modify, translate or create
derivative works of the Software.
LIMITED WARRANTIES AND LIMITATION OF LIABILITY. The limited
warranties and limitation of liability in Section 1 of this file apply to, are incorporated
in, and are made a part of this Software License Agreement.
EXPORT LAW ASSURANCES. You acknowledge and agree that the Software is
subject to restrictions and controls imposed by the United States Export
Administration Act (the "Act") and the regulations there under. You agree and certify
that neither the Software nor any direct product thereof is being or will be acquired,
shipped, transferred or exported, directly or indirectly, into any country, or used for
any purpose, except as authorized by the Act and the regulations.
GOVERNMENT LICENSEE. If you are acquiring the software on behalf of any unit
or agency of the United States Government, the provisions of Section 3 apply to, are
incorporated in, and are made a part of this Software License Agreement.
GENERAL. This Software License Agreement will be governed by the laws of the
State of Florida, except for that body of law dealing with conflicts of law. Should you
have any questions concerning this Software License Agreement, or if you desire to
contact Albércorp for any reason, please contact:
Albércorp.
3103 No. Andrews Ave. Ext.
Pompano Beach, FL 33064
email: [email protected].

iii
3. GOVERNMENT PROVISIONS
The Government acknowledges the representations of the Albércorp software as
"Restricted Computer Software" as the term is defined in Clause 52.227-19 of the
Federal Acquisition Regulations (FAR) and is "Commercial Computer Software" as
that term is defined in Clause 52.227-7013(a)(1) of the Department of Defense
Federal Acquisition Regulation Supplement (DFARS). The Government agrees that:
(i) if the software is supplied to the Department of Defense (DOD), the software is
classified as "Commercial Computer Software" and the Government is acquiring only
"restricted rights" in the software and its documentation as that term is defined in
Clause 252.227-7013(c)(1) of the DFARS, and
(ii) if the software is supplied to any unit or agency of the United States Government
other than DOD, the Government's rights in the software and its documentation will
be as defined in Clause 51.227-19(c)(2) of the FAR.
RESTRICTED RIGHTS LEGEND. Use, duplication, or disclosure by the
Government is subject to restrictions as set forth in subparagraph (c)(1)(ii) of the
Rights in Technical Data and Computer Software clause at DFARS 252.227-7013.
Albércorp, 7775 West Oakland Park Blvd, Sunrise, FL 33351
Information in this document is subject to change without notice.
Cellcorder CRT-300 User's Guide, 4200-038R2.1, Book Revision 2.1
2015 Albércorp, 7775 West Oakland Park Blvd, Sunrise, FL 33351
This manual may not be copied in whole or in part without express written permission
from Albércorp.
Microsoft Windows, Microsoft Excel, Microsoft Access, and Microsoft Explorer are registered
trademarks of Microsoft Corporation. Pentium is a registered trademark of Intel Corp. Smart
Media is a registered trademark of Toshiba Corporation. Cellcorder is a registered trademark of
Albércorp. Palm OS, HotSync, and Palm are registered trademarks of Palm, Inc.
Printed in the United States of America

iv

v
Table of Contents
1SAFETY INFORMATION........................................................................ 1
2WHAT'S NEW ...................................................................................... 2
3SYSTEM REQUIREMENTS..................................................................... 3
4GENERAL DESCRIPTION ...................................................................... 4
5PANEL CONTROLS AND INDICATORS................................................... 6
6CRT-300 BASICS................................................................................ 8
6.1 Power On/Off................................................................................. 8
6.2 Reset Switch................................................................................... 8
6.3 Main Menu..................................................................................... 9
6.4 Using the Test Leads...................................................................... 9
6.5 Before Taking Measurements ...................................................... 10
6.6 Charging the Cellcorder ............................................................... 10
6.7 Using the Memory Card Drive..................................................... 11
7CRT-300 SETUP OPTIONS................................................................. 13
7.1 Battery Select............................................................................... 13
7.2 Thresholds.................................................................................... 13
7.3 Clear Memory .............................................................................. 15
7.4 Display ......................................................................................... 16
7.5 Sound ........................................................................................... 16
7.6 Frequency..................................................................................... 16
7.7 Date/Time..................................................................................... 17
8SETTING UP AND EDITING A SITE...................................................... 18
8.1 Navigating the Site Menu............................................................. 18
8.2 Setting Up a Site Before Test....................................................... 20
8.3 Linking a File to a Site After Test................................................ 21
8.4 Unlinking a File and Clearing Thresholds.................................... 22
8.5 Editing an Existing Site................................................................ 22
8.6 Deleting a Site.............................................................................. 22
8.7 Selecting a Site for Test ............................................................... 23
9MEASURING VOLTAGE...................................................................... 24
9.1 Taking Voltage Readings............................................................. 24
9.2 Digital Voltmeter Test Mode ....................................................... 25
10 MEASURING RESISTANCE ................................................................. 26
10.1 Resistance Test Overview............................................................ 26
10.2 Skewing Effect............................................................................. 26
10.3 Setting Amp Hours and Intercells ................................................ 27
10.4 Taking Resistance Readings......................................................... 28
11 MEASURING S/G AND TEMPERATURE............................................... 30
11.1 Hydrometer Data to Cellcorder via IR ......................................... 30
11.2 Hydrometer Data to Computer..................................................... 31

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12 WORKING WITH FILES....................................................................... 32
12.1 Saving to the Memory Card ......................................................... 32
12.2 Loading and Appending a File..................................................... 33
12.3 Deleting a File.............................................................................. 33
12.4 Sending Readings via IR to a Computer ...................................... 34
12.5 Printing Test Results .................................................................... 34
13 VIEWING RESULTS............................................................................ 36
13.1 Overall Voltage (OV) Data .......................................................... 36
13.2 Status Screen: Average ................................................................ 36
13.3 Status Screen: Min-Max............................................................... 36
13.4 Status Screen: Faults .................................................................... 36
14 DIAGNOSTICS MENU......................................................................... 38
14.1 Keypad......................................................................................... 38
14.2 Display......................................................................................... 38
14.3 IR Port.......................................................................................... 38
14.4 Safety Relay................................................................................. 39
14.5 Memory Card ............................................................................... 39
14.6 Load Module................................................................................ 39
14.7 A/D Linearity ............................................................................... 39
14.7.1 Voltage Channel................................................................... 39
14.7.2 Test I Channel ...................................................................... 40
14.7.3 ICr Channel.......................................................................... 40
14.7.4 A/D Reference...................................................................... 40
14.8 Protection Circuit ......................................................................... 40
14.9 Modem ......................................................................................... 40
14.10 Buzzer ...................................................................................... 40
14.11 Fan............................................................................................ 40
14.12 Temperature Sensors................................................................ 41
14.13 Error Codes .............................................................................. 41
15 SERVICE MENU................................................................................. 42
15.1 Entering the Password.................................................................. 42
15.2 Changing the Password................................................................ 42
15.3 Factory Defaults........................................................................... 43
16 CRT-300 CALIBRATION.................................................................... 44
16.1 Equipment Required..................................................................... 44
16.1.1 Flash Code............................................................................ 44
16.2 Opening the Calibration Screen ................................................... 44
16.3 Recording the As Found K-Constants.......................................... 45
16.4 Voltage Channel Setup................................................................. 45
16.5 Voltage Channel Calibration........................................................ 45
16.5.1 1V to 2V Range.................................................................... 46
16.5.2 4V to 6V Range.................................................................... 46
16.5.3 8V to 12V Range.................................................................. 47
16.5.4 16V Range............................................................................ 47

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16.6 Test I Channel Setup.................................................................... 48
16.7 Test I Channel Calibration ........................................................... 48
16.7.1 1V to 2V Load (I1)............................................................... 49
16.7.2 4V to 6V Load (I2)............................................................... 49
16.7.3 8V to 12V Load (I3)............................................................. 50
16.7.4 16V Load (I4)....................................................................... 50
16.8 ICr Channel Setup and Calibration .............................................. 51
16.9 Recording the As Left K-Constants ............................................. 52
16.10 Backing Up and Restoring the Calibration............................... 52
17 BATTERY MAINTENANCE SCHEDULE................................................ 53
18 UPGRADING THE FIRMWARE............................................................. 54
18.1 Upgrading Using the Memory Card............................................. 54
18.2 Upgrading Using the IR Port........................................................ 54
19 PDA MOBILE SOFTWARE.................................................................. 58
19.1 General Description: PDA ........................................................... 58
19.2 System Requirements: PDA......................................................... 58
20 MAIN PAGE FILE DATABASE............................................................. 58
21 OPTIONS MENU................................................................................. 59
21.1 User Preferences........................................................................... 59
21.2 Delete All Strings: PDA............................................................... 60
21.3 About............................................................................................ 60
22 DATA TRANSFER TO PDA VIA IR...................................................... 61
22.1 File Transfer from Cellcorder to PDA ......................................... 61
22.2 Data Transfer from Hydrometer to PDA...................................... 61
23 VIEWING AND EDITING READINGS:PDA.......................................... 62
23.1 View String Data.......................................................................... 62
23.2 Edit Cell Data............................................................................... 63
23.3 Insert Readings............................................................................. 63
23.4 Delete Readings ........................................................................... 64
24 ANALYZING CELL DATA................................................................... 64
24.1 Stats (Statistics)............................................................................ 65
24.2 Site Information ........................................................................... 65
24.3 Thresholds.................................................................................... 66
24.4 Add/Edit Comments..................................................................... 66

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25 PRINTING .......................................................................................... 67
26 FILE TRANSFER FROM PDA TO PC.................................................... 67
27 ADDING OR REPLACING STRING DATA ............................................. 68
28 DELETE STRING DATA...................................................................... 68
29 SERIAL ERRORS ................................................................................ 69
30 CELLCORDER PARTS LIST................................................................. 71
31 CRT-300 SPECIFICATIONS................................................................ 72
32 APPLICATION NOTE CC-001............................................................. 74
33 APPLICATION NOTE CC-002-A......................................................... 87
34 CONNECTION OPTIONS...................................................................... 93

ix
Table of Figures
Figure 1. Data in Memory Messages and Main Menu................................... 8
Figure 2. Typical Battery Power Warnings.................................................. 11
Figure 3. Setup Menus ................................................................................. 13
Figure 4. Threshold Limits........................................................................... 15
Figure 5. Data in Memory Messages ........................................................... 16
Figure 6. Data Setup..................................................................................... 18
Figure 7. Definable Site Items ..................................................................... 20
Figure 8. New Site ....................................................................................... 20
Figure 9. Active Site .................................................................................... 21
Figure 10. Restore Messages........................................................................ 22
Figure 11. Voltage Displays......................................................................... 24
Figure 12. Amp Hour/Intercell Type Setup ................................................. 27
Figure 13. No VFloat Readings Message..................................................... 28
Figure 14. Resistance and Test Progress...................................................... 29
Figure 15. Memory Card as a Disk .............................................................. 33
Figure 16. Print Options............................................................................... 35
Figure 17. Status Displays ........................................................................... 36
Figure 18. Fault Displays............................................................................. 37
Figure 19. Diagnostics Menu (Typical) ....................................................... 38
Figure 20. Password Screen......................................................................... 42
Figure 21. Change Password........................................................................ 42
Figure 22. Flash Version, Service and Calibration ...................................... 44
Figure 23. Voltage Channel Setup ............................................................... 45
Figure 24. Voltage Channel Menus ............................................................. 45
Figure 25. Current Channel Setup................................................................ 48
Figure 26. Current Channel Menus.............................................................. 48
Figure 27. Intercell Channel Setup............................................................... 51
Figure 28. Intercell Channel Menus............................................................. 51
Figure 29. Battery Maintenance Schedule ................................................... 53
Figure 30. Typical Main Page...................................................................... 58
Figure 31. Options Menu ............................................................................. 59
Figure 32. User Preferences......................................................................... 59
Figure 33. Delete All Data ........................................................................... 60
Figure 34. Download Cellcorder.................................................................. 61
Figure 35. Download Hydrometer ............................................................... 62
Figure 36. View String Data ........................................................................ 62
Figure 37. Edit Cell Data ............................................................................. 63
Figure 38. Insert Readings ........................................................................... 63
Figure 39. Delete Cell Readings .................................................................. 64
Figure 40. String Options Menu................................................................... 64
Figure 41. Stats Page.................................................................................... 65
Figure 42. String Site Information ............................................................... 65
Figure 43. String Thresholds........................................................................ 66

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Figure 44. Add String Comments ................................................................ 66
Figure 45. Print Options Page...................................................................... 67
Figure 46. Upload File to PC ....................................................................... 67
Figure 47. Adding or Replacing Cellcorder / Hydrometer Data .................. 68
Figure 48. Deleting String Data ................................................................... 68
Figure 49. Serial Receive Errors .................................................................. 69

Safety Information
1
1 Safety Information
You must read and understand the following safety precautions and those
printed elsewhere in this manual before using the Cellcorder.
Except as explained in this manual, do not attempt to service Albér
equipment yourself. Opening the equipment may expose you to
dangerous voltages. Refer servicing beyond that described in this
manual to authorized personnel.
Do not allow liquids or moisture to get into the equipment. If liquid does
get into the equipment, unplug it immediately and contact your nearest
authorized service center or Albér directly.
Ensure equipment is provided adequate ventilation. Do not block
equipment ventilation openings.
Do not exceed equipment voltage or power ratings or capabilities.
Do not let unauthorized persons operate the equipment.
The maximum voltage the Cellcorder can read is 20V. Do not attempt to
read Overall Volts (OV). The Cellcorder calculates OV based on cell
voltage readings.
Never let any Cellcorder metal surfaces come in contact with a battery
post or grounded rack while testing with the unit.
Do not attempt to read internal resistance of an open cell/module while
the battery is on-line.
Do not perform any testing with the Cellcorder when the AC Power
indicator is lit or when the charger module is connected to the
Cellcorder. Injury to personnel or damage to equipment could result.
Use of this product in a manner not specified could compromise the
designed-in safety of this product.
High voltage or current may be present in the equipment. Only qualified
personnel should perform the operations described in this manual.

What's New
2
2 What's New
The CellcorderCRT-300 battery cell voltage and resistance tester is the
newest addition to the Albér Cellcorder line. The CRT-300 is lightweight,
stylish, rugged, and durable. Special features include new, user-friendly
operation, Smart Mediamemory card, infrared (IR) communication, a
graphical LCD display, and redesigned cables and clamps.
Voltage and Current Protection - An internal circuit helps protect the
Cellcorder if inadvertently placed across a high voltage. Circuitry senses the
input voltage across the current carrying leads and, if the input voltage
exceeds 20 volts, a beep sounds and the test current relays are disabled. As a
reminder, it is still potentially hazardous to exceed the rated voltage of the
Cellcorder (20 volts).
New ExcelCompatible .CSV File Format - The CRT-300 creates a .CSV
file when a .CDF Cellcorder data file is created. The .CSV file is used by
Microsoft Excel to display data in spreadsheet format.
Help Screens and Menu Selections - The new CRT-300 has easier-to-use
screens, many of which offer Help pages that provide details about options
on the screen.
In addition, you now select options using the F1 to F4 function buttons
instead of the keypad. To speed up the selection process, function locations
have been standardized: Yes and No are at F1 and F2, and Cancel and Back
appear on F4 or F3 when possible.
Main Menu > Get a coffee | Read this manual | Use the CRT-300
To make the manual easier to use, menu sequences appear about paragraphs
describing specific operations. This manual contains a complete description
of all Cellcorder features and specifications.

System Requirements
3
3 System Requirements
A typical Cellcorder system requires the following manuals:
Cellcorder CRT-300 User's Guide, 4200-038
Battery Analysis System User's Guide, 4200-002 (if a computer is used)
UPS (uninterruptible power supply) manufacturer's instruction manual (if a
UPS is used)
USB Media Reader/Writer manufacturer's instruction manual (Belkin
Components, Smart Media or other)
Hydrometer manual (if a hydrometer is used)
Data storage module (used with the hydrometer)

General Description
4
4 General Description
The CRT-300 Cellcorder battery cell voltage and resistance tester features a
Smart Mediamemory card, infrared communication, graphical reflective
LCD display, and newly designed cables and clamps. The Cellcorder reads
single cells and multicell modules, and displays and records cell float
voltage, internal cell resistance, and intercell connection resistance. A
compatible hydrometer can transfer specific gravity and temperature data via
the IR port.
The self-contained CRT-300 Cellcorder is comprised of a microprocessor,
load resistor, display, and rechargeable battery. Voltmeter probes and a three
clip resistance set are provided; optional test leads are available from Albér.
The CRT-300 functions well even in high noise environments, without the
need to disconnect the battery from service. A 60 amp DC load (on 2V cells)
is used to calculate internal cell resistance and intercell resistance. Circuitry
rejects the 50Hz/60Hz ripple and associated harmonics often troublesome to
AC-based impedance and conductance meters.
The CRT-300 ships with an 8M memory card, USB memory card
reader/writer, resistance and voltage test leads, carrying case, charger
module, and Battery Analysis System (BAS) software. An optional thermal
printer is available.
Data Memory and Communication - The removable memory card stores a
large amount of data in both CRT-300 .CDF and Excel.CSV file formats.
The memory card or IR port transfers readings to a computer for analysis
and report generation.
System Display - The high contrast, 128 x 64 pixel, backlit graphical display
shows menus, warnings, and test results.
Power - The CRT-300 is powered by a lithium ion rechargeable battery. It
does not operate on AC power. A fully charged unit can test for seven hours.
Isolated operation helps ensure safety. A charger module is included.
Float Voltage Readings - The CRT-300 measures the voltage applied
during full float operation. The voltage range covers all cells or modules up
to 20 volts. Accuracy of readings is to four full digits.

General Description
5
Internal Cell Resistance - Using a patented process, the CRT-300 applies a
momentary load and calculates internal cell resistance by determining
instantaneous voltage drop and load current. Cells floating on-line or off-line
can be measured. This method helps find weak, potentially failing cells when
comparing internal cell resistance of all like cells in the string.
TIP: Refer to Application Note CC-001 for more about cell resistance. Tips
throughout this book alert you to key points.
Intercell Resistance - The CRT-300 measures the resistance between two
electrically connected cell terminals. The measurement consists of connector
resistance and contact resistance at the points of connection to the cell
terminals.
Auto Ranging - The CRT-300 automatically selects the correct voltage
range, load resistor, and test time.
Data Extraction and Analysis - The memory card or IR interface transfer
data to a computer. The BAS program analyzes data, displays results in
graph or tabulated formats, and prints reports. It also exports report files in
ASCII, Excelor comma-delimited format so other programs can generate
customized reports. Refer to the Battery Analysis System User's Guide.

Panel Controls and Indicators
6
5 Panel Controls and Indicators
This section describes the Cellcorder controls, indicators, and connectors.
Menu items on the LCD display are described in the sections of the manual
where they are used.
Top Panel Indicators
AC Power.................Red. On when Cellcorder battery charger is connected.
Charge......................Green. On when charger is connected and battery is
charging. Off indicates fully charged battery.
Smart Media Card....Yellow. On when Cellcorder is accessing the Smart
Media memory card for read or write.
Test ..........................Red. On when resistance test is in progress. Flashing
indicates a problem with the resistance test.
Beeper......................Emits audible feedback when enabled.
Top Panel Controls
Shift..........................Press Shift, release Shift, then press another key to
select orange text on a key. (Shift+key name).
F1 to F4....................The F1, F2, F3 and F4 buttons select the functions on
the LCD directly above. The buttons also have the
following options.
Print (Shift+F1) ....Sends data to the printer via IR.
Send (Shift+F2)....Sends data to the computer via IR.
Save (Shift+F3) ....Saves data to the memory card.
Site (Shift+F4)......Displays the site selected.
Power.......................Press and release to power on the CRT-300. Press and
hold to power off.
Enter / Arrows..........Five functions: Enter plus Arrow keys. Press Enter
after typing data, such as password. Press Up, Down,
Left or Right arrows to navigate screens.
Test ..........................Press to initiate cell testing.
0 to 9........................The keypad offers alphanumeric data entry and the
following options.
Start (Shift+1) ......Start. Displays the Main Menu.
Time(Shift+2) ......Time. Sets the date format and time.
Mem(Shift+3) ......Memory. Clears stored data.
Hz (Shift+4) ......Frequency (Hz) for 50Hz/60Hz ripple frequency.