Cofko LLC. BC-7000 User manual

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BC
BCBC
BC-
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-7
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7000
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000
CAPACITY TESTER
OPERATIONS MANUAL
COFKO LLC.
COPYRIGHT © 2013

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UNPACKING
As you unpack your new BC-7000 battery capacity tester, inspect the tester for signs of shipping damage. f shipping
damage is present, stop and contact the shipping company for damage claims information. The box should contain the
BC-7000 tester, operators instruction manual, AC power cord, USB cable, battery disconnect (7017-2), 2 battery adapter
cables, and BC eport software.
IMPORTANT: Save the shipping box and packaging material. They should be used to repack the tester if it needs to be
shipped back for warranty or service.

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INTRODUCTION
Congratulations on acquiring your new BC-7000 battery capacity tester. The BC-7000 battery capacity tester has been
designed to provide the operator with accurate battery capacity testing and ease of operation.
The features of the BC-7000 are:
- Adjustable constant current load in 0.1 Ampere increments from 0.5 Ampere to 15 Ampere.
- Adjustable constant current load in 1.0 Ampere increments from 15 Ampere to 55 Ampere.
- Universal AC power input 85~264Vac 1 PH (47 to 63Hz)
- LCD display.
- 10mv voltage resolution.
- Over temperature protection.
- Audio warning when capacity test is complete or malfunction of the unit.
- USB 2.0 port for PC connection.
- WindowsTM XP or Higher compatible BC Repo t Utility software for test data hardcopy print out.
- Real time internal clock with battery backup.
- 1 year warranty.
Before operating your new BC-7000 battery capacity tester, familiarize yourself with this operators manual and the unit.
Questions?
Call: [phone] Mon.-Fri.8:00 A.M. to 5:00 P.M. PST or suppo [e-mail]
Thank you,
COFKO
Manual: BC-7000
Revision: C Date: 04/05/13

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CONTENTS PAGE
BC-8000 History of Revisions
……………………………….............................................................................................. 5
BC-7000 SAFETY NOTES
………………………………………………………………….…….................................................… 6,7
BC REPORT UT L TY AND REAL T ME CLOCK SETUP
………………………………………………............................................................….......…….. 8
BC-7000 OPERAT ON
…………………………………………......................................................................…....……. 9,10,11
BC-7000 REPORT PR NT NG
….…………..…………………………………………...............................................…..............… 11
BC-7000 CARE
…………………………………………..............…………………........................…..……...........….. 12
BC-7000 TECHN CAL DATA
……………………………………………………………………………......................…..................….. 13,14
BC-7000 L M TED WARRANTY
………………………………............................................................................................... 15
BC-7000 NOTES
………………………………............................................................................................... 16
BC-7000 CERT FCAT ON OF FACTORY CAL BRAT ON
................................................................................................................................ 17

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Histo y of Revisions
Revision # Effective Date Description of Change Approval By
A 11/11/2010 Initial issue M.C.
B 10/23/2012 Increase Maximum Operation Altitude from 6000’ to 6500’ M.C
B 10/23/2012 Change Description of Box Contents M.C.
C 04/05/2013 Minimum and Maximum Operation Temperature M.C.

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SAFETY NOTES
Your new BC-7000 battery capacity tester has been designed with operator safety as a function of its design,
construction, and operation. Understanding how to safely operate the BC-7000 battery capacity tester is important.
Failure to follow the operation and safety guidelines when using the BC-7000 can result in pe sonal inju y to the
ope ato and damage to the BC-7000. Always review the battery manufacturer’s battery capacity testing guidelines
before testing batteries.
Look for this symbol to identify Safety and Danger precautions. Be Alert- Your safety is
involved! ersonal injury or equipment damage can occur if guidelines are not followed.
RECAUTIONS:
recautions:
1 CAUTION: Aircraft batteries are certified to have a certain minimum capacity for emergency operations in
the event of an electrical generator system failure. Never “jump start” an aircraft that has a discharged or
“dead” battery.
2 WARNING: ELECTRIC SHOCK HAZARD. Do not touch un-insulated portions of the connector or the battery
terminals. A possibility of serious electrical shock exists. Do not lay tools or other metal objects on the
battery as arcing or explosion could occur. Remove conductive jewelry before working around battery,
charger, or test equipment.
3 CAUTION: ELECTRIC BURN HAZARD. Do not wear conductive rings, belt buckles, or other jewelry when
working with batteries, chargers, or test equipment. Do not lay tools or other metal objects on the battery
as arcing and severe burns could occur.
4 WARNING: Batteries on charge or discharge produce hydrogen gas, which can explode if ignited. Do not
smoke, use an open flame, or cause sparking near a battery. Charge, service or test a battery only in a well
ventilated area. The use of exhaust fans may reduce the risk of explosion.
5 WARNING: Batteries contain sulfuric acid which will cause burns. DO NOT TOUCH EYES AFTER TOUCHING
BATTERY. Do not get acid in your eyes, or on your skin, or clothing. n the event of acid in the eyes, flush
thoroughly with clean cool water for several minutes. Get professional medical attention. Refer to battery

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MSDS for additional information.
6 WARNING: Wear proper eye, face and hand protection at all times when working with batteries. Know the
location and use of emergency eyewash and shower nearest the battery charging area.
7 CAUTION: To prevent damage to the connector, arc burns, or explosion, batteries should never be
connected or disconnected while being charged or discharged. Batteries must be connected or disconnected
only when the circuit is open. Ensure the aircraft battery switch, external power source, or the
charger/analyzer is in the “OFF” position before connecting or disconnecting the battery. Battery terminal
protectors should be installed whenever the battery is not connected in the aircraft or to the test
equipment.
8 CAUTION: Batteries contain hazardous materials. Know the location and proper use of emergency response
materials. Refer to battery Material Safety Data Sheet (MSDS) for additional information.
9 Caution / Warning: Only constant potential charging may be done on the aircraft. DO NOT constant current
charge a battery on the aircraft. There could be a serious risk of injury to personnel and / or damage to the
aircraft or aircraft systems due to high voltage and generation of explosive gases when charging constant
current.
10 DANGER: Never connect or disconnect BC-7000 tester main power connector with the switch on. Connecting
or disconnecting the BC-7000 tester with discharge current applied can cause a spark and possible battery
explosion.
11 DANGER: Never capacity test batteries without first inspecting all battery wires and connection for condition
and tightness. Replace all defective wires and bad connections before capacity testing batteries. Defective
wiring and bad connections can cause overheating during a capacity test.
12 DANGER: never connect the BC-7000 capacity tester to batteries with voltage or capacity currents outside
the ratings of the tester. The BC-7000 tester is designed for 12 and 24 volt batteries. Connecting the tester to
batteries with different voltages can permanently damage the tester and endanger the operator. Any
questions that arise about the battery or tester ratings, email [e-mail]
13 DANGER: never obstruct the BC-7000 tester air intake or hot air exhaust openings. Obstructing either
opening can cause the tester to overheat.

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BC Repo t Utility and Real Time Clock Setup
NOTE: The BC Repo t Utility software MUST be installed on the compute used to connect to the BC-7000
tester first. Do not connect the USB communication cable to the BC-7000 until this is done.
1 Remove the BC Repo t Utility CD from the protective sleeve and place disk into the PC CD drive. The BC Repo t Utility
will automatically start installing. (Manual installation can be done with commands: Start\Run\ d:\setup.exe
2 Windows Application Security Warning dialog box may prompt you about installing the BC Repo t Utility. To continue
installing the BC Repo t Utility, click on the INSTALL button. The installation may take some time as WindowsTM installs
all the necessary software.
3 When prompted to install the Silicon Labs CP210x USB to UART bridge driver, click the INSTALL button to install all
needed drivers. (C:\Program Files\Silabs\MCU\CP210x\) Note: The CP210x drivers are on the BC Repo t Utility CD disk.
4 After the BC Repo t Utility software installation is completed, remove the BC Repo t Utility CD disk from the drive
and return to the protective sleeve. Now restart the PC .
5 The WindowsTM desktop should now contain the BC Repo t Utility program icon. Plug the USB cable supplied with the
BC-7000 into a working USB port on the PC with the BC Repo t Utility installed. Connect the AC power cord to the BC-
7000 and set the power switch to the ON position. Now plug the remaining USB cable end into the USB port located on
the right side rear of the BC-7000. f the connection is made between the PC and the BC-7000 the PC may respond with
an audio sound confirming a device has been found.
6 To run the BC Repo t Utility, place the mouse pointer on the icon and press the left mouse button. This action will
start the BC Repo t Utility program and display the program window.
7 Before updating the BC-7000 internal date and clock, check the computer date and time for proper setting and adjust
if needed. This is the date and time the BC-7000 will use. Located in the lower middle of the BC-7000 Report window is
the SET Date & Time button. To set the BC-7000 Date & Time place the mouse pointer on the Set Date & Time button and
click the left mouse button. The status bar located in the lower left corner will display a series of messages showing the
communications activity between the BC-7000 and the PC. The first message displayed is Sea ching fo BC-7000. Second
message is Setting Date and Time. And the final message will be Done. With the date and time set, the BC-7000 is now
ready to test batteries and print test result reports.
8 f any difficulties are experienced with communications between the BC-7000 and the PC, check cable connections
first and review BC Repo t Utility installation second. Lastly make sure the PC USB port drivers are installed and working.
Review your WindowsTM software help menu for guidelines in checking USB ports.

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BC-7000 OPERATION
NOTE: Before capacity testing a battery, eview all testing p ocedu es as equi ed by the batte y
manufactu e . Failure to do so can result in inaccurate test date.
NOTE: Before capacity testing a battery, RECHARGE THE BATTERY FOLLOWING THE
MANUFACTURERS RECHARGING GUIDELINES.
NOTE: Befo e putting the BC-7000 into se vice the REAL TIME clock must be set. See instruction in the BC
Repo t Utility section. Failure to do so will result in incorrect printed time on test reports.
1. Make sure the power switch is in the OFF position. Connect the AC power cord female end into the power
receptacle located in the left rear side of the BC-7000. Connect the male end of the power cord into the AC
power outlet. Now connect the g ay BC-7000 battery connector to the battery to be tested.
DANGER: Never attempt to connect the BC-7000 capacity tester to a battery using anything but the proper
connector. Doing so can damage the teste , batte y, o cause inju y to the ope ato . Capacity testing data will be
invalid if incorrect connections are made.
2. Place the OFF/ON power switch to the ON position. The BC-7000 LCD display will flash tester model and
software version.
NOTE: f Replace Clock Coin Batte y is displayed on screen, remove case top and install new coin battery.
Replacement battery number is 3V #CR2032. Use BC Repo t Utility software to update date and time after battery

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replacement. See BC Repo t Utility Software section for instructions.
3. First select which Mode? CAPAC TY or D SCHARGE to 1 Volt. Use the U or DOWN button to change you
selection. D SCHARGE mode is used to discharge Nickel Cadmium batteries.
4. Push the NEXT button. Now select the battery voltage to be tested. Pressing the DOWN button will change
battery testing voltage to 12 volts.
NOTE: f incorrect battery voltage is selected the BC-7000 display will inform the operator.
5. Push the NEXT button . Select the End Point Voltage (EPV) cutoff. The default EPV is 20 volts for 24 volt battery
and 10 volts for a 12 volt battery. The BC-7000 allows for EPV adjustment from the default values. For a 24 volt
battery the EPV can be lowered to 18 volts. For 12 volt batteries the EPV can be lowered to 9 volts. Check with your
battery manufacturer for specified EPV points.
6. Push the NEXT button. Select the battery manufacturer C1 (one hour) battery discharge amperage rate. Press the
U or DOWN buttons. Pressing the U button will increase the discharge amperage rate.
7. Press the NEXT button to display the start test menu.
8. To start the test, press the NEXT button again. f you wish to stop the test before the End Point Voltage (EPV) is
reached, press the NEXT button and the BC-7000 will stop testing. If testing is stopped befo e EPV is eached the
batte y must be echa ged following the batte y manufactu e ’s echa ge p ocedu es before retesting.
9. After pressing the NEXT button to start the test, the BC-7000 cooling fan motor will start and the LCD display will
show the C1% reading, battery voltage, flash TESTING, and test amperage. Note: While the BC-7000 is testing or at
the conclusion of the test, pressing the UP button will display the test run time in minutes. The LCD will display TM:
60.2’ (The symbol ‘ indicates minutes)
10. Upon reaching the EPV the BC-7000 test will stop. The cooling fan motor will stop and the audio warning beeper
will beep. The display will show C1% battery capacity. Test amperage and Pass or Failed is displayed.
f the BC-7000 COOLING FAN MOTOR FAILS TO START press the NEXT button stopping the test. Place the
OFF/ON switch to the OFF position and return the BC-7000 for service.
“Passing” is based upon a battery capacity of 85% or greater of its C1 rating.