Cofko LLC. BC-7000 User manual

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BC
BCBC
BC-
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-7
77
7000
000000
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.

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“Failing” is a battery with less than 85% of its C1 rating.
Befo e etu ning the batte y to se vice follow the batte y manufactu e ’s echa ging p ocedu e.
REMEMBER SAFETY FIRST!
BC-7000 Repo t P inting
1. Disconnect the BC-7000 from the test battery. Place the OFF/On power switch to the OFF position. Connect the
USB cable from the PC to the BC-7000 USB port located in the rear of the tester. Start the PC and run the BC Repo t
Utility software located on the WindowsTM desktop.
2. With the BC Repo t Utility window active on the desktop, type the battery serial number into the Batte y Se ial
Numbe : box. Make sure the data source is F om BC-7000 by highlighting the indicator circle.
3. Place the mouse cursor on the Load Data button and press the left mouse button. The status bar in the lower left
corner of the BC Repo t Utility window will display program activity and status messages as data is transferred.
4. To print the report, place the mouse cursor on the Print Report button and press the left mouse button. The
WindowsTM print preview window will appear showing the report available to print. Place the mouse cursor on the
printer icon and press the left mouse button.
TIP: A pape less epo t copy can be obtained by using a p int d ive that will c eate a PDF file. These
d ive s a e available fo sale o f eewa e and install in the WindowsTM p inte devices. This epo t fo mat allows BC-
7000 test epo ts to be sent elect onically by means of e-mail attachments .
5. To print a BC-7000 battery test report that has been already down loaded, use the F om Disc function to print the
report. Change the file source F om BC-7000 to F om Disc. The data file uses the file extension .tdf. The file name is a
combination of battery serial number, date, and time and can be found in the Concord file located at C:\Concord\BC-
7000. Place the mouse cursor on the Load Data button and press the left mouse button. The Open test data file window
will open on the desktop. Choose the data file that is to be printed by selecting the file with the left mouse button. Click
Open at the bottom of the window. Place the mouse cursor on the P int Repo t button and press the left mouse button.
The Print Preview window will become active on the disk top. To print report, left mouse click the printer icon.

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BC-7000 CARE
Your BC-7000 battery capacity tester should be treated as precision test equipment, misuse will shorten its ability to
perform accurate battery testing. Some simple guidelines of care will insure years of trouble free operation.
1. Do not drop the BC-7000 or expose it to rough handling.
2. Do not expose the BC-7000 to water or fluids of any kind.
3. Do not operate the BC-7000 in a closed up area.
4. Do not connect the BC-7000 to batteries of improper voltage ratings.
5. Do not operate the BC-7000 with the air intake or exhaust outlet blocked or restricted.
6. Do not carry the BC-7000 by the main power cable.
7. Do not operate the BC-7000 near flammable materials.
8. Do not expose the BC-7000 to direct sunlight during operation.
9. Do not expose the BC- 7000 to any other heat sources.
10. Always call the technical support line for questions on BC-7000 safety and operation.
PH: [phone] , E-mail [e-mail]
REMEMBER SAFETY FIRST!

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TECHNICAL DATA
BC-7000 SPECIFICATION:
AC nput Voltage
………………………………......................................................... 90~264VAC 1 Phase (47 to 63Hz)
AC nput Current
………………………………......................................................... 0.75A @115VAC ; 0.50A @ 230VAC
Maximum Battery nput Voltage
……………………………………………………………………………......... 28.0VDC
Minimum Battery nput Voltage
………………………………………………………………….....…............. 9.0VDC
Maximum Operating Altitude1
………………………………....……………………………….................... 6500ft(1828.8m)
End Point Voltage (EPV)2
12V Battery EPV
…………………………………………………………………………........….. 10VDC EC
24V Battery EPV
………………………………………………………………………….........…. 20VDC EC
Constant Current Load
………………………….…………………......................................….. 0.5Adc to 15Adc 0.1A steps (+ - 1.5%)
……………………………….......................................................... 15Adc to 55Adc 1A steps (+ - 1%)

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Testing Operational Temperature3
…………………………………………………………….............………….....… 59°F or higher
Operation Temperature Range
………………………………............................................................... -20 to 50 Deg. C
Case Length
……………………………………………….………………...............…....……. 12 in(304.8mm)
Case Width
…………..………………………………………………………..............……...… 9 in(228.6mm)
Case Height
……………..……………………………………………............……......…..…… 7.5 in(190.5mm)
Weight
……….………………………………………………………………..............….... 10 lbs(4.5kg)
PC Communication Port
……….………………………………………………………………...............…... USB 2.0
BC REPORT Utility Software
……….…………………………………………………..……............................ WindowsTM XP or Higher
1. Consult factory for testing above maximum altitude rating.
2. Consult battery manufacturer for End Point Voltage (EPV).
3. Based upon 24 hour battery temperature stabilization in a 59°F or higher environment before testing battery. Consult
battery manufacturer for capacity testing at higher or lower temperatures.

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BC-7000 LIMITED WARRANTY
STATEMENT OF WARRANTY
COFKO LLC warrants to the original purchaser (end user) of the BC-7000 battery capacity tester that it will be free of
defects in workmanship and materials. This warranty is void if COFKO LLC finds that the BC-7000 battery capacity tester
has been subjected to improper care, abnormal operation, or modification.
WARRANTY PERIOD:
The warranty period covers the original purchaser (end user) from the date of shipping.
1 Year: Covers each BC-7000 battery capacity tester for workmanship, material, and labor.
TO OBTAIN WARRANTY COVERAGE:
You are required to notify COFKO LLC, of any defects within the warranty period. Written notification is recommended.
WARRANTY REPAIRS:
f upon inspection COFKO LLC confirms the existence of a defect covered by this warranty, the defect will be corrected by
repair or replacement at COFKO LLC option.
WARRANTY COST:
The purchaser must bear the cost of shipping the BC-7000 to COFKO LLC as well as the return shipping cost.
IMPORTANT WARRANTY LIMITATIONS:
1. COFKO LLC will not accept responsibility for repairs made without authorization.
2. COFKO LLC shall not be liable for consequential damages (such as lost business, etc.) caused by a defect or
reasonable delay in correcting a defect to the BC-7000 battery capacity tester.
3. COFKO LLC liability under this warranty shall not exceed the cost of correcting the defective BC-7000 battery
capacity tester.
4. This written warranty is the only expressed warranty covering the BC-7000 battery capacity tester. All
warranties implied by law such as Warranty of Merchantability are limited to the duration of this limited
warranty of the BC-7000 battery capacity tester. Check your local legal rights for further rights you may have.

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BC-7000 NOTES
1. ___________________________________________________________________________
2. ___________________________________________________________________________
3. ___________________________________________________________________________
4. ___________________________________________________________________________
5. ___________________________________________________________________________
6. ___________________________________________________________________________
7. ___________________________________________________________________________
8. ___________________________________________________________________________
9. ___________________________________________________________________________
10. ___________________________________________________________________________

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COFKO LLC.
5517 RIVERVIEW DR.
RIVERSIDE, CA. 92509
[phone]
COFKO.COM
[e-mail]
CERTIFICATION OF FACTORY CALIBRATION
EQUIPMENT: BATTERY CAPACITY TESTER
MODEL#: BC-7000
Application : Automatic battery capacity tester for 12/24
volt Lead-Acid aircraft batteries with C1 test
ratings between 0.5 to 50 ampere-hour
Specification:
Universal AC Powered: 85~264vac (47 to 63Hz)
Operation Voltage Range : 28VDC to 9VDC
Operator Selected Battery Voltage: 24-12Vdc
Operator Selected C1 amperage level: 0.5 - 50Adc
Operator Selected Test Amperage Steps: 0.1Adc steps 0.5A to 15Adc;1Adc steps 15A to 50Adc.
(16X2) LCD Information Display.
Displayed Voltage Resolution 10mv
Cutoff Voltage 12V Battery 10.00Vdc (IEC 60952-1) +/-100mv
Cutoff Voltage 24V Battery 20.00Vdc (IEC 60952-1) +/-100mv
Displayed Battery Capacity (C1) Percent %
Displayed Pass or Fail Battery Condition
WindowsTM Compatible Test Data Print Utility (BC Report Utility)
Notes: Calibrated with NIST traceable equipment.
Test Equipment Manufacturer: Model: Serial# Control#
Volt Meter #1 HP 3456A 2015A01818 12617
Volt Meter #2 HP 3455A 1622A11888 12618
Frequency Counter HP 5316A 2632A10545 12693
Shunt Deltec WB 100 100 NA. 137317MLQA5
Product: Automatic Battery Capacity Tester
Model: BC-7000
Calibration Due: Once A Year
Shipped Condition: Calibrated within Specified Tolerance _____- Passed
Procedure: CF1_FINALCAL
COFKO LLC. CERTIFIES THAT THE ABOVE LISTED TEST EQUIPMENT MEETS OR EXCEEDS ALL SPECIFIED TOLERANCES. THE TESTER
STATED ABOVE HAS BEEN CALIBRATED WITH NATIONAL INSTITUTE OF STANDARDS AND TECHNOLOGY(NIST) TRACEABLE EQUIPMENT
LISTED ABOVE.
DATE MANUFACTURED:____/____/_______ S/N: ________________________1
SIGNATURE:__________________________
-----------------------------------------------------------------------------------------------------------------------------------------------------------------------
Date of First Use: ____/____/______ Signature:________________________
1. BC-7000 serial number location- bottom of case.