Cadex C7000 User manual

C7000 & C7000ER
Battery Analyzer
User’s Manual

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C7000 & C7000ER Battery Analyzer
User’s Manual
Disclaimer
Whileeveryeffortismadetoensurethattheinformationcontainedinthismanualisaccurate
andup-to-date,CadexElectronicsInc.doesnotwarrantorguaranteetheaccuracyofthe
contentsofthismanual.Further,Cadexmakesnowarranties,eitherexpressedorimplied,asto
themerchantabilityorfitnessforaparticularpurposeoftheC7000andC7000ERBattery
Analyzerequipmentand/oritsdocumentation.
Inno event will Cadex or its officersor employees be responsible foranyconsequential,
incidental,orindirect damages (including damages for loss of business profits, business
interruption,andthelike)arisingoutoftheuse or inability to use the C7000 and C7000ER
BatteryAnalyzer equipment and/oritsdocumentation.
Year 2000 Compliance
Allfunctions and performance of the Cadex C7000 andC7000ERBatteryAnalyzersare
independentof the date stored in the analyzer.Therefore,allfunctions and the performance of
theC7000andC7000ERBatteryAnalyzersare not affectedbydatesduringandaftertheyear
2000.
Cadex Electronics Inc.
22000Fraserwood Way
Richmond,British Columbia
Canada V6W1J6
Tel: [phone] Fax: [phone]
Web:www.cadex.com Email:[email protected]
Copyright
Copyright©2000byCadex Electronics Inc. All rights reserved. No part of this publication or the
firmwarecontrollingCadex product(s) may be reproduced, transmitted, transcribed, stored in a
retrievalsystem,or translated into any language or computer language in any form or byany
meanswithoutthe express written permission of Cadex Electronics Inc.
CadexElectronicsInc.reservestherighttorevisethispublicationandmakechangesinits
contentswithoutobligation to notify any person of such changes.
Trademark
CADEXisa registered trademark of Cadex Electronics Inc. All other trademarksmentioned
hereinarethe property of their respective owners.
89-207-1001Rev8 March, 2000 Printed inCanada i

ii C7000& 7000ER Battery AnalyzerV3.5
1 Overview.............................................................................. 1
Product Features ............................................................................................ 1
What’s New in the C7000 V3.5 firmware ........................................................2
Firmware Upgrade: Resetting the System ......................................................3
Connecting to BatteryShop™ ......................................................................... 3
Peripherals ...................................................................................................... 4
2 Getting Started.................................................................... 5
Contents of Box ..............................................................................................5
About this Manual ........................................................................................... 5
Conventions .................................................................................................... 5
Symbols .......................................................................................................... 6
Abbreviations and Acronyms ..........................................................................6
Commonly Used Terms................................................................................... 7
3 Operating Principles........................................................... 8
Components ................................................................................................... 8
Option Boards ................................................................................................. 9
Components ............................................................................................... 9
Battery Adapters ........................................................................................... 10
Special Handling Tip for Smart Cable Adapters ....................................... 11
User Interface ............................................................................................... 12
Display ...................................................................................................... 12
Menu ......................................................................................................... 14
Commands ............................................................................................... 15
Function Keys ........................................................................................... 15
Lights (LEDs) ............................................................................................ 16
4 Basic Battery Service ....................................................... 17
Servicing Batteries with Bar Code ................................................................ 20
5 Battery Service Programs ................................................ 21
Basic Programs ............................................................................................ 21
Specialty Programs...................................................................................... 22
Target Capacity ............................................................................................. 23
Selecting a Program or Setting Target Capacity ...........................................24
Editing Program Settings .............................................................................. 25
Duration of Service .......................................................................................26

iii
Contents
6 Battery Configuration/C-Codes....................................... 27
Basic C-Code................................................................................................ 27
Extended C-Code ......................................................................................... 28
Viewing C-Codes .......................................................................................... 30
Managing C-Codes ....................................................................................... 30
Selecting Correct Voltage ......................................................................... 31
Intrinsically Safe Settings ......................................................................... 31
Default Settings for Extended C-Codes.................................................... 32
7 Custom Programs............................................................. 33
Cycle 1 and Cycle 2...................................................................................... 34
Test ............................................................................................................... 35
True and False Statements ........................................................................... 37
Phase Done .................................................................................................. 38
Example ........................................................................................................ 38
Creating or Modifying a Custom Program..................................................... 40
8 System Security................................................................ 41
Password Requirement................................................................................. 41
Setting Security............................................................................................. 42
Changing Password and Removing Security................................................ 42
9 System Setup .................................................................... 43
Setting Up System Information ..................................................................... 44
Calibration Procedures ................................................................................. 44
Calibrating Voltage .................................................................................... 44
Calibrating Station .................................................................................... 45
Output Devices ............................................................................................. 46
Serial Port Settings ...................................................................................46
Serial and Parallel Port Device Settings ...................................................47
10 Print Utilities...................................................................... 48
Printing Report or Label................................................................................49
11 Event Log .......................................................................... 50
Log Events .................................................................................................... 51
Managing Event Log..................................................................................... 51

iv C7000& 7000ER Battery AnalyzerV3.5
12 Messages and Warnings .................................................. 52
By Detail .......................................................................................................53
By Code ........................................................................................................ 63
13 Services and Upgrades .................................................... 66
Replacing the Primary (Input) Fuse .............................................................. 67
Standard Model (C7000-1, C7000-2, C7000-9)........................................ 67
Extended Range Model (C7000ER) .........................................................68
Replacing the Station Fuses......................................................................... 69
Standard Model (C7000-1, C7000-2, C7000-9)........................................ 69
Extended Range Model (C7000ER) .........................................................70
Replacing Backup Battery (with OP-70 or OP-72 only) ................................71
IEC320 Power Cord ...................................................................................... 72
14 Specifications ................................................................... 73
Hardware ...................................................................................................... 73
Firmware ....................................................................................................... 74
15 Getting Help/Problem Solving ......................................... 75
Troubleshooting.............................................................................................75
Manual Updates and Other References .......................................................78
Technical Support ......................................................................................... 78
16 Safety Notice and Warranty ............................................. 80
Radio Interference ........................................................................................ 80
Explosion Hazard.......................................................................................... 81
Shock Hazard ............................................................................................... 82
Warranty & Services .....................................................................................83
Obtaining Warranty Service ...................................................................... 83
Non-warranty Repairs ...............................................................................83
Index........................................................................................ 84

The Cadex C7000 and C7000ER Battery Analyzers are sophisticated
programmable battery analyzers capable of servicing batteries with different
electricalproperties andmechanical dimensions.
Product Features
•Service Nickel Cadmium (NiCd), Nickel-Metal Hydride (NiMH), Sealed Lead
Acid (SLA) and Lithium Ion (Li-Ion). The C7000 and C7000ER are also
capable of supporting Smart Batteries based on the ‘single wire’ and SMBus
system.
•Operate each station simultaneously and independently of each other.
•Support over 600 interchangeable battery adapters for easy interface with
most commercially available battery models.
•The battery adapter contains the battery configuration code, also know as
C-Code , which automatically sets the analyzer to the correct parameters for
serving the battery. Each adapter contains 10 C-Codes to accommodate
different batteries in the same product family.
•Offer a variety of programs for battery services: 3 Basic Programs (Auto,
Charge,Prime), 6 Specialty Programs and 4 user-programmable Custom
Programs.
•Easy to use menu-driven interface, plain English messages and status lights.
•Produce Service Reports and Battery Labels.
•Support fleet management. Support bar code entry, print Bar Code Labels
and Battery Labels, and produce a range of reports.
•Can be networked for automated battery maintenance with BatteryShop™.
1
1
Overview 1

What’s New in the C7000 V3.5 firmware
At Cadex, it is our goal to continue to listen to feedback and suggestions from
customers, and improve our products. Below is a list of product enhancements:
2C7000& 7000ER Battery AnalyzerV3.5
Version New Features/Changes
3.5 Runtime program
Support for BatteryShop 3.0
Definable Resistance Threshold in OhmTest
Recognition of 16Kb Battery Adapters
Improved NiMH charge algorithm
Reorganized programs, separated Basic and Specialty Programs
4 additional Custom Programs
Improved user interface
3.4 Support for BatteryShop
General updates
3.3 Improved OhmTest
Incorporation of OhmTest into the Auto, Prime and Charge programs
Automatic identification of battery parameters through Battery Adapters
3.2 OhmTest to test battery internal resistance in 5 seconds
Support for label printer
Temperature sensor to improve safety
Display of battery model numbers
Improved NiMH charge algorithm
Improved bar code

Firmware Upgrade: Resetting the System
If you are upgrading the analyzer firmware to V3.5 from an older version, you
need to reset the system to the factory defaults to erase the old system
parameters.
Some of the parameters that are reset include:
•OhmTest, Runtime, Self-Discharge, Life-Cycling and Custom Programs
•Battery Startup settings
•Parallel Port Device to Printer
•Serial Port Device to LabelMaker
•Voltage Display to Volts/Cell
•Number of batteries serviced (Service Counter) to 0
!Press and release the Alt key, then press 0.
Note that this function also serves as a general system reboot.
Connecting to BatteryShop™
BatteryShop™is a powerful Windows-based battery management tool that
allows automation of the C7000 and C7000ER functions to increase productivity.
•Provides control and monitoring of large scale battery services by
connecting up to 120 analyzers to service 480 batteries simultaneously.
•Contains a database of over 2000 battery models that provides easy
access to C-Code settings and other information. Even a novice user can
perform a variety of tests and programs.
Refer to
Serial and Parallel Device Settings or BatteryShop Help on preparing
the analyzer for BatteryShop.
To find out how BatteryShop can enhance your battery maintenance system,
contact Cadex.
Overview 1
3

Peripherals
The C7000 and C7000ER support the following peripherals to maximize performance:
•Epson compatible dot-matrix printer to print reports.
•Label Printer to print labels. The DYMO LabelWriter SE300 is recommended.
For more information on label printers, contact Cadex or DYMO-CoStar.
•Bar Code Scanner to scan bar-coded labels. The bar code scanner is included
with the purchase of the OP-72 option board.
4C7000& 7000ER BatteryAnalyzerV3.5

Contents of Box
The Cadex C7000/C7000ER Battery Analyzer package includes:
•1 C7000/C7000ER Battery Analyzer
•1 IEC320 Power Cord (C7000-1 only)
•1 User’s Manual
About this Manual
The C7000 & C7000ER Battery Analyzer User’s Manual contains the concept,
procedures, and information that is necessary to operate the analyzer.
Conventions
2
Getting Started
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5

Symbols
Abbreviations and Acronyms
Symbol Meaning
Information that, if ignored, can result in damage to
the C7000/C7000ER Battery Analyzer, Battery
Adapters or the battery.
Shock Hazard.
Explosion Hazard.
6C7000& 7000ER BatteryAnalyzerV3.5
Abbreviation Name or Term
AWG American Wire Gauge. A U.S. wire size standard.
BMS Battery Maintenance System.
LCD Liquid Crystal Display. Referred to as Display.
LED Light Emitting Diode. Referred to as Light.
Li-Ion Lithium-Ion battery chemistry.
NiCd Nickel Cadmium battery chemistry.
NiMH Nickel-Metal Hydride battery chemistry.
OEM Original Equipment Manufacturer.
RF Radio Frequency.
P/N Part Number.
SLA Sealed Lead Acid battery chemistry.

Commonly UsedTerms
Getting Started 2
7
Term Explanation
Ampere Hour (Ah) Battery capacity or rating. A battery that provides a
current of 1 ampere for 1 hour is rated at 1Ah.
Configuration Code
(C-Code) Battery parameters stored in Battery Adapters to service a battery. Refer to Battery Configuration/C-Codes.
C-Rate Unit by which charge and discharge times are scaled.
For example, a battery rated at 1000mAh provides
1000mA for 1 hour if discharged at 1C. A discharge of
1C draws a current equal to the rated capacity. The same
battery discharged at 0.5C would provide 500mA for two
hours.
Intrinsically Safe (I/S) Battery with built-in safety protection circuitry. These
batteries are primarily used in explosive environments.
Recondition A deep discharge below 1.0V/Cell with a controlled
current. Recondition helps to revert large crystals as a
result of memory to small desirable sizes, often restoring
the battery to its full capacity. Applies to NiCd and NiMH
only.
Residual Capacity Charge capacity remaining in the battery when inserted in
an analyzer.
Smart Battery Battery equipped with specialized circuitry that can
communicate with an analyzer and provide battery
information.
Target Capacity The battery capacity benchmark for pass/fail set by the
user.

Operating Principles
Components
8C7000& 7000ER Battery AnalyzerV3.5
Component Function
Battery Stations Take Battery Adapter.
Prog Key Access service programs and Target Capacity.
Print Key Print labels and reports.
CCode Key Access battery parameters.
Esc Key Exit menus or cancel changes.
Fn Key Shortcuts to common functions when pressed with a second
key.
Alt Key Reset to factory defaults when pressed with the 0key after
a firmware upgrade or as a general system reboot.
ENTER Key Save settings and start servicing.
Menu Key Access menu.
Numeric Keypad Enter numeric parameter settings.
LED Indicators Provide current status of batteries in service. Activated
when a service starts.
LCD View status for each station and detailed service
information.
Station Keys View C-Codes, details of a service, or as cursor keys in
editing mode.
Battery Stations
Prog Key
Print Key
CCode Key
Esc Key
Fn Key
Alt Key
ENTER Key
Menu Key
Numeric
Keypad
LED
Indicators
LCD
Station
Keys
Ventilation Grill

3
Option Boards
All models of the C7000 and the C7000ER come with a RS-232 Serial Port that
connects to a label printer or to BatteryShop. There are 2 option boards, OP-70 and
OP-72, that can be purchased for additional support. (The C7000ER is already
equipped with the OP-70 option board.) The option board sticker is at the back of
the analyzer. The option board configuration is also displayed during start-up.
Note that the option board is blank unless purchased.
Components
•Parallel Printer Port: connects to a parallel printer. Refer to System Setup
on how to set up the parallel port device settings.
•Battery Backup RAM: retains test data on power interruption, resumes
service when power is restored, and retains dates and time.
•Bar Code Wand: reads bar-coded labels.
You can upgrade your standard analyzer to OP-70 or OP-72. Contact Cadex for
upgradeinformation.
Power Input
(ER model on side panel)
Input Fuse Drawer
5-pin DIN Bar Code Wand
RS-485 Ports (Not Used)
Parallel Printer Port
Option Board
Fan Outlet RS-232 Serial PortOn/Off Switch
OP-70 OP-72
Parallel Port
Battery Backup RAM
Bar Code Wand Not Activated
"
"
"
"
"
9

Battery Adapters
Adapters are designed to fit specific battery types and shapes. The snap lock latch
allows easy insertion and removal.
There are 3 types of battery adapters:
Custom Adapter
Smart Cable Adapter
(Universal Adapter)
10 C7000& 7000ER Battery AnalyzerV3.5
Adapter Type Description
Custom Adapters Accommodate any specific battery shape.
There are over 600 Custom Adapters available.
Dual-station
Custom Adapters Designed to handle dual packs that contain 2 separate battery systems.
Smart Cable Adapters
(Universal Adapters) Used when a Custom Adapter for a battery is not available. Alligator clips attach to positive
and negative terminals.
Dual-station
Custom Adapter

Operating Principles 3
11
Each adapter contains up to 10 battery parameters (C-Codes) for optimal battery
services. Once the adapter is inserted, the battery station receiving the adapter
automatically chooses the last selected C-Code as the active C-Code.
Note that Smart Cable Adapters need to be programmed, and the user must enter
the correct C-Code settings for the battery to be serviced. Refer to
C-Codes for more information.
For Li-Ion batteries of greater than 7.2V (2 cells), a custom designed
adapter is strongly recommended.
Cadex continuously designs adapters for new battery models and also designs
custom adapters for a nominal fee. Please contact Cadex for a current adapter
catalog or download a copy from our Web site, www.cadex.com.
Special Handling Tip for Smart Cable Adapters
!Insert a battery only when the Smart Cable Adapter is inserted into the
station. Likewise, do not remove the adapter before the battery is removed.

User Interface
Display
••
••
•Global Display: provides status information of stations and batteries in service
at a glance.
••
••
•Detailed Display: provides detailed information about the battery service or
station
when the appropriate station key is pressed . For example, during a service
in Station 1, the following is displayed when the S1 key is pressed:
Pressing the station key again will give additional details such as warning codes,
cycles and program phases.
Process
Station
Charge/Discharge Current
Average Cell Voltage Resistance Program Duration (hh:mm)
Temperature
S1 CHARGING
S1 CHARGINGS1 CHARGING
S1 CHARGING
1.35V/Cell 1006mA 233m
1.35V/Cell 1006mA 233m 1.35V/Cell 1006mA 233m
1.35V/Cell 1006mA 233mΩ
ΩΩ
Ω 32
32 32
32o
oo
oC 1:05
C 1:05C 1:05
C 1:05
EMPTY EMPTY NO ADAPT NO ADAPT
EMPTY EMPTY NO ADAPT NO ADAPT EMPTY EMPTY NO ADAPT NO ADAPT
EMPTY EMPTY NO ADAPT NO ADAPT
Au o Charge
Au o Charge Au o Charge
Au o Charge
Adapter inserted Adapter not inserted
Program
12 C7000& 7000ER Battery AnalyzerV3.5
CHARGE EMPTY NO ADAPT NO ADAPT
CHARGE EMPTY NO ADAPT NO ADAPT CHARGE EMPTY NO ADAPT NO ADAPT
CHARGE EMPTY NO ADAPT NO ADAPT
1.35V Charge
1.35V Charge 1.35V Charge
1.35V Charge
Process
Voltage/Current

••
••
•Menu Display: provides access to various functions of the analyzer when
the Menu key is pressed.
!Use the !!
!!
!(S1) and ""
""
"(S2) keys to scroll through the menu and press
ENTER when the desired function is displayed. For example, you will see
the following if System Security is selected:
See
Menu for the overview of the functions.
Operating Principles 3
SYSTEM SECURITY 17:53:10
SYSTEM SECURITY 17:53:10 SYSTEM SECURITY 17:53:10
SYSTEM SECURITY 17:53:10
Se Securi y
Se Securi ySe Securi y
Se Securi y
System Security
feature
MAIN MENU 17:52:55
MAIN MENU 17:52:55 MAIN MENU 17:52:55
MAIN MENU 17:52:55
Sys em Securi y
Sys em Securi ySys em Securi y
Sys em Securi y
Time
13

Menu
The menu-driven interface allows access to the various functions of the analyzer. Refer
tothe individual functions for details and instructions.
SYSTEM
SECURITY
PRINT
UTILITIES
SYSTEM
SETUP
EVENT LOG
Set Security
Change Password
Remove Security
Date/Time
Battery Startup
Program Settings
Company Name
Calibration
Output Devices
Sound Control
Voltage Display
Battery Service Report
Battery Label
Bar-Code Label
System Setup Report
Auto-Print
View Event Log
Print Event Log
Clear Event Log
Events to Log
ENTER
S2S1
S2S1
S2S1
S1, S2 to scroll,
ENTER to select,
Esc to exit.
Menu
ENTER
ENTER
ENTER
PROGRAM
SETTINGS OhmTest
Runtime
Self-Discharge
Life-Cycling
Discharge Only
Extended Prime
Custom 1
Custom 2
Custom 3
Custom 4
BASIC PROGRAMS
ENTER
PROGRAM
SETTINGS Auto
Charge
Prime
SPECIALTY PROG.
ENTER
OUTPUT
DEVICES Serial Port Device
Serial Port Settings
Parallel Port Device
ENTER
BatteryShop
14 C7000& 7000ER Battery AnalyzerV3.5
CALIBRATION Voltage Calibration
Station Calibration
ENTER