Cadex C7200 User manual

Cadex C7000 Series Battery Analyzer i
Cadex C7000 Series
Battery Analyzer
User’s Manual
Cadex C7200, C7400 & C7400ER
Cadex Electronics Inc.
22000 Fraserwood Way
Richmond, British Columbia
Canada V6W 1J6
Tel: [phone] Fax [phone]
Web: www.cadex.com E-mail: [email protected]
Manual P/N: 89-307-1013 Rev 11
November 2005
Printed in Canada
Firmware Version 6.11

Safety Notice
ii Cadex Electronics Inc.
Trademark
Cadex, BatteryShop, QuickLearn and QuickTest are registered trademarks of
Cadex Electronics Inc. All other trademarks mentioned herein are the property of
their respective owners.
Copyright
Copyright © 2005 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 this publication and make
changes in the contents thereof without obligation to notify any person of such
changes. Please contact Cadex Electronics Inc. ([e-mail]) 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 the merchantability or fitness for a particular
purpose of the Cadex C7000 Series Battery Analyzers (C7200, C7400 and
C7400ER) equipment and/or its documentation.
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 Series Battery Analyzers (C7200, C7400 and
C7400ER) Battery Analyzer equipment and/or its documentation.

Safety Notice
Cadex C7000 Series Battery Analyzers iii
Safety Notice
Use of Equipment
The Cadex C7000 Series Battery Analyzers (C7200, C7400 and C7400ER) 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 Series Battery
Analyzers (C7200, C7400 and C7400ER) 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 Notice
iv Cadex Electronics Inc.
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 adequate corrective measures.
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.

Safety Notice
Cadex C7000 Series Battery Analyzers v
Explosion Hazard
Batteries can burst if treated improperly. Follow these precautions at all times.
 Clean battery contacts before servicing. To clean battery contacts, use a lint-
free cotton swab dipped in 100% isopropyl alcohol.
 Press the battery firmly into the adapter to ensure a good connection.

Ensure that the selected C-code is correct for the chemistry, voltage, and
rating of the battery being serviced.
 Observe 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.
Fast charging 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.
 Do not attempt to charge non-rechargeable and primary batteries such as
alkaline, carbon-zinc, or non-rechargeable lithium batteries.

Do not short the positive and negative battery terminals together at any time.

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.
 Do not exceed the battery manufacturer’s recommended charge current and
voltage limits for batteries.

Do not remove the adapter from the analyzer while the battery is
running.

Safety Notice
vi Cadex Electronics Inc.
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.
• Never connect cells in parallel and/or series that are not designed for that
purpose. A cell mismatch may overcharge and vent with flames.
• Never charge or discharge the battery without connecting a working
protection circuit. Each cell must be monitored individually and the current
disconnected if an anomaly occurs.
• Always attach a temperature sensor when charging and discharging the
battery. The temperature sensor must disconnect the current on excess
temperature.
• Only connect cells that are matched and have the identical state-of-charge.
• Pay special attention when using an unknown brand. Not all brands contain
intrinsic safety features that protect the cell when stressed.
• During experiments, place the test battery into a well-ventilated fireproof
container. Never leave the battery unattended while under charge or
discharge.

Safety Notice
Cadex C7000 Series Battery Analyzers vii
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 or internal backup battery (see Chapter 11, Services and
Upgrades, page 114).

To reduce the risk of electrical shock hazard, service batteries only when they
are removed and disconnected from their end-use equipment.

Use the analyzer only as specified in the documentation. Other uses may
impair the protection provided by the unit.
 Use only a grounded AC outlet to power the analyzer.

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.

Replace fuses only with fuses of the same type and rating (see Replacing
the Primary (Input) Fuse, page 114).
 Replace the internal backup battery only with the same type of battery (see
Replacing the Backup Battery, page 115). Observe the correct polarity
when installing the backup battery. Discard the used battery according to the
battery manufacturer’s instructions.

Warranty & Service
viii Cadex Electronics Inc.
Warranty & Service
Cadex Electronics Inc. warrants your Cadex Battery Analyzer against defective
materials and workmanship for a period of three (3) years from the original
purchase date.
The warranty does not cover:
• 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 your
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.

Warranty & Service
Cadex C7000 Series Battery Analyzers ix
Non-warranty Repairs
Before sending the unit in for service, contact Cadex Technical Support at 1 800
565-5228. If your product is not covered by warranty, the representative will
provide the contact information for the nearest service center. You may contact
the service center directly to 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 Order or written authorization to proceed with repairs.

Table of Contents
x Cadex Electronics Inc.
Table of Contents
Chapter 1 Overview.................................................................................................1
Product Features...............................................................................................................1
Connecting to Cadex BatteryShop™................................................................................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...................................................................22
Basic Programs...............................................................................................................22
Auto .............................................................................................................................23
Charge.........................................................................................................................24
Prime ...........................................................................................................................25
QuickTest™.................................................................................................................25
Advanced Programs .......................................................................................................27
SelfDCH (Self-Discharge Test) ...................................................................................29
Life-Cycle.....................................................................................................................30