Cadex C4000 SERIES User manual

ADEX 4000 SERIES
SATTERY ANALYZER
USER'S MANUAL
ADEX ELE TRONI S IN .
111- 7400 MacPherson Ave.
Burnaby, B.C. Canada V5J 5B6
Tel [phone]
Fax [phone]
Toll Free 1-800-565-5228

ARRANTY
DISCLAIMER
REVISIONS
TRADEMARK
COPYRIGHT
ADEX ELE TRONI S IN . warrants the adex 4000
Battery Analyzer against defective materials and workmanship
for ONE YEAR from the purchase date. Service is available by
returning the unit to the manufacturer. The manufacturer will
assume one half of the shi in cost.
The information contained herein is accurate to the best of our
knowledge and belief. Since the conditions of handling and use
are beyond our control, we make no guarantee on results if
equipment is improperly handled or misused.
CADEX ELECTRONICS INC. reserves the right to revise this
publication and make changes in the contents hereof without
obligation to notify any person of such changes.
CADEX is a registered trademark of ADEX ELE TRONI S
IN .
opyright (c) 1993 by CADEX ELECTRONICS INC. All rights
are reserved. No part of this publication or the firmware
controlling the ADEX 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, electronic, mechanical, magnetic, optical,
chemical, manual or otherwise without the written permission of
ADEX ELE TRONI S IN . 111- 7400 MacPherson Ave.
Burnaby, B. ., anada V5A 3G1.
Document MU 49503
Firmware Versions V3.00 &V3.00P
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DO'S AND DONT'S
Do: Connect the C4000 Battery Analyzer to the correct line voltage.
The operating voltage is indicated on the instrument label on bottom of
the unit.
Recharge NiCd batteries between SoC and 3S 0C (410F and 96
oF). Fast-charging outside this temperature range may cause damage
to the battery.
Note Allow cold battery to warm up before charging;
Allow hot battery to cool before charging.
Use the correct battery for which the adapter is configured to.
Failure to do so may cause damage to the battery. Battery parameters
can be verified by pressing the appropriate Display Key when the
Station is empty.
Don't:
Clean battery contacts before servicing
Do not short 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 will cause a fuse to blow. A shorted battery will
cause no harm.
Do not transmit in close proximity. The C4000 is equipped with high
frequency switch-mode power supplies. The advanced circuits may be
sensitive to RF interference.
Rule of Thumb: The following distances should be observed when
transmitting:
0.5 Watt of transmit power 0.3m (1')
1 Watt of transmit power 0.6m (2')
2 Watts of transmit power 1.2m (4')
4 Watts of transmit power 204m(8')
Do-not restrict the airflow of the analyzer. Leave the fan opening
clear. Fan operation is automatic.
Do not expose LCD to direct sunlight.

WARRAN Y
DO'S AND DON' S
able of Contents
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CHAP ER 1 - IN RODUC ION 1-1
1. Overview of Cadex C4000 1-2
2. Getting Started 1-3
CHAP ER 2 - BASIC OPERA ION 2-1
1. Power Up 2-2
2. Analyzing Batteries 2-3
3. Evaluation of Battery Results 2-6
CHAP ER 3 - PROGRAMS ARGE CAPACI Y 3-1
1. Application Table 3-2
2. Prime 3-3
3. Charge 3-5
4. Auto 3-6
5. Custom 3-8
6. Standby 3-8
7. Target Selector 3-9
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8. Calculation of Target Capacity 3-10
CHAP ER 4 - S A US INDICA ORS 4-1
1. LED ndicators 4-2
2. Audible Tone Signals 4-3
3. Status ndicator Tables 4-4
4. Display (LCD) 4-6
5. Display Messages 4-8
CHAP ER 5 - FAUL CODES 5-1
1. Application Tables 5-2
2. Correctable Faults 5-4
3. Voltage Faults 5-6
4. Timing Faults 5-9
5. Temperature Criteria 5-10
6. Electrical Limitations 5-11
7. Corrected Faults 5-12
CHAP ER 6 - BA ERY ADAP ERS 6-1
1. Battery Adapter Styles 6-2
2. nstallation 6-4
3. Battery Adapter Errors 6-5
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able of Contents
CHAP ER 7 - PROGRAMMING BA ERY ADAP ERS 7-1
1. C-Code Definition 7-2
2. C-Code Structure 7-3
3. Quick View of Battery Parameters 7-4
4. Menu Tree 7-4
5. Menu Functions 7-6
CHAP ER 8 - U ILI IES 8-1
1. Reset to Factory Default 8-2
2. Copy Settings 8-3
3. Set Password 8-3
4. Station Target Capacity 8-5
5. Company Name 8-5
6. Calibrate Station 8-6
CHAP ER 9 - CUS OM PROGRAMS 9-1
1. Setting up Custom Program 9-2
2. Typical Applications 9-5
3. Code Definition 9-8
4. Program Variations 9-11
CHAP ER 10 - OP IONS 10-1
1. Data Retention 10-2
2. DatelTime 10-3
3. Printer Interface 10-4
4. Print Formats 10-5
5. Computer Interface 10-7
6. Event Log 10-8
CHAP ER 11 - C-CODE ABLES 11-1
1. Battery Type 11-7
2. Number of Cells 11-8
3. Battery Rating 11-9
4. C-Rate 11-11
5. Trickle Charge 11-13
6. Recondition Discharge 11-14
7. Capacity Offset 11-15
8. Temperature Sensor 11-17
9. Negative Slope 11-17
10. End of Discharge 11-18
11. End of Recondition (NiCd, NiMH) 11-19
12. charge method 11-19
13. Float Voltage (SLA) 11-20
14. Voltage Limit (SLA) 11-21
15. Topping Charge Plateau (SLA) 11-22

CHAP ER 12 - DIAGNOS ICS
. RAM/Clock/LCD Check
2. Start-up Messages
CHAP ER 13 - SERVICE
. Static Precautions
2. Replacing Fuses
3. Replacing Back-up Battery
4. Replacing the EPROM
5. Installing OPTION-P
6. Motherboard Layout
CHAP ER 14 - SPECIFICA IONS
APPENDIX
GLOSSARY
INDEX
able of Contents
12-1
2-2
2-3
13-1
3-2
3-2
3-3
3-5
3-6
3-8
14-1
A-1
G-1
1-1
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HAPTER 1
HAPTER 1
INTRODU TION
1-1
INTRODU TION

ntroduction
. Overview of Cadex C4000
-ON-OFF S .
witch on the back panel
Liquid Crystal Display (LCD)
Station without Battery Adapters
Program Selector Switch
Run
Read~
Fail'Y~ LED Indicators (0 ne group per Station)
1-2
Menu Key
Display Key
Target Selector S .
witch

•
ntroduction
2. Getting Started
Plug in and turn on Plug and on-off switch are located on the back of the
4000.
Select the program The Program Selector Switch is on the front of the
analyzer.
elect: • PR ME for new or stored batteries prior to use
• CHARGE for fast-charging only (no analysis)
• AUTO to service batteries with unknown conditions.
Set Target Selector Target Selector switch is on the right hand side of the
front panel.
elect: • 80% for most requirements
• 90% or 100% for more demanding applications
• 60% or 70% for less critical applications.
•
Battery Adapter
nsert the Battery
When battery servicing
is complete
Display
Configured Battery Adapters are pre-programmed for
specific battery types. To reprogram, refer to CHAPTER
7 - PROGRAMM NG BAT ERY ADAPTERS .
When contact is made, a "Beep" is heard and the
yellow RUN LED comes on.
The Green READY LED is on if the battery has
successfully completed the program.
The red FA L LED comes on if the battery has failed to
meet the specified requirement.
Global The status of each battery is shown on the top line of
the LCD display. The lower section of the LCD shows
the relative voltage of each battery in a line-graph form.
Detailed Detailed information about the battery can be seen by
pressing the corresponding Display Key.
•
After completion of the
program Record the test results. The battery may be removed or left in the analyzer until needed. When the battery is
removed, the test results are canceled .
1-3

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HAPTER 2 BASI OPERATION
HAPTER 2
ASIC OPERATION
2-1

asic Operation
1. Power Up
Start-up messages
Global Display
attery Adapters
Before connecting the C4000, check for the correct line
voltage. The line voltage label is located on the bottom
of the unit. The on-oft switch is on the back panel.
When the power is turned on, the display (LCD)
message briefly reads:
,gM9! "(ll~'. .B.~ .eEElmgrff !~nISi . . :):;i }:;:),:::::::
:MeBstQN#::alQOfR:::::n::QIAGNQSTIGS}PA$$}~;tjj: :::',::::: .
The display then shows the Target Capacity setting
briefly, then switches to the Global Display. If the
Battery Adapters are installed in Stations 1, 2 & 3, but
not 4, the display shows:
The analyzer is now ready to service batteries in
Stations 1, 2 & 3.
Note It is advised to install a Battery Adapter in all
vacant stations. This prevents damage by static
electricity.
The batteries interface with the C4000 through Battery
Adapters. You can install, replace and reprogram the
adapters while other batteries are being serviced. For
more details on the various types of Battery Adapters,
refer to CHAPTER 6 - BATTERY ADAPTERS.
2-2

Basic Operation
. Analyzing Batteries
Set Program Before servicing a battery, select the desired program
(refer to CHAPTER 3 - PROGRAMS & TARGET
CAPACITY).
Set Target Capacity Select the Target Capacity. If you are not certain what
setting to use, select 80%. For more detail. refer to
CHAPTER 3 - PROGRAMS & TARGET CAPACITY.
Verify correct battery
setting Check that the Battery Adapter is set to the correct
battery parameters. With the display indicating EMPTY,
press the appropriate Display Key. The display now
indicates the setting of the Battery Adapter in question.
STATIQII 4
ZOfE
VQ.TAGE
Battery rating
STATION 3
STATION
Battery voltage
NiCd (STD.); AUTO-SCALED
1 CELLS (15.00V); 4000 mAh
Z0fE1
EN) OF DISCHARGE
SHORT
2
1
2
3
4
EN) OF
Number of cells
C4000 Battery Parameter Display For A NiCd Battery
Station number
STAros
Q.TACE
Figure 2.1
Viewing different
display frames Since not all information can be shown on one display
frame, the battery parameters are contained in several
frames. The basic information is shown in the first
frame. followed by more detailed definitions in the
subsequent frames.
To step through the frames, press the appropriate
Display Key several times. For more details on the
display, refer to CHAPTER 4 - STATUS INDICATORS.
Reverse polarity and
short protection The C4000 is electronically protected against reverse
connection and short circuits. No harm is done to the
equipment if the battery has a short or is accidentally
connected in reverse polarity .
2-3

asic Operation
"Dead" batteries
Connect battery
rogram Sequence
RIME and AUTO
If the battery to be serviced has no voltage reading, an
initial brief charge by a designated charger is required.
The C4000 will not start the program if battery voltage is
not detected.
After selecting the program and target capacity, you are
now ready to connect the battery. Battery connection is
acknowledged with a beep tone. While the battery is
being serviced, the yellow RUN LED is on.
The program starts with discharge, followed by charge.
If the battery has no capacity (no energy), the program
starts with charge.
CHARGE On the CHARGE program, the battery commences with
charge. No discharge is applied.
Method of battery
analysis
Definition of battery
capacity
It is not possible to obtain an immediate capacity
reading by inserting a battery. The capacity is derived
by discharging the battery at a calibrated current to the
end-of-discharge threshold voltage. The elapsed time
is measured and displayed as the derived battery
capacity.
When the batt-ery starts discharging, the Global Display
reads "CAP: %". The flashing capacity figure indicates
that the number is counting upwards. When the battery
voltage has dropped to the end-of-discharge threshold,
the discharge terminates. The readings stop flashing
and the true capacity is then known.
Several capacity readings may be shown. If more than
five discharge-charge cycles have been applied, the
2nd, 3rd, 4th and 5th readings indicate the latest four
capacities. The first reading (Residual Capacity)
remains visible at all times.
The capacity reading is the percentage of the
manufacturer's battery rating. The rating is measured in
mAh (milliampere per hour). For more information, refer
to CHAPTER 11, "3. Battery Rating".
2-4

Interrupt
Changing control
settings
Full Load
asic Operation
Example A fully-charged battery rated at 1000mAh
must be able to provide a discharge current of 1000mA
for one hour. If the battery can provide this current for
that time, the derived capacity is 100%. If the battery
can only provide the current for 30 minutes, the capacity
is 0%.
When a battery is disconnected while in service, a beep
tone sounds. If the battery is reconnected within five
seconds, service resumes without interruption. If not re-
connected, the Station resets to EMPTY in five seconds
and the battery data is lost.
Pressing the Display Key during the five-second
interrupt resets the Station immediately.
Changing the Program Selector while a battery is
serviced does not affect the program in progress. To
restart with a different program, remove the battery and
press the appropriate Display Key to reset the station.
Select the new setting and re-insert the battery .
Changing the Target Selector during service is possible.
Since the Target Capacity setting is read at the end of
each discharge, the effect of changing the setting will
depend on the battery's position in the program
sequence at the time of change.
Batteries requiring charge or discharge power in excess
of the unit's capacity are put on a waiting queue. The
display message for batteries on hold reads WAITING.
When the charge or discharge power becomes
available, a battery that is waiting resumes service.
Note Energy from discharging batteries is used to
charge the other batteries .
2-5

asic Operation
3. Evaluation of attery Results
Global Display The status of each battery in service is shown on the
first line of the display. The average cell voltages are
displayed in bar-graph form on the second line.
Detailed Display Pressing the Display Key allows you to get more detail
on the battery services. Several capacity figures are
shown on multi-cycle programs. Average cell voltage
and battery Fault Codes (if present) are also displayed.
For more information, refer to CHAPTER 5 - FAULT
CODES.
Evaluation by LEDs
RIME and AUTO
CHARGE
Evaluation by display
Each Station is equipped with RUN, READY and FAIL
LEOs. During service, the RUN LED is on. When the
program is completed and the battery has met or
exceeded the Target Capacity, the READY LED lights
up. If the Target Capacity has not been reached, the
FAIL LED comes on. A flashing FAIL indicates incorrect
battery voltage due to defective cells.
Since no capacity reading is taken on the CHARGE
program, the READY LED blinks when the battery is
fully charged. For a summary of LED signals, refer to
CHAPTER 4-STATUS INDICATORS.
In addition to the RUN, READY and FAIL LEOs, the
C4000 is equipped with an aO-character display.
2-6

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HAPTER 3 PROGRAMS
TARGET APA ITY
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HAPTER 3
PROGRAMS & TARGET APA ITY
3-1

rograms Target Capacity
Introduction
Selection
Indicators
he CADEX C4000 features user-selectable programs
with decision-making capabilities that evaluate the bat-
tery and apply an appropriate service to improve or
restore a battery. his section explains the different
applications, and recommends the best choice of
program and target capacity settings to be used.
he programs are selected through the Program Selec-
tor Switches on the front panel of the C4000. You can
set each Station to a different program.
mportant Select the correct program before connecting the
battery. Changing the setting after the battery is
connected will have no effect.
While the program is running, the RUN LED for that
Station is on. he program is completed when the RUN
LED turns off and either the READY or FAIL LED comes
on (refer to CHAP ER 4-S A US INDICA ORS).
•
1. Application Table
able 3.1 summarizes the typical applications of
program setting.
RIME CHARGE AUTO
WHEN O USE I Prepare new batteries for Fast-charge only. Restore batteries affected
field use. by "memory".
Condition batteries that op-up charge of Identify marginally
have been in storage. partially discharged performing batteries.
batteries.
Verify battery condition Weekly or monthly routine
to support a warranty battery maintenance.
claim.
IME (in hours) NiCd
l
to 10 1. 2. to 10
NiMH2 10 to 20
3
to 18
SLA3 40 to 80 10 20 to 40
able 3.1
( ime at Default C-Rate of 1C.
z ime at Default C-Rate of 0.5C.
3 ime at Default C-Rate of 0.3C charge and 0.1 discharge.
3-2
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rograms &Target Capacity
2. rime
When to use it
rogram time
How it works
Prepare new batteries for field use.
Condition batteries that have been in storage.
Verify battery condition to support warranty
claim.
PRIME is used to condition new batteries prior to use. A
new (or stored) battery may require several charge/
discharge cycles until peak performance is reached.
The time required may vary depending on the battery
type. At a C-Rate of 1C, the program time is:
iCd 5 to 10 hours
iMH 10 to 20 hours
SLA 40 hours or longer.
For more information on C-Rates. refer to
CHAPTER 11 - C-CODE TABLES .
The battery first discharges to the end-of-discharge
threshold voltage and recharges. A second discharge-
charge cycle is applied and its resulting capacity is
compared with the first reading.
%improvement
Very low-capacity
battery
If the improvement is 5 %or higher, a further charge-
discharge is applied. This cycle is repeated until the
improvement is less than 5 %. At this percent, it is
assumed that the battery has reached the peak
performance. The program concludes with a final
charge.
A battery that cannot obtain a capacity of 5% is cycled
four times. This feature allows additional priming cycles
on a new battery that cannot accept a full charge at
first.
Empty battery A fully-discharged battery will proceed with charge
immediately.
Trickle charge After the service is completed, trickle charge is applied.
If one or more cells within the battery are bad then the
battery fails. No trickle charge is applied.
3-3

rograms &Target Capacity
Indicators
ights • READY if the battery meets or exceeds the Target
Capacity.
FAIL if the battery cannot meet the Target Capacity .
Display When the program is successfully completed, the Global
Display shows the Final Capacity reading. By pressing
the appropriate Display Key, the display shows
additional information. If the battery failed, a Fail Code is
shown (refer to CHAPTER 5 - FAULT CODES).
The Global Display shows a maximum of five capacity
readings on PRIME. The first reading is the Residual
Capacity, the middle readings are the Transitional
Capacities and the last is the Final Capacity.
• Residual Capacity is the charge that is left before
• Transitional Capacities are the middle readings.
• Final Capacity represents the final reading.
3-4

rograms Target Capacity
3. Charge
When to use it
rogram Time
How it works
Top-up partially charged batteries.
Serves as a fast-charger.
The time required may vary depending on the battery
type. At a C-Rate of 1C, the charge time is:
iCd 90 minutes typically
iMH 3 hours typically
SLA 10 hours typically.
For more information on C-Rates, refer to CHAPTER 11
- C-CODE TABLES.
CHARGE fully charges a battery. After full charge is
reached, trickle charge is applied to maintain full charge
capacity. Full charge is detected by the Negative Slope
method. Poorly matched cells that do not produce an
adequate slope are timed out by the Plateau Timer. The
combination of these two methods provides an accurate
and safe means to terminate the fast-charge. No
temperature sensing is required if the battery is serviced
within the recommended temperature range.
Partially or fully charged The analyzer recognizes a partially or fully charged
batteries battery. On these batteries, the charge time is
shortened accordingly. A shorter charge time also
applies to batteries that have a low capacity.
Reverse Load Charge Reverse Load Charge is used to promote the
Method recombination of gases generated during the fast-
charge of the NiCd and NiMH batteries. The Reverse
Load Charge intersperses discharge currents between
the charge pulses. The results are a cooler and more
effective charge than conventional chargers. In addition,
the "memory" phenomenon is reduced as the battery is
stimulated while charging. Refer to "4. Auto" for
definition of memory.
Note Reverse Load Charge is used for all charge and
trickle charge functions .
3-5