Hioki BT4560 User manual

BT4560
Instruction Manual
BATTERY
IMPEDANCE METER
EN
Aug. 2018 Revised edition 1
BT4560A981-01 18-08H

i
4 Customization
of Measurement
Conditions 37
4.1 Setting the Measurement
Starting Conditions (Trigger
Functions)....................................... 37
Setting the trigger .......................................37
Inputting the external trigger .......................38
4.2 Starting the Measurement After
the Response of the Measuring
Object is Stable (Sample Delay
Function)......................................... 38
4.3 Maintaining Voltage
Measurement Accuracy (Self-
Calibration Function) ..................... 41
4.4 Stabilizing the Measurement
Values (Average Function) ............ 42
4.5 Compensating the Potential
Slope Due to Electric Discharge
(Slope Correction Function).......... 43
4.6 Preventing the Overcharge due
to Measurement Signal (Voltage
Limit Function) ............................... 45
4.7 Prevents Charging and
Discharging due to the
Measurement Signal
(Measurement Signal Zero
Cross Stop Function)..................... 47
5 Judging Measurement
Results (Comparator
Function) 49
5.1 Turning the Comparator
Function ON and OFF .................... 50
5.2 Setting the Upper and Lower
Limit Value ...................................... 51
5.3 Voltage is Judged with the
Absolute Value ............................... 54
5.4 Checking the Judgment with
Sound .............................................. 55
5.5 Checking the Judgment Result .... 56
Contents
Introduction................................................ 1
Registered trademark ...................................1
Verifying Package Contents ..................... 1
Safety Information..................................... 3
Operating Precautions.............................. 6
1 Overview 11
1.1 Product Overview and Features ....11
1.2 Names and Functions of Parts ..... 12
1.3 ScreenCongurationand
Operation ........................................ 15
Measurement screen ..................................15
Settings screen ...........................................15
1.4 Measurement Flow......................... 16
2 Preparation 17
2.1 Connecting the Power Cord.......... 17
2.2 Connecting the Measurement
Probe and Temperature Sensor
(Optional) ........................................ 18
Connect the four-terminal cable to the
instrument ...................................................18
Connect the temperature sensor to the
instrument ...................................................18
2.3 Turning the Power ON or OFF....... 19
2.4 Inspection Before Use ................... 19
3 Basic Measurement 21
3.1 Selecting the Measurement
Functions ........................................ 21
3.2 Selecting the Measurement Range22
3.3 Setting the Measurement Speed... 23
3.4 Setting the Measurement
Frequency ....................................... 24
When the measurement time is long
(Display of the Progress Bar)......................25
3.5 Performing the Zero Adjustment .. 26
Performing the zero adjustment..................26
Connection when performing the zero
adjustment ..................................................29
3.6 Checking the Measurement
Results ............................................ 30
Detecting the measurement abnormality ....30
Temperature measurement indication ........32
Overrange indication...................................32
3.7 Basic Measurement Examples...... 33
BT4560A981-01
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Appx. Index

Contents
ii
9 Communication
(RS-232C, USB) 95
9.1 Features of Interface...................... 95
Specications..............................................95
9.2 Connecting and Setting Method ... 96
Using the USB interface .............................96
Using the RS-232C cable ...........................98
Setting the transmission speed
(Common for USB, RS-232C) ....................99
9.3 Controlling the Communication
and Acquiring the Data ................ 100
Remote state/Local state ..........................100
10 Specications 101
10.1 SpecicationsofMeasurement
Functions ...................................... 101
10.2 Additional Function ..................... 104
10.3 User Interface ................................110
10.4 External Interface ..........................110
10.5 Accuracy ........................................112
10.6 GeneralSpecications .................115
Standards ................................................. 116
Accessories .............................................. 116
Options ..................................................... 116
11 Maintenance and
Service 117
11.1 Troubleshooting ............................117
Q&A (Frequent inquiries) .......................... 117
Error display and remedy..........................121
11.2 Inspection, Repair and Cleaning 123
11.3 Discarding the Instrument........... 124
Lithium battery removal ............................124
6 Saving and Reading
Measurement
Conditions 57
6.1 Saving the Setting Conditions
(Panel Saving Function) ................ 58
6.2 Reading the Setting Conditions
(Panel Loading Function) .............. 60
6.3 Deleting the Contents of the Panel61
7 System Setting 63
7.1 Making the Key Operation
Effective or Ineffective................... 63
7.2 Setting the Sound of the Key
Operation Effective or Ineffective. 65
7.3 Adjusting the Contrast of the
Screen ............................................. 66
7.4 Adjusting the Backlight ................. 67
7.5 System Testing ............................... 68
7.6 ConrmInstrumentInformation ... 73
7.7 Initializing (Reset) .......................... 74
Initial setting table .......................................76
8 External control (EXT.I/
O) 79
8.1 External Input/output Terminals
and Signals ..................................... 80
Switching the current sink (NPN) /the
current source (PNP) ..................................80
Arranging the usage connector and the
signals.........................................................80
Functions of each signal .............................82
8.2 Timing Chart ................................... 84
Acquiring the judgment results after
starting measurement .................................84
Timing of the zero adjustment.....................87
Timing of the self-calibration.......................87
Timing of the panel loading.........................89
Output signal status when turning ON
the power supply.........................................89
Taking-in ow with the external trigger........90
8.3 Internal Circuitry ............................ 91
Electrical Specications ..............................92
Examples of connection..............................93
8.4 Checking the External Control...... 94
Testing the inputs/outputs (EXT.I/O
testing functions).........................................94

Contents
iii
Appendix A1
Appx. 1 Measurement
Parameters and
Calculation Formula ................A1
Appx. 2 Four-terminal Pair Method ......A2
Appx. 3 Cautions When Making
Your Own Measurement
Probe.........................................A4
Appx. 4 Measurement Probe
Structure and Extension .........A6
Appx. 5 Measurement Value
in the Four-terminal
Measurement
(Difference in
Measurement Value Due
to the Measurement Probe) ....A7
Appx.6 InuenceoftheEddyCurrent A8
Appx. 7 Zero Adjustment ......................A8
Appx. 8 Measurement Probe (Option)A12
Appx. 9 Precautions When
Making the Switching Unit ....A13
Appx. 10 Precautions When
Measuring the Battery ...........A15
Appx. 11 Calibrating the Instrument....A18
Appx. 12 Rack Mounting .......................A20
Appx. 13 Dimensional Diagram ............A22
Index Index1
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Appx. Index

Contents
iv

1
Introduction
Introduction
Thank you for purchasing the HIOKI BT4560 Battery Impedance Meter. To obtain maximum
performance from the instrument, please read this manual rst, and keep it handy for future
reference.
Registered trademark
Microsoft and Windows are either registered trademarks or trademarks of Microsoft Corporation in
the United States and other countries.
Verifying Package Contents
When you receive the instrument, inspect it carefully to ensure that no damage occurred during
shipping.
In particular, check the accessories, panel switches, and connectors. If damage is evident, or if it
fails to operate according to the specications, contact your authorized Hioki distributor or reseller.
Conrm that these contents are provided.
BT4560 Battery Impedance Meter Instruction Manual
Power Cord CD (Communications Command Instruction
Manual, Application Software*, USB Driver)
*The latest version can be downloaded
from our website.
USB Cable (A-B type)
Zero Adjustment Board
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Verifying Package Contents
Options (p. A12)
The following options are available for the instrument. Contact your authorized Hioki distributor or
reseller when ordering.
L2002 Clip Type Probe L2003 Pin Type Probe
Z2005 Temperature Sensor 9637 RS-232C Cable (9pin-9pin/1.8 m)

3
Safety Information
Safety Information
This instrument is designed to conform to IEC 61010 Safety Standards, and has been thoroughly
tested for safety prior to shipment. However, using the instrument in a way not described in this
manual may negate the provided safety features.
Before using the instrument, be certain to carefully read the following safety notes.
DANGER
Mishandling during use could result in injury or death, as well as damage to the
instrument. Be certain that you understand the instructions and precautions in
the manual before use.
WARNING
With regard to the electricity supply, there are risks of electric shock, heat
generation, re, and arc discharge due to short circuits. If persons unfamiliar
with electricity measuring instrument are to use the instrument, another person
familiar with such instruments must supervise operations.
Notation
In this manual, the risk seriousness and the hazard levels are classied as follows.
DANGER Indicates an imminently hazardous situation that will result in death or serious injury to
the operator.
WARNING Indicates a potentially hazardous situation that may result in death or serious injury to
the operator.
CAUTION Indicates a potentially hazardous situation that may result in minor or moderate injury
to the operator or damage to the instrument or malfunction.
IMPORTANT Indicates information related to the operation of the instrument or maintenance tasks
with which the operators must be fully familiar.
Indicates a high voltage hazard.
If a particular safety check is not performed or the instrument is mishandled, this may
give rise to a hazardous situation; the operator may receive an electric shock, may get
burnt or may even be fatally injured.
Indicates prohibited actions.
Indicates the action which must be performed.
*Additional information is presented below.
[ ] Setting items and names on the screen are indicated in brackets [ ].
SET
(Bold character) Bold characters within the text indicate operating key labels.
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Safety Information
Symbols on the instrument
Indicates cautions and hazards. When the symbol is printed on the instrument, refer to a
corresponding topic in the Instruction Manual.
Indicates the ON side of the power switch.
Indicates the OFF side of the power switch.
Indicates a grounding terminal.
Indicates DC (Direct Current).
Indicates AC (Alternating Current).
Symbols for various standards
Indicates the Waste Electrical and Electronic Equipment Directive (WEEE Directive) in EU
member states.
This symbol indicates that the product conforms to regulations set out by the EC Directive.
Accuracy
We dene measurement tolerances in terms of rdg. (reading) and dgt. (digit) values, with the
following meanings:
rdg. (Reading or displayed value)
The value currently being measured and indicated on the measuring instrument.
dgt.
(Resolution)
The smallest displayable unit on a digital measuring instrument, i.e., the input value that
causes the digital display to show a “1” as the least-signicant digit.

5
Safety Information
Measurement categories
To ensure safe operation of measurement instruments, IEC 61010 establishes safety standards
for various electrical environments, categorized as CAT II to CAT IV, and called measurement
categories.
DANGER
•Using a measuring instrument in an environment designated with a higher-
numbered category than that for which the instrument is rated could result in a
severe accident, and must be carefully avoided.
•Using a measuring instrument without categories in an environment designated
with the CAT II to CAT IV category could result in a severe accident, and must
be carefully avoided.
CAT II: When directly measuring the electrical outlet receptacles of the primary electrical
circuits in equipment connected to an AC electrical outlet by a power cord (portable
tools, household appliances, etc.).
CAT III: When measuring the primary electrical circuits of heavy equipment (xed installations)
connected directly to the distribution panel, and feeders from the distribution panel to
outlets.
CAT IV: When measuring the circuit from the service drop to the service entrance, and to the
power meter and primary overcurrent protection device (distribution panel).
Outlet
CAT II
Internal Wiring
Distribution Panel
Service Entrance
Service Drop
CAT IV
Power Meter
CAT III
Fixed Installation
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Operating Precautions
Operating Precautions
Follow these precautions to ensure safe operation and to obtain the full benets of the various
functions.
DANGER
This instrument carries a maximum electric current up to 1.5 A to the measuring
object. Do not measure the primary battery. Doing so may cause damage to the
measuring object.
Battery may cause ignition and damage due to overcharge/over discharge. Be
certain in managing battery voltage when measuring.
WARNING
If the measurement probe or the instrument is damaged, there is a risk of electric
shock. Before using the instrument, perform the following inspection.
•Before using the instrument, check that the coating of the measurement
probes are neither ripped nor torn and that no metal parts of connection cord
are exposed. Using the instrument under such conditions could result in
electrocution. Replace the measurement probes with those specied by our
company.
•Before using the instrument for the rst time, verify that it operates normally
to ensure that no damage occurred during storage or shipping. If you nd any
damage, contact your authorized Hioki distributor or reseller.
Instrument installation
Installing the instrument in inappropriate locations may cause a malfunction of instrument or may
give rise to an accident. Avoid the following locations.
For details on the operating temperature and humidity, see the specications p. 115.
WARNING
•Exposed to direct sunlight or high temperature
•Exposed to corrosive or combustible gases
•Exposed to water, oil, chemicals, or solvents
•Exposed to high humidity or condensation
• Exposed to a strong electromagnetic eld or electrostatic charge
•Exposed to high quantities of dust particles
•Near induction heating systems (such as high-frequency induction heating systems
and IH cooking equipment)
•Susceptible to vibration

7
Operating Precautions
Installation
To prevent overheating, be sure to leave the specied clearances around the instrument.
CAUTION
•Do not install the instrument with any side except the bottom facing down.
•Ventilation holes for heat radiation are provided on the side, bottom and rear panels
of the instrument. Leave sufcient space around the ventilation holes and install
the instrument with the holes unobstructed. Installation of the instrument with the
ventilation holes obstructed may cause a malfunction or re.
Unplugging the power cord kills power to the instrument. Be sure to provide enough unobstructed
space to unplug the power cord immediately in an emergency.
Greater than 10 mm
Rear
Greater than 50 mmGreater than 50 mm
Greater than 15 mm
“Raising/closing the stand” (p. 13)
Handling the instrument
DANGER
To avoid electric shock, do not remove the instrument’s case. The internal
components of the instrument carry high voltages and may become very hot
during operation.
CAUTION
•Do not place the instrument on an unstable table or an inclined place. Dropping or
knocking down the instrument can cause injury or damage to the instrument.
•To avoid damage to the instrument, protect it from physical shock when transporting
and handling. Be especially careful to avoid physical shock from dropping.
This instrument may cause interference if used in residential areas. Such use must be avoided
unless the user takes special measures to reduce electromagnetic emissions to prevent
interference to the reception of radio and television broadcasts.
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Operating Precautions
Before connecting the power cord
WARNING
•Before turning the instrument on, make sure the supply voltage matches that
indicated on its power connector. Connection to an improper supply voltage
may damage the instrument and present an electrical hazard.
•To avoid electrical accidents and to maintain the safety specications of this
instrument, connect the power cord provided only to a 3-contact (two-conductor
+ ground) outlet.
CAUTION
•To avoid damaging the power cord, grasp the plug, not the cord, when unplugging it
from the power outlet.
•Avoid using an uninterruptible power supply (UPS) or DC/AC inverter with rectangular
wave or pseudo-sine-wave output to power the instrument. Doing so may damage the
instrument.
IMPORTANT
•Turn off the power before disconnecting the power cord.
• Use only the specied power cord. Using a non-specied cord may result in incorrect
measurements due to poor connection or other reasons.
Before connecting measurement probe/temperature sensor
DANGER
•To avoid electrical hazards and damage to the instrument, do not apply voltage
exceeding the rated maximum to the input terminals.
•The maximum rated voltage to earth of the SOURCE-H terminal and the
SENSE-H terminal is ±5 V DC. The maximum rated voltage to earth of the
SOURCE-L terminal and the SENSE-L terminal is 0 V DC. Attempting to measure
voltages exceeding this level with respect to ground could damage the
instrument and result in personal injury. (Do not apply voltage to earth since the
SOURCE-L terminal and SENSE-L terminal where pseudo earthing is provided
in the internal circuit.)
•To avoid electrical shock, be careful to avoid shorting live lines with the
measurement probe.
WARNING
To avoid injury or damage to the instrument, do not attempt to measure AC
voltage, or DC voltage exceeding 5 V DC.

9
Operating Precautions
CAUTION
•To avoid damage to the instrument, do not apply voltage or current to temperature
sensor terminal.
•To prevent cable damage, do not step on cables or pinch them between other objects.
Do not bend or pull on cables at their base.
•The sensor used in the temperature sensor is a thin, precision platinum lm. Be aware
that excessive voltage pulses or static discharges can destroy the lm.
•Avoid subjecting the temperature sensor tip to physical shock, and avoid sharp bends
in the sensor. These may damage the probe or break a wire.
•When measuring high temperatures, do not let the temperature sensor exceed the
specied temperature range.
•When disconnecting the BNC connector, be sure to release the lock before pulling off
the connector. Forcibly pulling the connector without releasing the lock, or pulling on
the cable, can damage the connector.
Releasing the lock
1 2
Use only the specied measurement probe and the temperature sensor. Using a non-specied
one when measuring may result in incorrect measurements due to poor connection or other
reasons.
Before connecting the communication cable
WARNING
•Always turn both devices OFF when connecting and disconnecting an interface
connector. Otherwise, an electric shock accident may occur.
•After connecting, be sure to tighten the screws. When the mounting screws
are not rmly tightened, the input module may not perform to specications, or
may even fail.
•To avoid electric shock or damage to the equipment, always observe the
following precautions when connecting to connectors.
•Be careful to avoid exceeding the ratings of connectors .
•During operation, a wire becoming dislocated and contacting another
conductive object can be serious hazard. Use screws to secure RS-232C.
CAUTION
The USB and RS-232C are not insulated to the ground (earth). Grounding (earthing) for
the instrument and the controller must be wired as the common earth. Different earthing
may cause a voltage potential difference between the GNDs of the instrument and the
controller. Connecting the communication cable under condition that there is a voltage
potential difference may cause a malfunction and/or a failure. When different earthing is
required, connecting instruments and devices must be isolated.
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Operating Precautions
Before switching the current sink (NPN) and the current source (PNP)
CAUTION
You must not operate the EXT.I/O MODE changing over switch (NPN/PNP) during
Power-ON status of the instrument.
Set the NPN/PNP based on devices that are externally connected.
Before connecting the EXT.I/O terminals
WARNING
•The EXT.I/O of the instrument cannot be applied to from an external power. Do
not apply external power to the instrument. (The ISO_5V terminal of the EXT I/O
connector is a 5 V (NPN)/-5 V (PNP) power output.)
To avoid electric shock or damage to the instrument, always observe the
following precautions when connecting to the connector.
•Always turn off the main power switch to the instrument and to any device to be
connected before making connections.
•Be careful to avoid exceeding the ratings of the signal of the EXT.I/O terminals.
(p. 111)
During operation, a wire becoming dislocated and contacting another
conductive object can be serious hazard. Use screws to secure the external
connectors.
Precautions during shipment
When shipping the instrument, observe the following.
Hioki cannot be responsible for damage that occurs during shipment.
CAUTION
During shipment of the instrument, handle it carefully so that it is not damaged due to a
vibration or shock.
CD disc precautions
IMPORTANT
•Exercise care to keep the recorded side of discs free of dirt and scratches. When writing text
on a disc’s label, use a pen or marker with a soft tip.
•Keep discs inside a protective case and do not expose to direct sunlight, high temperature, or
high humidity.
•Hioki is not liable for any issues your computer system experiences in the course of using this
disc.

11
1Overview
1.1 Product Overview and Features
The BT4560 is a variable-frequency impedance meter.
This instrument is equipped with a highly accurate voltmeter and a temperature measurement function,
and optimal for quality control of batteries.
This instrument has the circuit conguration with high noise immunity, and thus, can provide stable
measurement even at production sites.
What can the instrument
BT4560 measure?
•The instrument can measure the internal impedance of a battery using
the AC four-terminal method.
(Frequency: 0.1 Hz to 1050 Hz, Minimum resolution: 0.1 µΩ)
•This instrument can also measure the DC voltage (the electromotive
force of the battery) simultaneously.
(Resolution: 10 µV, Measurement accuracy: ±0.0035% rdg.±5 dgt.)
•In addition, temperature measurement, which is important for battery
control, can be performed. (Temperature measurement accuracy:
±0.5°C)
What is the difference
between the instrument BT4560
and the existing battery impedance
instruments?
•The instrument has a simple structure, which does not need a loading
device. It is not necessary to congure a system.
•This is a compact instrument and measurement can be performed
without other instruments or devices.
Can the instrument BT4560 be
used at production lines or sites?
•Optional measurement probes can be extended up to a maximum of
4 m, corresponding to an operating environment.
•This can provide highly accurate measurement with a measurement
conguration that resists the inuences of external noise and contact
resistance.
•The built-in comparator function can perform quality judgment of
batteries.
•PLC control using the EXT. I/O is possible.
Can the instrument BT4560
analyze the internal resistance of
batteries?
•A personal computer with application software connected to the
instrument can continuously measure any frequency in the range of
0.01 Hz to 1050 Hz and necessary points.
•This instrument is able to draw Cole-Cole plots*.
* The Cole-Cole plot is a plot of the frequency characteristics of battery
impedance in which the horizontal axis represents the real part of
impedance and the vertical axis represents the imaginary part of
impedance. This plot is used to evaluate the internal resistance of the
battery.
1 Overview
1
Overview

12
Names and Functions of Parts
1.2 Names and Functions of Parts
Front
Display
Monochrome graphic LCD
Operating keys (p. 14)
Temperature sensor terminal
Connects the Z2005
temperature sensor.
Measurement terminal
Connect the measurement probe.
Refer to p. 8.
Voltage detection terminal
(SENSE-L, SENSE-H)
Current detection terminal
(SOURCE-L)
Current generation terminal
(SOURCE-H)
Rear
Power inlet
Connects the power
cord (accessory).
(p. 17)
Refer to p. 8.
RS-232C interface
Connects to the
computer. (p. 95)
Manufacturer’s serial number
Indicates the serial number.
Do not remove this label, as it is required for product
support.
USB interface
Connects to the
computer. (p. 95)
EXT.I/O terminal
Connects to an
external controller.
(p. 79)
Refer to p. 10.
Power
switch
(p. 19)
EXT.I/O NPN/PNP switch
Left: Current sink (NPN)
Right: Current source (PNP)
(p. 80)
Vents
Keep clear of
obstructions .

13
Names and Functions of Parts
Bottom panel
Stands
Vents
Side
Raising/closing the stand
CAUTION
Do not apply heavy downward pressure with the stand extended. The stand could be
damaged.
1
Overview

14
Names and Functions of Parts
Operating keys
1
2
3
4
5
6
8
7
9
10 11
12
13 14
Key Description
1Selects the measurement function (combination of the voltage measurement and
the impedance measurement).
2Sets the measurement range.
3Sets the measurement speed of impedance.
4Sets the measurement speed of voltage.
5Sets the measurement frequency of impedance.
6Sets the power switch of ON-OFF and the upper and lower limit values ,etc. of the
comparator.
7Saves and reads the measurement conditions.
8Sets each of the functions (Trigger, Sample delay, Self-calibration, etc.).
9Releases the remote state and enables key operation.
10 Performs the zero adjustment.
11 Starts and stops the measurement.
12
•Moves setting items and digits.
•Changes numerical values.
13 •Cancels the settings being set.
•Erases a display message.
14 Conrms the setting.