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

5
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

9
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.

10
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.