Cadex C7200 User manual

Cadex C7000 C-Series
Battery Analyzer
User’s Manual
Cadex C7200, C7400 & C7400ER (C-Series)
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: 89-307-1016
Document Number PSMAN0048 Rev7
September 2009
Firmware Version 1.10
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Safety Notices
i
Trademark
Cadex, BatteryShop, QuickLearn, QuickTest, QuickSort, FlexArm, RigidArm are
registered trademarks of Cadex Electronics Inc. All other trademarks mentioned
herein are the property of their respective owners.
Copyright
Copyright © 2008 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.
RevisionRights
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 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 the merchantability or fitness for a particular
purpose of the Cadex C7000 C-Series Battery Analyzers (C7200-C, C7400-C and
C7400ER-C) equipment and/or its documentation.
In no event will Cadex or its officers or employees be held 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/or its documentation.

Safety Notices
Safety Notices
UseofEquipment
The Cadex C7000 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.
ModificationofEquipment
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.
DisposalofWasteElectricalandElectronicEquipment(WEEE)inthe
EuropeanUnion
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.
Cadex Electronics Inc. C7000-C Series Battery Analyzers .
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Safety Notices
ROHSCompliance
The C7000 C-Series of Battery Analyzer complies with the European Union’s Directive
2002/95/EC, Restrictions of Hazardous Substances (RoHS).
RadioInterference
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.
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Safety Notices
ExplosionHazard
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.
Cadex Electronics Inc. C7000-C Series Battery Analyzers .
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Safety Notices
ChargingandDischargingLithium-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.
 Never leave the battery unattended while under charge or discharge.
 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.
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Safety Notices
 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.
Cadex Electronics Inc. C7000-C Series Battery Analyzers .
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Safety Notices
ShockHazard
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 109).
 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 109).
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Warranty & Service
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 not cover:
• Damage caused by abusive operation, negligence, accident, or improper
installation.
• Damage caused by an attempted repair not authorized by Cadex.
• Cosmetic damage or similar.
• Normal wear and tear.
• Damage from external causes such as leakage spills, power fluctuations or
power failure.
• Damage caused by inadequate packaging for shipping or storage.
• Product received without the appropriate model number, serial number, or
safety markings.
• Products used for rental purposes.
WarrantyService
Before sending the unit for service, contact Cadex Technical Support at
E-mail: contact [email protected]
(Canada) 1-604-231-7777
(USA Toll Free) 800-565-5228
(Europe) [phone].
If the product requires warranty service, the representative will provide a Return
Authorization form or number and the location of the nearest service center.
Cadex Electronics Inc. C7000-C Series Battery Analyzers .
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Warranty & Service
• 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-WarrantyRepairs
Before sending the unit in for service, contact Cadex Technical Support at;
E-mail: contact [email protected]
(Canada) 1-604-231-7777
(USA Toll Free) 800-565-5228
(Europe) [phone].
If the analyzer is not covered by warranty, the representative will provide the
contact information for the nearest service center. 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 repair.
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Table of Contents
Table of Contents
Chapter 1 Overview.................................................................................................1
Product Features...............................................................................................................1
Connecting to Cadex BatteryShop™.................................................................................2
Chapter 2 Getting Started.......................................................................................3
Contents of the Box...........................................................................................................3
Using this Manual..............................................................................................................3
Conventions ......................................................................................................................5
Direction Keys................................................................................................................5
Symbols.........................................................................................................................5
Abbreviations and Acronyms .........................................................................................6
Commonly Used Terms .................................................................................................7
Chapter 3 Operating Principles............................................................................10
Components ....................................................................................................................10
Front LCD Display Interface ............................................................................................13
Lights (LEDs) ...............................................................................................................15
Menu Structure................................................................................................................16
Battery Adapters..............................................................................................................17
Chapter 4 Basic Battery Service...........................................................................20
Chapter 5 Battery Service Programs...................................................................25
Basic Programs ...............................................................................................................25
Auto .............................................................................................................................26
Charge.........................................................................................................................27
Prime ...........................................................................................................................27
QuickSort.....................................................................................................................28
Cadex Electronics Inc. C7000-C Series Battery Analyzers .
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Table of Contents
Advanced Programs ....................................................................................................... 30
SelfDCH (Self-Discharge Test) ................................................................................... 31
Life-Cycle .................................................................................................................... 32
DCHOnly (Discharge Only) ......................................................................................... 34
ExtPrime (Extended Prime)......................................................................................... 35
OhmTest ..................................................................................................................... 35
Runtime....................................................................................................................... 37
Boost........................................................................................................................... 38
Learn........................................................................................................................... 40
Q-Learn (QuickLearn) ................................................................................................. 41
QuickTest™ ................................................................................................................ 44
Custom 1, 2, 3, and 4.................................................................................................. 45
Battery Service Times..................................................................................................... 46
Chapter 6 C-codes (Configuration Codes).......................................................... 47
Basic C-code Parameters............................................................................................... 48
Program ...................................................................................................................... 48
Target Capacity........................................................................................................... 49
Chemistry.................................................................................................................... 49
Battery Voltage (Volts) ................................................................................................ 49
Battery Rating (mAh)................................................................................................... 50
C-code Setup Name.................................................................................................... 50
Scaled C-code............................................................................................................. 51
C-code Matrix.............................................................................................................. 51
Locked C-code............................................................................................................ 51
Extended C-code Parameters......................................................................................... 51
Charge Rate................................................................................................................ 51
Discharge Rate ........................................................................................................... 52
Trickle-Charge Rate (NiCd and NiMH only) ................................................................ 53
Recondition Discharge Rate (NiCd and NiMH only).................................................... 53
Temperature Sensing.................................................................................................. 53
Negative Slope (NiCd and NiMH only) ........................................................................ 54
End-Of-Discharge ....................................................................................................... 54
End of Recondition (NiCd and NiMH only) .................................................................. 55
Charge Method (NiCd and NiMH only)........................................................................ 56
Maximum Standby Voltage (SLA and Li-ion only) ....................................................... 56
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Table of Contents
Maximum Charge Voltage (SLA and Li-ion only) .........................................................57
End of Charge (SLA and Li-ion only) ...........................................................................57
Default Extended C-code Settings...................................................................................57
Default Extended C-code for NiCd Batteries................................................................58
Default Extended C-code for NiMH Batteries...............................................................58
Default Extended C-code for SLA Batteries.................................................................59
Default Extended C-code for Li-ion Batteries...............................................................59
Default Extended C-code for Li-Ph Batteries ...............................................................59
Extended C-code Settings for Special Cases..................................................................60
Intrinsically Safe Batteries............................................................................................60
Hawker SLA Batteries..................................................................................................60
Gell SLA Batteries........................................................................................................61
Managing C-codes ..........................................................................................................61
Select a C-code ...........................................................................................................61
Display a C-code .........................................................................................................61
Change Target Capacity or Program ...........................................................................62
Create or Edit a C-code ...............................................................................................62
Add or Edit the C-code Setup Name............................................................................64
Reset Extended C-code to the Default settings ...........................................................64
Delete a C-code...........................................................................................................65
Copy a C-code (including QuickTest matrix)................................................................65
Copy all C-codes (and matrices) from One Adapter to Another...................................65
Chapter 7 System Setup And Options.................................................................67
Date and Time.................................................................................................................67
Company Name...............................................................................................................67
Sound Options.................................................................................................................68
Voltage Display................................................................................................................69
Battery Service Counter ..................................................................................................70
Connecting to BatteryShop or a Printer ...........................................................................71
Connecting to BatteryShop..........................................................................................71
Connecting Other Devices to the Serial Port ...............................................................72
Security ...........................................................................................................................74
Security Level Functions..............................................................................................74
Cadex Electronics Inc. C7000-C Series Battery Analyzers .
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Table of Contents
Program Parameters....................................................................................................... 77
Starting Battery Service .............................................................................................. 77
Performing an Automatic OhmTest ............................................................................. 78
Optimizing Charge Time or Capacity .......................................................................... 79
Termination Condition on dT/dt ................................................................................... 79
Saving Program and Target Capacity Settings ........................................................... 80
Resuming Service After Power Failure........................................................................ 81
Short Key Functions.................................................................................................... 82
Recalibration Counter ................................................................................................. 82
Chapter 8 Reports and Labels............................................................................. 83
Automatically Print Reports or Labels (Auto-Print).......................................................... 86
Automatic Report or Label printing.............................................................................. 86
Manually Print Reports and Labels ................................................................................. 87
Chapter 9 Events and Data Logs......................................................................... 89
Logging Events............................................................................................................... 89
Setting up the Event Log............................................................................................. 89
Using the Event Log.................................................................................................... 90
Logging Data .................................................................................................................. 91
Sample text strings...................................................................................................... 94
Setting up the Data Log .............................................................................................. 96
Using the Data Log ..................................................................................................... 98
Chapter 10 Custom Programs............................................................................ 100
Cycle 1 and Cycle 2...................................................................................................... 101
Test............................................................................................................................... 102
IF Statements............................................................................................................ 102
THEN and ELSE Statements .................................................................................... 104
Phase Done.................................................................................................................. 104
Creating and Editing Custom Programs........................................................................ 105
Sample Custom Program.......................................................................................... 107
Chapter 11 Services and Upgrades................................................................... 109
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Table of Contents
Replacing the Primary (Input) Fuse...............................................................................109
Upgrading the Firmware ................................................................................................110
Resetting the System ....................................................................................................110
Cleaning the Analyzer ...................................................................................................111
Chapter 12 System Calibration...........................................................................112
Voltage Calibration ........................................................................................................112
Servicing the Voltage Calibration Adapters................................................................113
Adapter Calibration........................................................................................................113
Adapter Calibration Values ........................................................................................114
Acceptable Calibration Values for New Adapters.......................................................114
Chapter 13 Solving Problems and Getting Help................................................116
Troubleshooting.............................................................................................................116
Manual Updates and Other References ........................................................................120
Technical Support..........................................................................................................121
Appendix A Messages and Warnings................................................................123
Non-Coded Messages...................................................................................................124
By Code.........................................................................................................................125
By Detailed Message.....................................................................................................129
Appendix B Charge Algorithms.........................................................................148
NiCd and NIMH batteries...............................................................................................148
SLA, Li-ion and Li-Ph Batteries......................................................................................150
Appendix C Specifications.................................................................................152
Hardware.......................................................................................................................152
Appendix D Parts and Accessories...................................................................154
Cadex Electronics Inc. C7000-C Series Battery Analyzers .
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1
Chapter 1 Overview
The Cadex C7000 C-Series of Battery Analyzers include the C7200-C, C7400-C
and C7400ER-C.
Product Features
• Services rechargeable nickel-cadmium (NiCd), nickel-metal hydride (NiMH),
sealed lead-acid (SLA), lithium-ion (Li-ion), lithium-polymer (treated in the
same way as Li-ion) and Lithium-phosphate (Li-Ph). In this manual “Li-ion”
refers to both lithium-ion and lithium-polymer batteries.
• Programmable with a total of 17 programs including:
o Four basic programs: Auto; Charge; Prime and QuickSort.
o Ten advanced programs
o Four 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-codes of the most
common batteries.
• A menu-driven interface with messages in plain English and status lights.
• Prints battery service reports and battery service labels.
• Analyzers can be connected to a PC and operated with BatteryShop™
software.
• BatteryShop™ software allows automated operation and networking of multiple
analyzers.

Connecting to Cadex BatteryShop™
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 battery
models, 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 (see Connecting to BatteryShop™, page 71).
Cadex Electronics Inc. C7000-C Series Battery Analyzers .
2

3
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
The Cadex 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 1.10.
Chapter 1 - Overview provides basic information about product features and
connecting the Cadex analyzer to a computer.
Chapter 2 - Getting Started 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 Principles provides information about the Cadex analyzer,
components, display screen, interface and how to use Battery Adapters with the
analyzer.
Chapter 4 - Basic Battery Service provides the basic procedures for servicing a
battery.
Chapter 5 - Battery Service Programs provides detailed information about all the
battery service programs.

Chapter 6 - C-codes (Configuration Codes) provides detailed information on
selecting and managing battery parameters (C-codes).
Chapter 7 - System Setup and 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 - Reports and Labels provides information about printing battery service
reports and labels.
Chapter 9 - Events and Data Logs describes methods of obtaining and graphing
detailed voltage/current/temperature/impedance analysis.
Chapter 10 - Custom Programs describes how to create user-defined programs for
specialized or advanced applications.
Chapter 11 - Services and Upgrades provides information on servicing the Cadex
analyzer, including upgrading the firmware.
Chapter 12 - System Calibration provides 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 Warnings provides detailed information on fault codes
and messages that appear on the display.
Appendix B - Charge Algorithms describes the charge and discharge algorithms.
Cadex Electronics Inc. C7000-C Series Battery Analyzers .
4