Axcom SMAPL4P User manual

1
SMAPL4P
Battery Tester and Charger
Operating Instructions

2
CONTENTS
1...................................................................................................! CAUTION ! ! PLEASE READ ! 3
2.....................................................................................................TECHNICAL SPECIFICATIONS 4
3...........................................................................................................................INTRODUCTION 5
4............................................................SWITCHING ON THE BATTERY TESTER AND CHARGER 6
5...........................................................................................................................PROGRAMMING 7
5.1 EXTENDED PROGRAMMING MODE................................................................................................... 11
6.......................................CHARGING CURRENTS (TIPS FOR PROGRAMMING THE CURRENTS) 12
7.................................................................................................EXTERNAL PROGRAM MEMORY 12
8..........................................................................................................................LED FUNCTIONS 13
9................................................................................................................... MODE WORD TABLE 13
10........................................................................................................................TEST PROGRAM 13
11..................................................................................................................... SETUP PROGRAM 14
11.1 DISPLAY LANGUAGE ................................................................................................................... 14
11.2 NETWORK VERSION ................................................................................................................... 14
12............................................................................................................BLOCK PROGRAMMING 14
13....................................................................................................................... BATTERY TYPES 15
13.1 BATTERIES WITH EX PROTECTION AND INTEGRATED ELECTRONICS ............................................. 16
14.............................................................................................CONNECTING BATTERY BLOCKS 16
15..........................................................................................RECOGNIZING A FAULTY BATTERY 18
16..................................................................MONITORING FEATURES AND ERROR MESSAGES 18
17........................................TUNING OF VOLTAGES, CONTROL PARAMETERS AND CURRENTS 19
18...........................................................SAFETY TIPS FOR THE OPERATION OF THE CHARGER 20
19..............................................................................DESCRIPTION OF THE SERIAL INTERFACE 21
19.1 PIN ASSIGNMENT OF THE SMAPL-4P SERIAL CONNECTION CABLE <--> PC ................................ 21
20........................................................PRINTING OF THE BATTERY DATA AS TABLE OR LABEL 21
21.................................................................................. PC SOFTWARE "WIN III" FOR WINDOWS 23
22.........................................................................................................................................INDEX 28
Valid from EPROM Release 4.06.
Last updated March 2013

3
1 ! Caution ! ! Please read !
Read these operating instructions carefully. Damages that occur due to handling errors or because the
instructions of the manual were disregarded, will terminate any warranty claims. We are not liable for
consequential damages.
Before opening the device, please unplug the power cable and disconnect all batteries.
Caution! The heat sink and the transformer may be hot!
The charging device must be set up in a way that ensures proper ventilation through the ventilation
flaps and the removal of warm air.
Protect the device from humidity.
Before installing a battery block to the SMAPL-4P please verify all programmed values such as battery
type, number of cells and current. Incorrect programming of these values could lead to destruction of
the battery or in the worst case to explosion or fire.
APL-4 with external memory: plug in the charging adapter first, then tighten the screws of the 15-pin
plug and then install the battery. Before unplugging the external charging adapter, first take the battery
out of the battery adapter and then unplug the charging adapter.
If battery cells, which were purchased and used as single units instead of block units, are supposed to
be installed in the SMAPL-4P device, ensure that each cell is in the same charging condition and has
the same cell capacity. This means that the cells need to be selected. Different charging conditions of
battery cells could damage the cells during charging and discharging and will most probably make it
impossible to recognize the correct end of the charging procedure.
If an error occurs – e.g. if both the red and the green LED indicator blink simultaneously – do not con-
nect any new batteries.
Always connect minus and plus poles of a battery at the same channel.
Do not connect voltages larger than 24V to the charging connector.

4
2 Technical Specifications
According to the design of the charger device, the batteries are connected either via two 4-mm safety
plugs or a 15-pin D-connector. The SMAPL-4P is protected against incorrect polarization during the
connection process.
For the 15-pin design, the discharging/charging program for the battery is saved in an external
EEPROM. When changing the plug or the battery adapter respectively, the program that was saved in
the EEPROM is loaded into the SMAPL-4P and runs as soon as the battery is connected.
When loading Nickel-Cadmium (NiCd) batteries and Nickel-Metal-Hydride (NiMH) batteries you can
choose either "reverse pulse" charging current or continuous charging current. The end of charging is
recognized via –Delta/V.
Serial interface 9600 bps, 7 data bits, even parity, 1 stop bit, 9-pin D-connector.
Maximum charging voltage: 22.0 Volt.
The following battery types can be discharged and charged: NiCd and NiMH batteries with 1 to 12
cells, Lithium-Ion (Li-Ion) batteries and Polymer batteries with 1 to 5 cells and lead batteries with 1 to 9
cells.
Maximum discharging and charging current for each channel is 2.0A. Discharging and charging cur-
rents can be set individually in 5mA intervals, from 10mA to 2.0A. Total charging power: 8.0A.
Mains supply: 100 - 240VAC 50/60Hz 200VA.
Power supply switch with inlet connector for non-heating apparatus and fuse are found on the rear of
the device.
Mains fuse: 3,15/inert 250V
Power cable with connector for non-heating apparatus, 1.5 m
Measurements: 350mm x 290mm x 110mm (WxLxH)
Weight: 6 kg

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3 Introduction
The product SMAPL-4P is a universal charging and discharging device, controlled by microprocessors.
The SMAPL-4P is controlled via four push keys. The Parameters are displayed via an illuminated LCD
with 16 x 2 characters. Two LED's per channel are reserved for the indication of operation.
For the SMAPL-4P the charging/discharging program for the batteries is saved by 4mm safety plugs
with no-volt protection, within the charging device.
For the SMAPL-4P with a 15-pin D-plug to connect the batteries, the discharging and charging pro-
gram for the batteries is saved in an EEPROM of the 15-pin D-connector or the external battery
adapter. When changing the plug or the battery adapter respectively, the program that was saved in
the EEPROM of the plug is loaded into the SMAPL-4P, and runs as soon as the batteries are connect-
ed.
For each battery type a specifical charging procedure is used which will disconnect the battery when it
becomes fully charged. Correct programming of the device will prevent overloading of the battery
blocks.
Charging and discharging currents can be set individually from 10mA to 2.0A in 5mA intervals.
All four channels can be operated simultaneously, each with a different battery program.
During charging and discharging the battery capacity is measured. The measured values are shown on
the display and can be printed via the serial interface.
If an ideal capacity for a battery is programmed, the report "Battery OK/faulty" is displayed.
Batteries can be checked for self-discharging (one hour to 200 days).
It is possible to automatically switch to "Trickle Charge" after the battery is "Charged“.
For batteries which suffer from capacity loss (memory effect), you can program the operation "Form-
ing". During this operation, the battery is discharged and charged multiple times. For batteries with
memory effect the capacity values are improved with each operation.
The SMAPL-4P automatically recognizes when a battery is connected, and executes the programmed
operation accordingly.
The battery blocks can remain connected when the device is switched off. The device will not be dam-
aged. The internal resistance value of the SMAPL-4P is approximately 50kOhm.
Using the PC software "WIN III", the SMAPL-4P can be programmed via a personal computer. The
batteries are managed via a database. The battery data are displayed on the PC monitor numerically
and graphically.
Using the network version of the SMAPL-4 and of the PC software "WIN III-N" multiple SMAPL-4P can
be connected to the serial interface of the personal computer.

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4 Switching on the Battery
Tester and Charger
Use the power switch to switch the SMAPL-4P on and off.
After switching the SMAPL-4P on , the following message will be displayed for approximately 2 sec-
onds:
A
X
C
O
M
G
m
b
H
S
M
A
P
L
4
P
V
x
.
x
X
G
x
V x.xx stands for the software release number, G x stands for the GAL version.
(During operation the release number can be displayed by constantly holding down the key "-".)
After that the SMAPL-4P carries out a self-test .
After switching the SMAPL-4P on for the first time, after changing the EPROM (depending on the re-
lease number), or after data loss in the EEPROM a basic setting is loaded (Nickel-Cadmium battery,
charge with 200mA).
After repeatedly switching the SMAPL-4P on and off, the values programmed at that time are used for
further operation.
After the charger is switched on, the CPU, the EEPROM and the hardware are tested and possible
errors are displayed. The LED's are switched on for a short time. After the device is switched on and
during the self-test the ventilator inside of the charger is running.
If no error is reported, the following message is shown on the display window:
S
e
l
f
t
e
s
t
O
K
The programmed operation will not be executed immediately, if a battery was connected before the
device was switched on. The operation will start automatically after approximately 30 minutes, the rea-
son being, that a voltage failure that occured shortly before the charging operation is finished, might
not be recognized. The battery could be overcharged.
Installing a new EPROM version will – depending on the release number – lead to the display message
"New EEPROM loaded" and to the message that parameters are loaded. If the message "New
EEPROM loaded" is shown, the control parameters, the currents and the voltage have to be adjust.
This message can be deleted by pressing the key " Anzeige/Zurück ".
Caution! Do not connect a battery block until the control parameters are adjust!
Each time the device is switched on, the following display message will appear, if the parameters were
not adjust:
P
a
r
a
m
e
t
e
r
A
c
o
a
d
j
u
s
t
!
!
!
!
If a malfunction occurs during the operation, the channel is switched off and the message
"WATCHDOG RESET“ is shown. After this message has been shown for approximately 30 seconds,
the operation is continued as programmed, just as if the device had been switched on . This message
can be deleted by pressing the key "Anzeige/Zurück"

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5 Programming
For the SMAPL-4P with 4mm safety plugs inside the charging device, the discharging and charging
program for batteries is saved in an EEPROM, with no-volt protection.
For the SMAPL-4P with a 15-pin D-plug for battery connection, the discharging/charging program for
the batteries is saved in the 15-pin D-plug or or the external battery adapter. When changing the plug
or the battery adapter respectively, the program that was saved in the EEPROM of the plug is loaded
into the SMAPL-4P and runs as soon as the battery is connected.
When using the battery adapter with the 15-pin D-plug the SMAPL-4P does not need to be re-
programmed when changing the adapter. The battery program that is saved in the plug will be
automatically executed.
Programming the SMAPL-4P:
Use the keys "+" and "-" to choose the desired channel (A 1 to 4).
Use the key "Programmieren" to retrieve the programming mode. When in the programming mode,
use the key " Programmieren " to jump to the next programming step. The keys "+" and "-" will change
the values.
Use the key "Anzeige/Zurück" to terminate the programming mode. Earlier changes in the program-
ming mode will not be included.
By pressing the key " Programmieren " the display will show the following message:
P
r
o
g
r
a
m
m
i
n
g
:
The message "Programming" will be shown in the first display line as long the key " Programmieren " is
being held. Then the Cursor will blink in the second display line. During this programming step the bat-
tery type is programmed. The second display line will show the current battery type that is being pro-
grammed. Select the desired battery type by hitting the keys "+" or "-".
By pressing the key "+" the battery types will be displayed successively as follows:
Nickel-Cadmium, Nickel-Metal-Hydride, Lithium-Ion (Polymer), Lead battery, set voltage.
A
1
B
a
a
k
t
t
e
r
y
T
y
p
N
i
c
k
e
l
-
C
a
d
m
i
u
m
Using the operation "set voltage" the individual final charging or discharging voltage can be entered.
During the operation the battery is charged with a continuous charging current.
After choosing the desired battery type, press the key " Programmieren " again.
Now the desired operation can be programmed.
A
1
M
o
d
e
:
C
h
a
r
.
-
D
c
g
.
-
C
h
a
r
.
By pressing the key "+" the operations will be displayed successively as follows:
Charge, Discharge, Discharge-Charge, Char.-Dcg.-Char., Conditionin, Disch--Char xx Day, Keys set
mode.

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"Charging" means that the battery is charged only. "Discharging" means that the battery is dis-
charged only. " Char.-Dcg.-Char." will charge the battery, discharge it and then charge it again. "
Conditioning" will execute the operation "Discharge-charge" multiple times. " Disch-Char xx Day"
will discharge the battery and then charge it again. The battery will be discharged and charged accord-
ing to the number of days programmed. In between those programmed days, trickle charge is carried
out.
When you choose " Keys set mode", the desired operation is executed via keys after the connection
of a battery block to the SMAPL-4P. If " Keys set mode " was programmed, the next entry is the num-
ber of cycles for the operation "Conditioning".
After a battery block has been charged and all programmed operations are finished, trickle charge is
carried out automatically. The end of the operation is indicated via display and the LED "End of pro-
gram".
If you chose the operation " Conditioning ", the display will show the following message after you hit the
key "Programmieren" once more:
A
1
M
o
d
e
:
C
o
n
d
i
t
i
o
n
i
n
A
u
t
o
Choose the keys "+" or "-" to program the number of charging or discharging cycles.
It is possible to choose two to six discharging or charging cycles, or set the value to "Auto". After each
discharging operation, the operation "Auto" will compare the measured capacity with the previously
measured capacity. If the new value is a minimum of 2 % greater, the discharging operation will be
repeated. If the new value is smaller than 2 %, the operation will be terminated after the new charging
operation has begun and will be switched to trickle charge. The function "Auto" will discharge and
charge the battery at least twice. There is no limitation to the number of cycles.
The next step will program the number of cells.
The first display line will show the nominal voltage of the chosen battery type. The second display line
will show the number of cells. Example: Nickel-Cadmium battery with a nominal voltage of 1.2V per cell
and a default of six cells:
A
1
B
at
A
a
t
t
.
7
.
2
V
C
Z
e
l
l
s
6
Use the key " Programmieren" to get to the next step.
If the operation "Set voltage" was chosen earlier (when the battery type was requested), the display will
ask you to enter the voltage values now. In this case the number of cells cannot be programmed. If the
program was set on charging only, the final charging voltage has to be entered. If the battery only
needs to be discharged, the final discharging voltage has to be entered. If the battery is supposed to be
discharged and charged, both final discharging and charging voltages have to be entered. The small-
est programmable value for voltages is 0.9V; the maximum value is 22.0V. Enter the values in 10mV
steps. Pressing the key " Programmieren" will save the programmed values and take you to the next
step.
A
1
C
h.
L
h
a
r
g
e
v
o
l
t
a
g
e
1
5
.
0
3
0
V
A
1
D
E
i
s
c
h
a
r
g
e
v
o
l
t
a
g
e
6
.
1
2
0
V

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The next step will program the charging current.
A
1
C
h
ar
L
h
a
r
g
e
c
u
r
r
e
n
t
1
.
2
0
0
A
Enter the desired charging current in 5mA intervals with the keys "+" and "-".
The next program step will program the discharging current.
A
1
1
D
E
i
s
c
h
a
r
g
e
c
u
r
r
2
.
2
0
0
A
The discharging current should correlate with the current used for operating the battery.
Now the nominal capacity can be entered.
A
1
B
a
A
a
t
t
.
c
a
p
a
c
i
t
y
P
r
o
g
.
-
N
o
+
Y
e
s
Pressing the key "-" will skip the entering of the capacity value. Use the key "+" to enter the battery
capacity.
A
1
B
A
a
t
t
.
C
a
p
a
c
i
t
y
T
h
e
k
e
3
.
5
0
0
A
h
Use the keys "+" or "-" to enter battery capacity values between 10mAh and 40Ah.
Pressing the key „Programmieren“ will allow you to set the percentage of capacity for the message
"battery OK/faulty".
A
1
m
i
n
.
c
a
p
a
c
i
t
y
B
a
t
t
e
r
y
O
K
8
0
%
Use the keys "+" or '-" to enter the percentage for the message "Battery OK/faulty".
After a battery is discharged, the capacity that was measured while it was discharged is compared to
the programmed nominal capacity. Depending on the set percentage the battery is displayed as OK or
faulty. After the programming is finished the LED "End of program" also shows the battery condition. A
blinking LED indicates a faulty battery. A constantly illuminated LED shows that the condition of the
battery is OK.
Use the key "Programmieren" to jump to the display message, which will prompt you for the self-
discharging test of the battery.
A
1
S
e
l
f
-
d
i
s
c
h
g
r
.
t
e
s
t
-
N
o
+
+
Y
+
e
s
a
Hit the key "-" to skip entering data. Hit the key "+" to enter the period after which self-discharging is
tested.

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A
1
P
r
o
g
r
a
m
m
I
n
g
-
D
a
y
s
+
H
o
u
r
s
Hit the key "-" to enter how long it is until the test is executed in days, and hit the key "+" to enter how
long it is in hours.
A
1
T
e
s
t
s
S
e
l
f
d
c
.
a
f
t
.
2
0
h
o
u
r
(
s
)
The keys "+" and "-" enable the setting of a period of 1 to 200 hours and 1 to 200 days respectively.
If the test is programmed for the measurement of self-discharging of the battery, the display will
show the time left before the operation will be executed. When the programmed time has expired, the
battery is discharged and charged again. During the discharging operation, the measured capacities
before and after the programmed time are compared. The difference is shown as the self-discharging
value of the battery. Any small discharge of the battery as a result of the internal resistance of the
adapter is taken into consideration when calculating the values of the self-discharging operation.
Hitting the key "Programmieren" will offer you the option of selecting the extended programming mode.
A
1
E
xt
E
x
t
.
p
r
o
g
r
a
m
-
m
o
d
e
-
N
o
+
Y
e
s
The key "+" will select the extended programming mode. The key "-" or "Programmieren" will not select
the extended programming mode.
The extended programming mode is described in the next chapter.
When all the steps are programmed, the following message is displayed:
D
W
a
t
a
s
a
v
e
w
i
t
h
P
r
o
g
r
a
m
m
Hitting the key "Programmieren" will save the programmed values in the EEPROM. These values are
not lost when the device is switched off. The key "Anzeige/Zurück" will remove the changes and pre-
serve the old values. The display will show the current operation condition of the channel. The device is
in basic position.
After you hit the key „Programmieren“, the display will briefly show the following message.
D
W
a
t
a
i
n
E
E
P
R
O
M
s
a
v
e
d
Then the current operation condition of the channel is shown. If the battery type, the operation or the
number of cells have been changed compared to the basic settings, the SMAPL-4P will operate as if
the battery block had been disconnected and newly installed. The running charging operation is termi-
nated and the newly programmed operation is executed. If only the charging or discharging current
was modified, the new current is adjusted to the new value and the running charging or discharging
operation will not be interrupted.

11
Caution! When a battery has almost finished charging , it may become overloaded as the end
of charging is not always recognized exactly.
Risk of fire! Risk of Explosion!
In the programming mode a rapid adjustment of values can be achieved by permanently pushing the
keys "+" or "-" .
The key "Anzeige/Zurück" will end the programming mode. The old values are preserved and the cur-
rently running charging or discharging operations are not influenced.
The programming mode will automatically terminated when no key is hit for more than 60 seconds.
The old programmed values will be preserved and the current charging or discharging operations will
not be influenced.
5.1 Extended Programming Mode
In the extended programming mode, first the condition for "End of Charging" by loading via I/U charac-
teristic is entered.
A
1
C
h
a
r
g
e
e
n
d
I
/
U
5
%
If the end of charging is determined via the I/U characteristic (by reducing the charging current ), e.g.
for lead batteries, the end of charging occurs when the charging current is down to a predetermined
percentage of the programmed charging current. The basic setting for this value is 5 %. At a pro-
grammed charging current of 1.0A the end of charging would occur at a charging current of 50mA,
should the percentage be set at 5 %.
Use the keys "+" and "-" to set a value between 1 % and 50 %. If you increase the percentage, the
capacity that is loaded into the battery will increase. Decreased percentage will also lead to increased
charging times.
Hit the key „Programmieren“ to jump to the next step.
In this programming step it is possible to set the type of the charging current for Nickel-Cadmium bat-
teries and for Nickel-Metal-Hydride batteries. For these batteries, you can choose "Charging with or
without reverse pulse". When choosing "Charging without reverse pulse" the batteries are loaded with
continuous current.
Hit the key "Programmieren" to jump to the next step.
A
1
D
i
s
c
h
a
r
g
e
c
u
r
r
e
n
t
o
n
Use the keys "+" and "-" to switch between "Measure discharge with current on" and "Measure dis-
charge current off".
For the programmed value "Measure discharge with current on ", the battery voltage is measured while
the discharging current is flowing.

12
For the programmed value "Measure discharge current off ", the battery voltage is measured during
discharging breaks, when no discharging current is flowing. In this mode, the battery is discharged for
approximately 10 seconds, then there is a charging break of approximately 1 second, during which the
battery voltage is measured.
The next programming step the charging mode for lead batteries can be set. "Mode 1" will charge a
lead battery with a charging voltage of 2.3V per cell. Charging time is limited to a maximum of 24
hours. Trickle charge is also executed with 2.3 V per cell. "Mode 2" will charge a lead battery with a
charging voltage of 2.4V per cell. Charging time is limited to a maximum of 12 hours. Trickle charge is
executed with 2.3V per cell.
The next programming step will set the charging mode for Lithium-Ion and Polymer batteries. "Mode 1"
will charge the battery with a charging voltage of 4.1V per cell. "Mode 2" will charge the battery with a
charging voltage of 4.2V. Charging time is limited to a maximum of 24 hours. Trickle charge is execut-
ed with the set charging voltage.
6 Charging Currents (Tips for Programming the Currents)
Most simple charging devices charge batteries with a charging current of C/10 of the battery capacity.
For example, a battery with a capacity of 300mAh would be charged with a charging current of 30mA.
It is possiblie to charge most batteries with a larger current than C/10, using the switch-off method of
the SMAPL-4P Battery Testers and Chargers.
We recommend a charging current of C/3 for these batteries. A battery with 600mAh would thus
be charged with 200mA.
Sometimes batteries can be charged with currents of 1C or higher. Charging currents that are set too
high could lead to increased self-discharge.
The following batteries should not be charged with currents higher than C/10, even with our charging
devices.
BOS areas: Bosch Stick Battery 12.0V 300mAh, 9V blocks.
New charging devices, which are included in the orders of battery-operated devices, sometimes also
load with larger charging currents than C/10. Those charging currents can be set at the SMAPL-4P
Battery Tester and Charger devices as well.
The discharging current should match the current for battery operation.
7 External Program Memory
For the SMAPL-4P with external memory: Always plug in the adapter and tighten its screws
first, only then insert the battery.
After connection, the external memory displays the message "No charging adapter", and the battery
program that was loaded into the external memory will only run when a key on the device is pushed, or
when a battery is being inserted or when the personal computer sends a battery program.

13
8 LED Functions
SMAPL – 1
Green LED "End of program“
End of program and battery OK
on
End of program and battery faulty
blinking
SMAPL – 4 P
Red LED
Green LED
No battery connected
off
off
Battery is being discharged
blinking
off
Battery is being charged
on
off
End of program and battery OK
off
on
End of program and battery faulty
off
blinking
Trickle charge is being carried out
on
on
Charger error or battery program error
blinking
blinking
9 Mode Word Table
Mode word 1. position: 1 Nickel-Cadmium battery
2 Nickel-Metal-Hydride battery
3 Lithium-Ion battery (Polymer battery)
4 Lead battery
5 Free programming of final discharging and charging voltage
Mode word 2. position: 1 Charge only
2 Discharge only
3 Discharge - Charge
4 Charge – Discharge - Charge
5 Multiple Discharge - Charge(Forming)
6 Discharge – Charge every xx days
7 Start key operation after connection of battery
Example:
M23 (2)- a Nickel Metal Hydride battery is (3)- discharged and then charged.
10 Test Program
Programmed values can be tested as follows:
Hit the key „Programmieren“ to get into the programming mode and to choose the next value. When
the display message "Save values – program key" appears at the end of the programming mode, hit
the key „Anzeige/Zurück“. That terminates the programming mode without affecting the connected
battery. If the key „Programmieren“ is hit accidentally, the display will show the message "Values saved
in EEPROM". If there have been no changes of any of the values in the programming mode, the con-
nected battery will not be affected.
Please do not hit the keys ""+" or "-" during the test operation. The key „Anzeige/Zurück“ will terminate
the programming mode any time. Using the key „Anzeige/Zurück“ will dismiss changes.

14
11 Setup Program
Hitting the keys „Anzeige/Zurück“ and "-" simultaneously, calls up the setup program.
11.1 Display Language
The first setting in the setup program is the display language. You can choose either German or Eng-
lish. The display shows the language selected. Use the keys "+" or "-" to switch between languages.
The key „Programmieren“ will save the selected language.
11.2 Network Version
Using the option "Network" you can connect multiple SMAPL-4P Battery Tester and Charger devices
to a personal computer via a serial interface and then control them with the PC software "WIN III N".
If you are using the network version, you will need to enter the device number after entering the display
language in the setup program. Use the keys "+" and "-" to enter the device number. Entering "0" will
turn the network function off. The SMAPL-4P will then react as a device without network function.
When entering the device number, make sure that each device within a network receives a different
device number.
Hit the key „Programmieren“ to save the device number and to activate the setting.
12 Block Programming
The programming can be blocked to stop unauthorized persons from changing the programmed values
in the SMAPL-4P.
After switching on the mains voltage (at the end of the self-test), the SMAPL-4P checks if the key „Pro-
grammieren“ is activated. If it is activated at the end of the self-test, the LCD displays the message
"Programming" on the first display line. On the second display line "unblocked" or "blocked" is shown.
Using the key „Anzeige/Zurück“, you can choose between "Block programming" or "Unblock program-
ming". Hitting the key „Programmieren“ will activate this setting. If programming is blocked, the pro-
gramming mode can be retrieved during operation by hitting the key „Programmieren“, and the values
can be changed. The changed values cannot be saved at the end of the programming mode and thus
they cannot be executed. The display will show the message "Block programming".
You can select blocked or unblocked programming for each channel individually. Use the keys "+" or "-
" to select the desired channel.
If you use an external program memory, the unblocking or blocking of the programming is set within
the external memory. This means, that the programming for each external memory can be individually
set on "block" or "unblock".

15
13 Battery Types
Nickel-Cadmium battery. This battery type is recognized using the –Delta-U method. When the bat-
tery is fully charged, the battery voltage decreases. The SMAPL-4P then recognizes the end of charg-
ing using the –Delta/v method. Discharging takes place up to 0.9V per cell. The Battery voltage is al-
ways measured under load. You can choose between charging with a "reverse pulse" charging current
or with a continuous charging current. The setting can be entered in the extended programming mode.
When loading with "reverse pulse" the battery is loaded for approximately 9.5 seconds. Then there is a
charging break consisting of a short-term discharging impulse and measurement of the battery voltage.
Trickle charge is executed every six hours. One cell correlates to a nominal voltage of 1.2V. For a bat-
tery with 7.2V you have to enter "6" when asked for the number of cells .
Nickel-Metal-Hydride battery. The same procedure applies as for Nickel-Cadmium batteries.
Lithium-Ion and Polymer batteries. Lithium-Ion and Polymer batteries are charged with a continuous
charging current . The charging takes place via an I/U characteristic. First, the battery is charged with
the programmed current; as soon as the battery voltage reaches the final charging voltage of 4.1V
(mode 1) or 4.2V (mode 2) per cell, the charging current is reduced. The charging current is reduced
according to the charging voltage so that the cell voltage is not exceeded. Discharging takes place up
to a cell voltage of 2.7V. One cell correlates to a nominal voltage of 3.6V. For a battery with 7.2V you
have to enter "2" when asked for the number of cells . Trickle charge is executed every six hours.
Caution! Lithium-Ion and Polymer batteries are very sensitive to overcharging.
Maximum charging voltage per cell: 4.2V. Risk of fire! Risk of Explosion!
Lead Battery. Lead batteries are charged with continuous charging current. The charging takes places
via an I/U characteristic. First, the battery is charged with the programmed current;.as soon as the
battery reaches the final charging voltage, the charging current is reduced to ensure that the maximum
cell voltage of 2.3V (mode1) or 2.4V (mode 2) per cell is not exceeded. Discharging takes place up to a
cell voltage of 1.8V. One cell correlates to a nominal voltage of 2.0V. For a battery with 12V you have
to enter "6" when asked for the number of cells. Trickle charging is executed every six hours.
( Mode 1 and 2 for Li-Ion and Lead batteries see chapter "Extended Programming Mode")
Set Voltage. Charging takes place with a continuous charging current via I/U characteristics. First, the
battery is charged with the programmed current; as soon as the battery voltage reaches the pro-
grammed final charging voltage, the charging current is reduced. The charging current is reduced to
ensure that the programmed final charging voltage is not exceeded. Discharging takes place up to the
programmed final discharging current. Trickle charge is executed every six hours.
Regarding charging and discharging currents, the operation "Set voltage" is the same as with Lead
batteries. The only difference is the additional entry of individual final charging and discharging voltag-
es.

16
General Information
When the end of charging is determined via the I/U characteristic (by reducing the charging current),
e.g. for lead batteries, the end of charging occurs when the charging current is down to a predeter-
mined percentage of the programmed charging current. The basic setting for this value is 5 %. This
value can be changed in the extended programming mode. The smallest possible value for the charg-
ing current is 10mA.
After 24 hours, charging or discharging will be terminated (safety disconnection). In addition, if the bat-
tery voltage does not increase during a period of several hours, the charging operation will be termi-
nated. The maximum charging time for trickle charge is six hours.
During the discharging and charging operation the according capacity values are recorded and saved
in the internal memory. The latest measured values for discharging and charging are shown on the
display. Further values can be printed via the serial interface.
13.1 Batteries with EX Protection and Integrated Electronics
Most batteries with EX protection, e.g. the Motorola GP900 EX, can be discharged and charged with
the SMAPL-4P. Depending on the design of the protective electronics, the discharging and charging
operations need to be adjusted by using the "Extended programming mode" of the SMAPL-4P de-
vice.
The GP900 EX must be charged with a continuous charging current (no reverse pulse charging). Dis-
charging can be measured "with load". It may be necessary to discharge some batteries "without load"
during voltage measurement.
Not every battery with integrated charging electronics can be charged with the SMAPL-4P.
14 Connecting Battery Blocks
If incorrect polarization occurs when connecting the batteries, the display shows a corresponding mes-
sage. The charging device is protected against incorrect polarization.
Always connect minus und plus poles of a battery at the same channel.
If the battery has been connected correctly and the battery block voltage is at a minimum of 0.4V, the
SMAPL-4P recognizes the installed battery and automatically starts the programmed charging opera-
tion.
Battery blocks with integrated charging circuits can only be connected under reserve.
After the battery is connected, the first display line will show the programmed operation "M13" in coded
form, the number of cells and the battery voltage. The second display line will show "Charging",
"Dischrg." or "Tric.chrg." for trickle charge as well as the actual current.
Charging:
A
1
M
1
3
5
C
6
,
4
0
V
C
L
h
a
r
g
e
1
,
0
0
0
A

17
Discharging:
A
1
M
1
3
5
C
4
,
8
0
V
D
E
i
s
c
h
a
r
g
e
0
,
8
0
0
A
Trickle (Standby) charge:
A
1
M
1
3
5
C
6
,
9
0
V
S
t
b
.
c
h
a
r
.
0
,
5
0
0
A
If "OP via keys"“ has been programmed, then the desired operation has to be started using a key after
installing the battery. The display will show help texts for the key functions.
The operations "discharge/charge" will be executed automatically when no keys are hit for approxi-
mately one minute.
Key functions: „“ Battery charge only, „“ Battery discharge/charge, „ “ Battery
Forming.
The key "DISPLAY" will enable you to switch between the values for time and measured capacity. The
first display line will show the channel number, the programmed mode and the time in minutes for the
current operation. When using trickle charge the time of the trickle charge is shown. The second dis-
play line shows the currently measured discharged "D" and the loaded capacity "C" in Ah. The dis-
played capacity values are not changed by the trickle charge. No capacity is measured when trickle
charge is taking place.
The following display shows a Nickel-Cadmium battery that is charged, then discharged and charged
again. A capacity of 1.200Ah was measured during 120 minutes while the battery was discharged.
While it was charged, a capacity of 1.454Ah was measured.
A
1
M
1
3
5
C
1
0
m
i
n
D
1
.
2
0
0
C
1
.
4
5
4
A
h
The cursor will blink on "D" during discharging, on "C" during charging and on "min." when trickle
charge is being executed.
When the programmed operation is fully completed, an appropriate message appears on the display.
Mode 13 finished, battery charged:
A
1
M
1
3
5
C
6
,
4
0
V
B
G
a
t
t
e
r
y
c
h
a
r
g
e
d
Mode 12 finished, battery discharged:
A
1
M
1
2
5
C
4
,
8
0
V
B
a
t
t
e
r
y
d
i
s
c
h
a
r
g
When the process is finished, the condition "Charged" or "Discharged" is shown on the display and via
the LED "End of program". If a nominal capacity was programmed for the battery, the LED blinks if a
faulty battery has been detected. The battery is OK when the LED is illuminated permanently.

18
If a nominal capacity for the battery was programmed for the current operation, once the capacity val-
ues are shown and the key „Anzeige/Zurück“ is pressed once more, the measured percentage value of
the battery will be displayed.
B
a
k
t
t
.
O
K
9
6
0
%
m
e
d
i
u
m
c
a
p
a
c
i
t
y
The display will then show the time until the self-discharging test is due to start, if this has been pro-
grammed earlier. If the value for self-discharging has been measured already, it will also be displayed.
If repeated discharging and charging after xx days was programmed, the amount of time until the next
discharging operation is due will be displayed.
15 Recognizing a Faulty Battery
The SMAPL-4P will test the connected battery for its condition. After the battery has been charged and
the program is finished, the battery voltage is tested. If the battery voltage is too low, the following
message is displayed:
B
A
a
t
t
.
f
a
u
l
t
y
V
ol
o
l
t
a
g
e
t
o
o
l
o
w
The error message "Voltage too low" may also be displayed when a wrong number of cells is pro-
grammed.
After the fault is recognized no more operations, such as trickle charge, repeated discharging/charging
or the self-discharging test, are executed. The green LED starts blinking.
After discharging the battery, the discharging capacity is compared to the programmed nominal capaci-
ty and the battery is displayed as OK or faulty according to the programmed percentage. After the pro-
gram is finished the green LED also shows the battery condition. The LED blinks when the battery is
faulty. The LED is illuminated permanently if the battery is OK.
16 Monitoring Features and Error Messages
A "WATCHDOG" constantly monitors the program sequences of the SMAPL-4P. If, for example, a
program error occurs because of very high electrostatic discharging, the currents are terminated and
the program is interrupted. The following message is displayed:
S
e
l
f
b
t
e
s
t
W
a
t
c
h
d
o
g
r
e
s
e
t
This message is displayed for 30 seconds. The key „Anzeige/Zurück“ will delete this message and the
operation can be continued as if the device has just been switched on.
Error messages can be deleted with the key „Anzeige/Zurück“.

19
The temperature of the heat sink is monitored as well. If the temperature gets too high, the discharging
and charging operations are interrupted and a message is displayed. As soon as the temperature has
dropped, the discharging and charging operations are automatically continued. Tuning of Voltages,
Control Parameters and Currents
In order to balance component tolerances and to receive exact measurement values, the voltages,
control parameters and currents need to be tuned. Only the exact setting of all parameters can ensure
secure discharging and charging of a battery block.
The control parameters determine how the charging current acts when the charging voltage is turned
on. An incorrectly set control parameter can cause the message "Over current" to appear, or the pro-
grammed charging current is reached too slowly.
The adapter is delivered with tuned voltages, control parameters and currents.
A new tuning has to be carried out when the message "New EEPROM" loaded is shown.
Tuning should be carried out with a battery block that has 9 or 10 cells. The battery block must endure
a charging current of 1.0A. The tuning can only be carried out, when the battery type is set to
Nickel-Cadmium or Nickel-Metal-Hydride.
If the values measured by the SMAPL-4P and the actual values are far apart from each other, the
EEPROM should be loaded with the basic settings before starting the tuning operation. The basic set-
tings are loaded by hitting the keys "+" and "-" simultaneously during the switching on process, until the
message "New EEPROM loaded" appears. Delete this message by hitting the key "DISPLAY", and
then start the tuning operation.
Calling up the tuning program
When the device is switched on, a self-test is being executed. At the end of this self-test the keys are
being prompted. At this point the keys „Anzeige/Zurück“ and „Programmieren“ need to be hit at the
same time. The display shows the message "Tune control parameters". Releasing the keys takes the
SMAPL-4P to the tuning program for the voltage value.
To carry out the voltage tuning, connect the battery block to the SMAPL-4P and install a voltage meas-
urement device parallel to the battery block. The voltage shown on the display of the charging device
has to exactly match the voltage of the voltage measurement device. The keys "+" and "-" will adjust
the displayed voltage.
The key „Programmieren“ will take you to the function "Tune shunt". This mode will tune the internal
resistance of the adapter and the specific resistance.
The SMAPL-4P will switch on a charging current of approximately 1.0A. As soon as the charging cur-
rent of 1.0A is reached, the voltage can be adjusted by hitting the keys "+" or "-".
Voltage tuning has to be executed very precisely.
False voltage tuning can lead to battery overload.
Voltage measurement must take place directly at the charging device.
To tune the control parameters hit the key „Programmieren“. If a battery block is connected, the
SMAPL-4P tunes its control parameters automatically. First, the control parameters for the charging
current are determined, then the value for the discharging current. After the tuning is successful the
display will show the message "Executed". If the control parameters cannot be determined within a set
time, the display will show the message "Failure". After connecting the battery, the 100 % value is be-
ing counted up until the target current of 10mA is reached.

20
With the key „Programmieren“ you can switch between the tuning of the control parameters, the tuning
of the charging and discharging currents and the tuning of the battery voltage.
To tune the current you need to install a current measuring device to the battery using a series connec-
tion. Switch to "Tune charging" or "Tune discharging" by hitting the key „Programmieren“. Tuning will
take place with a current of approximately 190mA. The current displayed on the charging device has to
match the current of the measuring device as precisely as possible. The keys "+" and
"-“ will adjust the displayed current.
The key „Anzeige/Zurück“ will take you to the next channel.
Hitting the keys „Anzeige/Zurück“ and „Programmieren“ simultaneously will end the tuning program.
Calling up the tuning program will reset error bits that may have been set.
During the tuning operation, a test for end of charging cannot be executed. The battery should
only be connected during the tuning operation. The battery must be suitable for a discharg-
ing/charging current of 1.0A. Protect the battery from overcharging during the tuning operation
of the function "charging".
Immediately disconnect the battery from the charging device when the measurement and the
tuning are finished.
17 Safety Tips for the Operation of the Charger
The charging cable for the batteries should be as short as possible, but have a large cross-section.
When connecting the charging cable to the battery, make sure that the contacting is ok and that there
is not much transition resistance.
For the connection of battery blocks, we recommend charging cables with safety plugs. If you
do not use safety plugs, connect the cables to the adapter first and then to the battery. Risk of
short-circuit!
During the charging operation of a battery, do not change either the operation or the charging
current. Changing these values can cause premature termination or overcharging of the bat-
tery.
Batteries with large internal resistance should not be discharged with high currents. Due to the voltage
drop at the internal resistance, the battery voltage drops quickly and the SMAPL-4P recognizes the
battery as discharged. The measured capacity is then lower than the actual battery capacity.
If battery cells, which were purchased and used as single units instead of block units, are supposed to
be installed at the SMAPL-4P device, you need to ensure that each cell is in the same charging con-
dition and has the same cell capacity. This means that the cells need to be selected. Different
charging conditions of battery cells can damage the cells during charging and discharging and will
most probably make it impossible to recognize the correct end of the charging procedure.
Risk of fire! Risk of explosion!