Cadex Electronic C7000-C Series User manual

Cadex C7000-C Series
Battery Analyzer
User’s Manual
Cadex C7200, C7400 & C7400ER (C-Series)
Cadex Electronics Inc.
22000 Fraserwood Way
Richmond,BritishColumbia
CanadaV6W1J6
Tel:[phone]Fax[phone]
Web:www.cadex.com E-mail: in[email protected]
ManualP/N:89-307-1016
DocumentNumber PSMAN0048Rev 3
July 2006
PrintedinCanada
Firmware Version 1.00

Safety Notices
i
Trademark
Cadex, BatteryShop, QuickLearn, QuickTest, QuickSort, FlexArm are registered trademarks
of Cadex Electronics Inc. All othertrademarks mentioned herein arethe property of their
respective owners.
Copyright
Copyright © 2006 by Cadex Electronics Inc. All rights reserved. No part of this publication
or the firmware controlling Cadex product(s) may be reproduced, transmitted, transcribed,
stored in a retrieval system, or translated into any language or computer language in any
form or by any means without the express written permission of Cadex Electronics Inc.
Revision Rights
Cadex Electronics Inc. reserves the right to revise thispublicationandmakechanges in
the contents thereof without obligation to notify any person of such changes. Please e-
mail [email protected] for suggestions or corrections.
Disclaimer
While every effort is made to ensure that the information contained in this manual is
accurate and up-to-date, Cadex Electronics Inc. does not warrant or guarantee the
accuracy of the contents of this manual. Further, Cadex makes no warranties, either
expressed or implied, as to themerchantability or fitness for a particular purpose of the
CadexC7000-C Series Battery Analyzers (C7200-C, C7400-CandC7400ER-C) equipment
and/oritsdocumentation.
In no event will Cadex or its officers or employees be responsible for any consequential,
incidental, or indirect damages (including damages for loss or business profits, business
interruption, and the like) arising out of the use or inability to use the Cadex C7000-C
Series Battery Analyzers (C7200-C,C7400-C and C7400ER-C) Battery Analyzer equipment
and/oritsdocumentation.

SafetyNotices
CadexElectronicsInc.C7000-C Series Battery Analyzers .
ii
Safety Notices
Use of Equipment
TheCadexC7000-C Series Battery Analyzers (C7200-C,C7400-C and C7400ER-C) are
designed with adequate safeguards to protect the user from shock and other hazards
when used as specified within this document. However, if the equipment is used in a
manner not specified by this documentation, the protection provided by this equipment
may be impaired. Please read this document and equipment labeling before using the
equipment.
Modification of Equipment
CE, FCC, CSA and other approvals apply only to Cadex C7000-C Series Battery Analyzers
(C7200-C, C7400-C and C7400ER-C) in the factory-authorized configuration. Changes or
modification to the equipment not expressly approved by Cadex will void the approvals and
void the user’s authority to operate the equipment.
Disposal of Waste Electrical and Electronic Equipment (WEEE) in the
European Union
This symbol on the product and package indicates that this product must not
be disposed of with unsorted municipal waste. Instead, it is your responsibility
to dispose of WEEE by handing it over to a designated collection point for the
disposal. The separate collection and recycling of waste equipment will help
conserve natural resources and ensure that it is disposed of in a manner that
protects human health and the environment. For more information about
where you can drop off your waste equipment for disposal, please contact
your local municipal office, waste disposal service or wherever you purchased
the product.

Safety Notices
iii
ROHS Compliance
The C7000-C Series of Battery Analyzer complies with the European Union’s Directive 2002/95/EC,
Restrictions of Hazardous Substances (RoHS)
Radio Interference
This equipment generates, uses and radiates radio frequency energy. If the equipment
is not installed and used in accordance with the instructions in this manual, it may
cause interference with radio communications. The equipment has been tested and
found to comply with the limits for a Class “A” digital device pursuant to Subpart B of
Part 15 of the FCC Rules, which are designed to provide reasonable protection against
such interference when operated in a commercial environment. Operation of this
equipment in a residential area may cause interference, in which case the user is
required to take whatever measures needed to correct the interference, at their own
expense.
EN55011/EN55022 Warning: This is a Class A product according to
EN55011/EN55022. In a domestic environment, this product may cause radio
interference, in which case the user, at their own expense, may be required to take
adequatecorrectivemeasures.
The equipment is designed with adequate safeguards to protect the user from shock
and other hazards when used as specified within this document. If the equipment is
used in a manner not specified by this documentation, the protection provided by the
equipment may be impaired. Please read the documentation and equipment labeling
before using the equipment.
The analyzer may be affected by interference from other devices. If the unit is running
abnormally, please ensure that the analyzer is moved away from any source of radio
interference.

SafetyNotices
CadexElectronicsInc.C7000-C Series Battery Analyzers .
iv
Explosion Hazard
Batteries can burst if treated improperly. Follow these precautions at all times.
ü
Clean battery contacts before servicing. To clean battery contacts, use a lint-free
cotton swab dipped in 100% isopropyl alcohol.
üPress the battery firmly into the adapter to ensure a good connection.
ü
Ensure that the selected C-Code is correct for the chemistry, voltage, and rating of the
battery being serviced.
üObserve battery temperature. Service batteries between 5°C (41°F) and 50°C
(122°F). Stop service if battery becomes very hot. The temperatures cited here are
the battery temperatures, not ambient the ambient temperatures. Fastcharging
outside this temperature range may damage or reduce the life of the battery. Allow
cold batteries to warm up and hot batteries to cool before charging.
û
Do not attempt to charge non-rechargeable and primary batteries such as alkaline,
carbon-zinc,ornon-rechargeable lithium batteries.
ûDo not short the positive and negative battery terminals together at any time.
û
Do not connect leads from one station to another, or to the case. An electrical short
to any point outside the station bypasses the current regulation loop and may blow a
fuse or cause permanent component damage.
ûDo not exceed the battery manufacturer’s recommended charge current and voltage
limits for batteries.
û
Do not remove the adapter from the analyzer while the battery is running.

Safety Notices
v
Charging and Discharging Lithium-ion (Li-ion) Batteries
Lithium-ion (Li-ion) batteries are safe when used as directed. Battery safety cannot be
assured when a battery pack is built with individual cells of an unknown nature with a serial
and parallel connection. Not all Li-ion cells are suited for multi-cell packs. Only cells that
meet tight voltage and capacity tolerances can be used for serial and parallel connection.
Mismatched packs are subject to overcharge resulting in venting with flame and fire. Check
with the cell manufacturer to see if the cells are suitable for multi-cell packs.
In the past, single Li-ion cells were only available to authorized battery manufacturers.
Today, imports are becoming readily available and often fall into the hands of the
inexperienced. While most brand name cells are equipped with an internal cell disconnect
that permanently opens the current path on high pressure, some brands do not provide
this safeguard. Many brands don’t’ use a separator that shuts down the battery when high
temperatures are reached. The internal safety features are omitted for cost reasons.
Please follow the following guidelines when charging and discharging
lithium-ion cell(s) and packs. Failing to follow these rules could result in
venting with flame, explosion, fire and personal injury.
ûNever connect cells in parallel and/or series that are not designed for that purpose. A
cell mismatch may overcharge and vent with flames.
û
Never charge or discharge the battery without connecting a working protectioncircuit.
Each cell must be monitored individually and the current disconnected if an anomaly
occurs.
ûNever leave the battery unattended while under charge or discharge.
ü
Always attach a temperature sensor when charging and discharging the battery. The
temperaturesensormustdisconnectthecurrentonexcesstemperature.
ü
Only connect cells that are matched and have the identical state-of-charge.
ü
Pay special attention when using an unknown brand. Not all brands contain intrinsic
safety features that protect the cell when stressed.
üDuring experiments, place the test battery into a well-ventilated fireproof container.

SafetyNotices
CadexElectronicsInc.C7000-C Series Battery Analyzers .
vi
Shock Hazard
The Cadex Battery Analyzer contains high-voltage circuits, and can
pose a shock hazard when the upper cover is removed. Do not attempt
to perform any service procedures on the analyzer other than
replacement of the external fuse (see Chapter 11, Services and
Upgrades,page 100).
ü
To reduce the risk of electrical shock hazard, service batteries only when they are
removed and disconnected from their end-use equipment.
ü
Use the analyzer only as specified in the documentation. Other uses may impair the
protectionprovided by the unit.
üUse only a grounded AC outlet to power the analyzer.
ü
Before attempting any internal service, remove all batteries from the battery stations,
turn the analyzer off and disconnect the power cord from the wall socket. Wait a few
minutes before opening the cover.
üReplace fuses only with fuses of the same type and rating (seeReplacing the Primary
(Input) Fuse,page100).

Warranty&Service
vii
Warranty & Service
Cadex Electronics Inc. warrants the Cadex Battery Analyzer against defective materials and
workmanship for a period of two (2) years from the original purchase date.
The warranty does notcover:
•Damage caused by abusive operation, negligence, accident, or improper installation.
•Damage caused by an attempted repair not authorized by Cadex.
•Cosmetic damage caused by normal wear and tear.
•Damage from external causes such as leakage spills, power fluctuations, power failure
or inadequate shipping.
•Product received without the appropriate model number, serial number, or safety
markings.
•Products used for rental purposes.
Warranty Service
Before sending the unit for service, contact Cadex Technical Support. If the product
requires warranty service, the representative will provide a Return Authorization form or
number and the location of the nearest service center.
•Ship the product to the service center with freight, insurance, and customs duties
prepaid. The Return Authorization form must be included to obtain warranty service.
•Ensure that the unit(s) is properly packed before shipping, preferably in the original
Cadex boxes. Damage caused in transit due to improperly packed items is not
covered under warranty.
•Products returned from warranty service are shipped with freight prepaid by Cadex.
Non-Warranty Repairs
Before sending the unit in for service, contact Cadex Technical Support at 1 800 565-
5228. If the analyzer is not covered by warranty, the representative will provide the
contact information for the nearest service center. Contact the service center directlyto

Warranty &Service
CadexElectronicsInc.C7000-C Series Battery Analyzers .
viii
arrange to send the product in for service. A Return Authorization form or number will be
provided only if the product is returning to the Cadex Head Office.
•Ship the product to the service center with freight, insurance and customs duties
prepaid.
•Ensure that the unit(s) is properly packaged before shipping.
Note Cadex Electronics Inc. and Cadex authorized service centers require a Purchase
Orderorwrittenauthorizationtoproceedwithrepair.

TableofContents
ix
Table of Contents
Chapter 1 Overview............................................................................................1
ProductFeatures...........................................................................................................................................1
ConnectingtoCadexBatteryShop™.........................................................................................................2
Chapter 2 Getting Started....................................................................................1
Contents of the Box.......................................................................................................................................1
Using this Manual..........................................................................................................................................1
Conventions....................................................................................................................................................3
Direction Keys............................................................................................................................................3
Symbols......................................................................................................................................................3
Abbreviations and Acronyms..................................................................................................................4
Commonly Used Terms............................................................................................................................5
Chapter 3 Operating Principles.............................................................................7
Components....................................................................................................................................................7
Front LCD Display Interface.......................................................................................................................10
Lights (LEDs)...........................................................................................................................................12
Menu Structure............................................................................................................................................13
Battery Adapters..........................................................................................................................................14
Chapter 4 Basic Battery Service..........................................................................17
Chapter 5 Battery Service Programs....................................................................21
Basic Programs............................................................................................................................................21
Auto...........................................................................................................................................................22
Charge......................................................................................................................................................23
Prime.........................................................................................................................................................23
QuickSort..................................................................................................................................................24

Table of Contents
CadexElectronicsInc.C7000-C Series Battery Analyzers .
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Advanced Programs....................................................................................................................................25
SelfDCH (Self-Discharge Test)...............................................................................................................26
Life-Cycle...................................................................................................................................................27
DCHOnly (Discharge Only).....................................................................................................................28
ExtPrime (Extended Prime)...................................................................................................................29
OhmTest....................................................................................................................................................30
RunTime....................................................................................................................................................31
Boost.........................................................................................................................................................33
Learn.........................................................................................................................................................34
Q-Learn(QuickLearn)...........................................................................................................................36
QuickTest™.............................................................................................................................................38
Custom 1, 2, 3, and 4............................................................................................................................39
Battery Service Times..................................................................................................................................40
Chapter 6 C-Codes (Configuration Codes).............................................................41
Basic C-Code Parameters...........................................................................................................................42
Program....................................................................................................................................................42
Target Capacity........................................................................................................................................43
Chemistry..................................................................................................................................................43
Battery Voltage (Volts)..........................................................................................................................43
Battery Rating (mAh)..............................................................................................................................44
C-Code Setup Name................................................................................................................................44
ScaledC-Code..........................................................................................................................................44
C-Code Matrix...........................................................................................................................................45
LockedC-Code.........................................................................................................................................45
ExtendedC-Code Parameters....................................................................................................................45
Charge Rate..............................................................................................................................................45
Discharge Rate........................................................................................................................................45
Trickle-Charge Rate (NiCd and NiMH only).........................................................................................46
Recondition Discharge Rate (NiCd and NiMH only)...........................................................................47
Temperature Sensing.............................................................................................................................47
Negative Slope (NiCd and NiMH only).................................................................................................47
End of Discharge.....................................................................................................................................48
End of Recondition (NiCd and NiMH only)..........................................................................................49
Charge Method (NiCd and NiMH only).................................................................................................49
Maximum Standby Voltage (SLA and Li-ion only)..............................................................................49

TableofContents
xi
Maximum Charge Voltage (SLA and Li-iononly)...............................................................................50
End of Charge (SLA and Li-ion only)...................................................................................................50
Default Extended C-CodeSettings............................................................................................................51
Default Extended C-Code for NiCd Batteries......................................................................................51
Default Extended C-Code for NiMH Batteries.....................................................................................51
Default ExtendedC-Code for SLA Batteries........................................................................................52
Default Extended C-CodeforLi-ion Batteries.....................................................................................52
Extended C-CodeSettingsforSpecialCases..........................................................................................53
IntrinsicallySafeBatteries.....................................................................................................................53
HawkerSLABatteries.............................................................................................................................53
GellSLA Batteries....................................................................................................................................53
ManagingC-Codes.......................................................................................................................................54
SelectaC-Code.......................................................................................................................................54
Display a C-Code.....................................................................................................................................54
Change Target Capacity or Program...................................................................................................54
Create or Edit a C-Code.........................................................................................................................55
Add or Edit the C-Code Setup Name....................................................................................................56
Reset Extended C-Code to the Default settings.................................................................................57
DeleteaC-Code.......................................................................................................................................57
CopyaC-Code (including QuickTest matrix)......................................................................................57
CopyallC-Codes (and matrices) from One Adapter to Another.....................................................58
Chapter 7 System Setup And Options...................................................................59
Date and Time..............................................................................................................................................59
Company Name............................................................................................................................................59
Sound Options..............................................................................................................................................60
VoltageDisplay............................................................................................................................................61
Battery Service Counter..............................................................................................................................62
Connecting to BatteryShop or a Printer..................................................................................................63
ConnectingtoBatteryShop...................................................................................................................63
Connecting Other Devices to the Serial Port......................................................................................64
Security..........................................................................................................................................................66
Security Level Functions........................................................................................................................66
Program Parameters..................................................................................................................................68

Table of Contents
CadexElectronicsInc.C7000-C Series Battery Analyzers .
xii
Starting Battery Service.........................................................................................................................68
PerforminganAutomaticOhmTest......................................................................................................69
Optimizing Charge Time or Capacity....................................................................................................70
Termination Condition on dT/dt............................................................................................................71
SavingProgramandTargetCapacitySettings...................................................................................71
Resuming Service After Power Failure.................................................................................................72
Short Key Functions................................................................................................................................74
Chapter 8 Reports and Labels............................................................................75
Automatically Print Reports or Labels (Auto-Print)................................................................................77
Automatic Report or Label printing......................................................................................................77
Manually Print Reports and Labels...........................................................................................................78
Chapter 9 Events and Data Logs........................................................................80
Logging Events.............................................................................................................................................80
Setting up the Event Log.......................................................................................................................80
Using the Event Log................................................................................................................................81
Logging Data................................................................................................................................................82
Sample text strings.................................................................................................................................85
Setting up the Data Log.........................................................................................................................86
Using the Data Log.................................................................................................................................88
Chapter 10 Custom Programs.............................................................................91
Cycle 1 and Cycle 2......................................................................................................................................92
Test................................................................................................................................................................93
IF Statements...........................................................................................................................................93
THEN andELSEStatements..................................................................................................................94
Phase Done..................................................................................................................................................95
Creating and Editing Custom Programs...................................................................................................96
Sample Custom Program.......................................................................................................................97
Chapter 11 Services and Upgrades....................................................................100
Replacing the Primary (Input) Fuse.......................................................................................................100
Upgrading theFirmware..........................................................................................................................101

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Resetting the System................................................................................................................................101
Cleaning the Analyzer...............................................................................................................................102
Chapter 12 System Calibration..........................................................................103
Calibrating Voltage....................................................................................................................................103
Servicing the Voltage Calibration Adapters......................................................................................103
Calibrating Adapters..................................................................................................................................104
Adapter Calibration Values..................................................................................................................105
AcceptableCalibrationValues for New Adapters.............................................................................105
Chapter 13 Solving Problems and Getting Help ....................................................106
Troubleshooting.........................................................................................................................................106
Manual Updates and Other References.................................................................................................110
Technical Support......................................................................................................................................110
Appendix A Messages and Warnings................................................................112
Non-Coded Messages...............................................................................................................................113
ByCode.......................................................................................................................................................114
By Detailed Message................................................................................................................................118
Appendix B Charge Algorithms........................................................................135
NiCd and NIMH batteries..........................................................................................................................135
SLA and Li-ionbatteries...........................................................................................................................137
Appendix C Specifications...............................................................................139
Hardware.....................................................................................................................................................139
Appendix D Parts and Accessories...................................................................141

Chapter 1 Overview
The CadexC7000-C Series of Battery Analyzers includes the C7200-C, C7400-C and
C7400ER-C.
Product Features
•Servicesrechargeablenickel-cadmium (NiCd), nickel-metal hydride (NiMH), sealed
lead-acid (SLA), lithium-ion (Li-ion) batteries and lithium-polymer (Li-Poly). In this
manual “Li-ion” refers to both lithium-ionandlithium-polymer batteries.
•Programmable with a total of 17 programs including:
oFour basic programs: Auto; Charge; Prime and QSort.
oTen advanced programs
oFour user-programmable programs.
•Battery Adapters allow convenient interface to all battery types. Over 1000 custom
Battery Adapters are available and specialty adapters can be ordered.
•Adapters can be programmed with 10 C-Codes. C-Codes contain the chemistry,
voltage and rating. Custom adapters are provided with C-Codesofthemostcommon
batteries.
•Amenu-driven interface with messages in plain English and status lights.
•Prints battery service reports and battery service labels.
•Analyzerscan be connected toa PC and operatedwithBatteryShop™software.
•BatteryShop™ software allows automated operation and networking of multiple
analyzers.

CadexElectronicsInc.C7000-C Series Battery Analyzers .
2
Connectingto CadexBatteryShop™
BatteryShop™ is a powerful Windows-based battery management software tool that
allows automation of the Cadex battery analyzer functions to increase productivity.
•Provides control and monitoring of large-scale battery services by connecting up to
120 Cadex analyzers to service up to 480 batteries simultaneously.
•Provides easy access to a database of information for over 1000 batterymodels,
including C-Code settings. Even a novice user can perform a variety of tests and
programs.
To find out how Cadex BatteryShop™ can enhance battery maintenance, contact Cadex Electronics
Inc (seeConnecting to BatteryShop™, page 63).

Chapter 2 Getting Started
Contents of the Box
•The Cadex Battery Analyzer package includes these items:
•One Cadex Battery Analyzer
•One IEC320 Power Cord (North American Version)
•One User’s Manual
Using this Manual
TheCadex C7000-C Series Battery Analyzer User’s Manual contains the concepts,
procedures and other information necessary to operate the Cadex battery analyzer
equipped with firmware version 1.00.
Chapter 1-Overviewprovides basic information about product features and connecting
the Cadex analyzer to a computer.
Chapter 2 -GettingStarted goes through the items that are included with the analyzer and
how the manual works. It also explains common symbols, abbreviations, acronyms and
commonly used terms.
Chapter 3 -Operating Principlesprovides information about the Cadex analyzer,
components, display screen, interface and how to use Battery Adapters with the analyzer.
Chapter 4 -BasicBatteryServiceprovides the basic procedures for servicing a battery.
Chapter 5 –Battery Service Programs provides detailed information about all the battery
service programs.

CadexElectronicsInc.C7000-C Series Battery Analyzers .
2
Chapter 6 -C-Codes(ConfigurationCodes) provides detailed information on selecting and
managing battery parameters (C-Codes).
Chapter 7 -System Setupand Options describes the analyzer’s menu system and
provides information about modifying the operation of the analyzer to suit particular
needs. Refer to this chapter when connecting devices to the analyzer (i.e. printers or a PC
with BatteryShop™ software).
Chapter 8 -ReportsandLabels provides information about printing battery service reports
and labels.
Chapter 9 -Events and Data Logsdescribes methods of obtaining and graphing detailed
voltage/current/temperature/impedance analysis.
Chapter 10-Custom Programsdescribes how to create user-defined programs for
specialized or advanced applications.
Chapter 11-Services and Upgradesprovides information on servicing the Cadex analyzer,
including upgrading the firmware.
Chapter 12-System Calibrationprovides instructions for calibrating the analyzer.
Chapter 13-Solving Problems and Getting Help provides solutions for common problems
that may occur when operating the analyzer.
Appendix A-Messages and Warningsprovides detailed information on fault codes and
messages that appear on the display.
AppendixB -Charge Algorithms describes the charge and discharge algorithms.

3
Conventions
Typeface Meaning
SMALLCAPS Menu options to select
Default settings
BOLD SMALL CAPS
Names of keys on the battery analyzer
Italics Emphasized words
Bold & Italic References to other sections in this manual
Direction Keys
Direction keys are represented in this manual as follows:
UP =5
DOWN =6
LEFT = 3
RIGHT =4
Symbols
Caution
Information that, if ignored, can result in damage to the Battery
Analyzer, Battery Adapters or the battery.
Potential shock hazard.
Potential explosion hazard.

CadexElectronicsInc.C7000-C Series Battery Analyzers .
4
Abbreviations and Acronyms
Abbreviation Name or Term
16k adapters These adapters have the extra memory to handle matrices for
QuickTest™. These adapters are marked “16K” on the rear
label.
AWG
American wire gauge (a U.S. wire sizestandard)
LCD Liquid Crystal Display (also calleddisplay)
LED Light Emitting Diode (also calledlight)
Li
Lithium-ionandLithium-polymer battery chemistry
Li-ion
Lithium-ion battery chemistry
Li-polymer Lithium-polymer battery chemistry. This chemistry is treated in
thesamewayasLi-ion.
mA Milliampere
mAh Milliampere hour
mOhm Milliohm
NiCd
Nickel-cadmium battery chemistry
NiMH
Nickel-metal-hydride battery chemistry
OEM
Originalequipmentmanufacturer
PC
IBM compatible personal computer
RF
Radio frequency
P/N
Part number
SoC State of Charge
SoH
State of Health
SLA Sealed Lead Acid battery chemistry
USB
Universal Serial Bus