Cadex C8000 User manual

C8000 Battery Testing System
User Manual (V2.x)
Cadex®Electronics Inc.
22000 Fraserwood Way
Richmond, British Columbia
Canada V6W 1J6
Phone: [phone]
FAX: [phone]
Web: www.cadex.com
E-mail: [email protected]

Trademark
Cadex®and BatteryLab®are registered trademarks of Cadex Electronics Inc. All other
trademarks or registered trademarks mentioned herein are the property of their
respective owners.
Copyright Notice
Copyright © 2010 by Cadex Electronics Inc. All rights reserved. No part of this
publication nor the software and/or 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 and
Online Help is accurate and up-to-date, Cadex Electronics Inc. does not warrant or
guarantee the accuracy of the contents of this manual and Online Help. Further, Cadex
makes no warranties, either expressed or implied, as to the merchantability or fitness for
a particular purpose of the C8000 Battery Testing System and/or its documentation.
In no event will Cadex or its officers or employees are 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
C8000 Battery Testing System and/or its documentation.
Document Number: PSMAN0056 Rev 3

C8000 Battery Testing System User Manual
Contents i
Contents
Contents..........................................................................................................................................i
1Safety and Warranty ............................................................................................................ 1
1.1 Cautions and Warnings................................................................................................... 1
1.1.1 Use of Equipment ....................................................................................................... 1
1.1.2 Modification of Equipment......................................................................................... 1
1.1.3 Hazard Symbols.......................................................................................................... 2
1.1.4 Disposal of Waste Electrical and Electronic Equipment (WEEE) in the European
Union…................................................................................................................................... 3
1.1.5 Radio Interference....................................................................................................... 3
1.1.6 Explosion Hazard........................................................................................................ 4
1.1.7 Charge and Discharge Lithium-ion (Li-ion) Batteries................................................ 5
1.1.8 Shock Hazard.............................................................................................................. 6
1.2 Warranty and Service...................................................................................................... 7
1.2.1 Warranty Service ........................................................................................................ 7
1.2.2 Non Warranty Repairs ................................................................................................ 8
1.3 Back Up and Restore Calibration Data........................................................................... 8
1.3.1 Back Up Calibration Data........................................................................................... 8
1.3.2 Restore Calibration Data............................................................................................. 8
2Battery Tester...................................................................................................................... 10
2.1 Getting Started with the Battery Tester ........................................................................ 10
2.1.1 The C8000 Battery Tester User Manual................................................................... 10
2.1.1.1 Topics You Need to Know ............................................................................... 10
2.1.2 What is in the Box..................................................................................................... 11
2.1.3 Optional C8000 Accessories..................................................................................... 12
2.1.3.1 C8000 Adapter Unit.......................................................................................... 12

C8000 Battery Testing System User Manual
ii Contents
2.1.3.2 RigidArmTM Universal Battery Adapter........................................................... 12
2.1.3.3 SnapLockTM Universal Battery Adapter (4-wire versions only)....................... 13
2.1.3.4 Load Capture Unit (LCU)................................................................................. 13
2.1.3.5 C8000 Rack Mounting Bracket Set .................................................................. 13
2.1.4 Front Panel................................................................................................................ 14
2.1.4.1 LCD Settings..................................................................................................... 14
2.1.4.2 Channel Key Buttons........................................................................................ 14
2.1.4.3 Arrow and ENTER Buttons.............................................................................. 15
2.1.4.4 Navigating the LCD Display ............................................................................ 15
2.1.4.5 Numeric Keypad............................................................................................... 15
2.1.4.6 Battery Port Connections.................................................................................. 16
2.1.5 Back Panel ................................................................................................................ 17
2.1.5.1 AC Input............................................................................................................ 17
2.1.5.2 Ethernet Port ..................................................................................................... 17
2.1.5.3 Serial Ports and USB Port................................................................................. 17
2.1.5.4 Cooling Fans..................................................................................................... 18
2.2 Cadex C8000 Adapter Unit........................................................................................... 18
2.2.1 Cadex C8000 Adapter Unit....................................................................................... 18
2.2.2 Connect the C8000 Adapter Unit to the C8000........................................................ 19
2.3 Cables............................................................................................................................ 20
2.3.1 Power Port Cable ...................................................................................................... 20
2.3.2 Connect the Power Port Cable to the C8000 ............................................................ 20
2.3.3 Auxiliary data cables (for I/O ports)......................................................................... 23
2.4 C8000 Specifications.................................................................................................... 26
2.4.1 C8000 System Techincal Specifications................................................................... 26
2.4.2 Auxillary Port Absolute Maximum Ratings............................................................. 28
2.4.3 Auxillary Port Operating Ratings ............................................................................. 29
2.5 Configure the C8000..................................................................................................... 30
2.5.1 Set Up the C8000...................................................................................................... 30
2.6 User Maintenance for the C8000.................................................................................. 30
2.6.1 User Maintenance Warnings..................................................................................... 30
2.6.2 Clean the C8000........................................................................................................ 31
2.6.3 Replace the Fuse ....................................................................................................... 31

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Contents iii
2.6.4 Replace the Backup Battery...................................................................................... 32
2.7 The Battery Tester Application..................................................................................... 35
2.7.1 Execute a Program on a Battery................................................................................ 36
2.7.1.1 Execute a Program without BatteryLab............................................................ 36
2.7.1.2 Suspend and Resume a Running Program........................................................ 39
2.7.1.3 Abort a Running Program................................................................................. 39
2.7.1.4 View Auxiliary Port Information...................................................................... 40
2.7.1.5 Jump to a Specific Program Step...................................................................... 41
2.7.1.6 View SM-Bus Information ............................................................................... 42
2.7.1.7 Select a Program to Run ................................................................................... 43
2.7.2 Test Results............................................................................................................... 45
2.7.2.1 View Test Results............................................................................................. 45
2.7.2.2 Print Test Results.............................................................................................. 46
2.7.2.3 Delete a Test Result .......................................................................................... 46
2.7.2.4 Delete All Test Results ..................................................................................... 47
2.7.3 Battery Profiles ......................................................................................................... 48
2.7.3.1 View and Edit a Battery Profile........................................................................ 49
2.7.3.2 Delete a Battery Profile..................................................................................... 51
2.8 C-Codes......................................................................................................................... 52
2.8.1 Add, Edit, and Delete C-Codes................................................................................. 52
2.8.1.1 Create a C-Code................................................................................................ 53
2.8.1.2 View and Edit a C-Code................................................................................... 53
2.8.1.3 Delete a C-Code................................................................................................ 56
2.8.2 Import a C-Code ....................................................................................................... 57
2.8.3 Export a C-Code ....................................................................................................... 58
2.9 Programs....................................................................................................................... 59
2.9.1 View a Custom Program........................................................................................... 59
2.9.2 Delete a Custom Program......................................................................................... 60
2.10 Waveforms.................................................................................................................... 61
2.10.1 View Information about a Waveform................................................................... 61
2.10.2 Delete a Waveform............................................................................................... 62
2.11 Specify System Options................................................................................................ 63
2.11.1 Set the Clock......................................................................................................... 63

C8000 Battery Testing System User Manual
iv Contents
2.11.2 User Information................................................................................................... 64
2.11.3 LCD Settings......................................................................................................... 65
2.11.4 Serial Ports............................................................................................................ 65
2.11.5 Specify the TCP/IP Address on the C8000........................................................... 66
2.11.6 Maintenance.......................................................................................................... 67
2.11.7 Options.................................................................................................................. 67
2.11.8 Security................................................................................................................. 69
2.11.9 System Information............................................................................................... 70
2.11.10 Factory Defaults.................................................................................................... 72
2.12 External Devices........................................................................................................... 73
2.12.1.1 Programmable DC Electronic Loads ............................................................ 73
2.12.1.2 Thermal Chambers........................................................................................ 73
3Cadex BatteryLab............................................................................................................... 74
3.1 System Setup................................................................................................................. 74
3.1.1 System Requirements................................................................................................ 74
3.1.2 Set Windows Explorer and My Computer to Display File Extensions. ................... 75
3.1.3 Create a Database for BatteryLab............................................................................. 75
3.1.4 Back Up the Data Files on the PC ............................................................................ 76
3.1.5 Install and Uninstall BatteryLab............................................................................... 76
3.1.5.1 Install BatteryLab.............................................................................................. 77
3.1.5.2 Uninstall BatteryLab......................................................................................... 80
3.1.6 Software Updates...................................................................................................... 81
3.1.6.1 Software Version .............................................................................................. 81
3.1.6.2 Update BatteryLab Software............................................................................. 81
3.1.7 BatteryLab Security Information.............................................................................. 82
3.1.8 Set Up BatteryLab..................................................................................................... 82
3.1.8.1 Connect the C8000 to the Network................................................................... 83
3.1.8.2 Set Up the C8000 to Use BatteryLab................................................................ 83
3.1.8.3 Choose IP Addresses for the Local Network.................................................... 83
3.1.8.4 Find the IP Address for Your PC...................................................................... 84
3.1.8.5 TCP/IP Settings................................................................................................. 84
3.1.8.6 Network Cable.................................................................................................. 85
3.1.9 Firewalls.................................................................................................................... 85

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Contents v
3.1.9.1 Ports .................................................................................................................. 86
3.1.9.2 Other Firewall Software or Hardware............................................................... 86
3.1.10 Selecting a TCP/IP Address for the C8000........................................................... 86
3.1.10.1 Before Entering the Settings......................................................................... 86
3.1.10.2 Ping the Network to Check for Available IP address ................................... 88
3.1.10.3 Add IP Addresses for C8000s on the PC...................................................... 88
3.1.10.4 Disable an IP address.................................................................................... 90
3.1.11 Start the BatteryLab Program ............................................................................... 90
3.1.11.1 The Menu Bar............................................................................................... 90
3.1.12 Set the Clock on the C8000 .................................................................................. 92
3.1.13 Set Security Setting on the C8000........................................................................ 93
3.1.14 Set the Password to Configure C8000 Functions ................................................. 94
3.1.15 C8000 Settings...................................................................................................... 94
3.1.16 Alert Window........................................................................................................ 96
3.1.17 Exit BatteryLab..................................................................................................... 97
3.2 Configure BatteryLab ................................................................................................... 98
3.2.1 Results Panel............................................................................................................. 98
3.2.2 Event Logging......................................................................................................... 101
3.2.3 Report Template Options........................................................................................ 102
3.2.4 Graph Options......................................................................................................... 102
3.3 View Battery Status in Real-Time.............................................................................. 104
3.4 Test Batteries with BatteryLab ................................................................................... 108
3.4.1 View the Status of a Test in BatteryLab................................................................. 110
3.4.1.1 Background Color of Tests Running .............................................................. 110
3.4.2 Cancel or Suspend a Test in BatteryLab................................................................. 111
3.4.2.1 Cancel a Test................................................................................................... 111
3.4.2.2 Suspend a Test ................................................................................................ 111
3.4.2.3 Resume a Suspended Test............................................................................... 111
3.4.2.4 Simulate a Battery Removal ........................................................................... 111
3.4.3 Retrieve Test Results from the C8000.................................................................... 111
3.5 Test Status................................................................................................................... 112
3.6 View Test Results in BatteryLab................................................................................ 113
3.6.1 Import Test Results................................................................................................. 114

C8000 Battery Testing System User Manual
vi Contents
3.6.2 Print a Search List................................................................................................... 114
3.6.3 View and Print Test Details.................................................................................... 115
3.6.3.1 Edit a Test Result Record ............................................................................... 116
3.6.3.2 Delete a Battery Test Record.......................................................................... 117
3.6.3.3 Print Test Result Document............................................................................ 117
3.6.3.4 View Details.................................................................................................... 118
3.6.3.5 View Program Steps ....................................................................................... 118
3.6.3.6 View a Battery Test Graph ............................................................................. 119
3.6.3.7 View C-Code Information .............................................................................. 119
3.6.3.8 Custom Waveform.......................................................................................... 120
3.6.3.9 Playback a Waveform..................................................................................... 120
3.6.3.10 Load Capture Waveform............................................................................. 121
3.6.3.11 View Termination Data............................................................................... 121
3.6.3.12 Cycle Graph ................................................................................................ 122
3.6.3.13 Print Results................................................................................................ 123
3.6.3.14 Print a Battery Test Graph .......................................................................... 123
3.6.3.15 Export Test Record Results to a File .......................................................... 123
3.6.3.16 Export Graph Data To a File....................................................................... 124
3.6.3.17 Export Termination Data to a File.............................................................. 125
3.7 Reports........................................................................................................................ 125
3.7.1 Print Battery Test Reports....................................................................................... 125
3.7.2 Add, Edit, and Delete Report Templates................................................................ 125
3.7.2.1 Add a Report Template:.................................................................................. 125
3.7.2.2 Edit a Report Template:.................................................................................. 127
3.7.2.3 Set the Default Report Template..................................................................... 128
3.7.2.4 Delete a Report Template ............................................................................... 129
3.7.2.5 Copy a Report Template................................................................................. 130
3.7.2.6 Set Up Your Printer ........................................................................................ 132
3.8 Battery ID Database.................................................................................................... 134
3.8.1 Add a Battery ID..................................................................................................... 134
3.8.2 Edit a Battery ID..................................................................................................... 135
3.8.3 Delete a Battery ID ................................................................................................. 136
3.8.4 Copy a Battery ID................................................................................................... 138

C8000 Battery Testing System User Manual
Contents vii
3.8.5 Import a Battery ID................................................................................................. 139
3.8.6 Export a Battery ID................................................................................................. 143
3.8.7 Search for a Battery ID........................................................................................... 147
3.8.8 Sort Battery IDs ...................................................................................................... 147
3.9 C-Code........................................................................................................................ 147
3.9.1 Add a C-Code ......................................................................................................... 147
3.9.2 Add a SM-BUS (Smart Battery) C-Code................................................................ 148
3.9.3 Edit a C-Code.......................................................................................................... 152
3.9.4 Delete a C-Code...................................................................................................... 153
3.9.5 Copy a C-Code........................................................................................................ 155
3.9.6 Import a C-Code ..................................................................................................... 156
3.9.7 Export a C-Code ..................................................................................................... 160
3.9.8 Search for a C-Code................................................................................................ 164
3.9.9 Sort the C-Codes..................................................................................................... 164
3.10 Programs..................................................................................................................... 164
3.10.1 Factory Default Programs................................................................................... 165
3.10.2 A Custom-Program Example.............................................................................. 171
3.10.3 A Custom-Program with Thermal Chamber Example........................................ 175
3.10.4 Add a Program.................................................................................................... 183
3.10.4.1 Add a Step to a Program............................................................................. 184
3.10.4.2 Remove a Step from a Program.................................................................. 193
3.10.4.3 Copy a Step in a Program ........................................................................... 193
3.10.4.4 Save the Custom Program........................................................................... 193
3.10.5 Add Folders......................................................................................................... 194
3.10.6 Edit a Program .................................................................................................... 195
3.10.7 Delete a Program................................................................................................. 196
3.10.8 Copy a Program .................................................................................................. 199
3.10.9 Organize Programs in Folders ............................................................................ 202
3.10.10 Import a Program................................................................................................ 203
3.10.11 Export a Program................................................................................................ 207
3.10.12 Search for a Program .......................................................................................... 210
3.10.13 Sort Programs and Folders.................................................................................. 210

C8000 Battery Testing System User Manual
viii Contents
3.11 Load Capture............................................................................................................... 211
3.11.1 Load Capture Programs Database....................................................................... 215
3.11.2 Add a Load Capture Program............................................................................. 215
3.11.3 Edit a Load Capture Program ............................................................................. 216
3.11.4 Delete a Load Capture Program.......................................................................... 218
3.11.5 Copy a Load Capture Program ........................................................................... 219
3.11.6 Import a Load Capture Program ......................................................................... 221
3.11.7 Export a Load Capture Program......................................................................... 222
3.11.8 Search for a Load Capture Program.................................................................... 224
3.11.9 Sort the Load Capture Programs......................................................................... 224
3.12 Waveforms.................................................................................................................. 224
3.12.1 Sample Custom Waveform................................................................................. 224
3.12.2 Add a Waveform................................................................................................. 228
3.12.2.1 Add a Step to a Waveform.......................................................................... 230
3.12.2.2 Remove a Step from a Waveform............................................................... 230
3.12.2.3 Copy a Step to Another Step in a Waveform.............................................. 230
3.12.2.4 Move the Order of Steps in a Waveform.................................................... 231
3.12.3 Organize Waveforms in Folders......................................................................... 231
3.12.4 Edit a Waveform................................................................................................. 233
3.12.5 Delete a Waveform............................................................................................. 234
3.12.6 Copy a Waveform............................................................................................... 235
3.12.7 Import a Waveform............................................................................................. 237
3.12.8 Export a Waveform............................................................................................. 240
3.12.9 Search for a Waveform....................................................................................... 244
3.12.10 Sort the Waveforms ............................................................................................ 244
3.13 Sequences.................................................................................................................... 244
3.13.1 Add a Program Sequence.................................................................................... 245
3.13.2 Edit a Program Sequence.................................................................................... 246
3.13.3 Delete a Program Sequence ................................................................................ 248
3.13.4 Copy a Program Sequence.................................................................................. 249
3.13.5 Import a Program Sequence................................................................................ 251
3.13.6 Export a Program Sequence................................................................................ 255