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Cadex C4000 SERIES User Manual

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CADEX C4000 SERIES
SATTERY ANALYZER
•
USER'S MANUAL
CADEX ELECTRONICS INC.
111- 7400 MacPherson Ave.
•
Burnaby, B.C. Canada V5J 5B6
Tel (604) 451-7900
Fax (604) 451-7991
Toll Free 1-800-565-5228

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Summary of Contents for Cadex C4000 SERIES

  • Page 1 CADEX C4000 SERIES SATTERY ANALYZER • USER'S MANUAL CADEX ELECTRONICS INC. 111- 7400 MacPherson Ave. • Burnaby, B.C. Canada V5J 5B6 Tel (604) 451-7900 Fax (604) 451-7991 Toll Free 1-800-565-5228...
  • Page 2 • WARRANTY CADEX ELECTRONICS INC. warrants the Cadex C4000 Battery Analyzer against defective materials and workmanship for ONE YEAR from the purchase date. Service is available by returning the unit to the manufacturer. The manufacturer will assume one half of the shi in cost.
  • Page 3 • DO'S AND DONT'S • Connect the C4000 Battery Analyzer to the correct line voltage. The operating voltage is indicated on the instrument label on bottom of the unit. Recharge NiCd batteries between SoC and 3S 0C (41 0 F and 96 •...

  • Page 4: Table Of Contents

    Table of Contents • WARRANTY DO'S AND DON'TS CHAPTER 1 - INTRODUCTION 1. Overview of Cadex C4000 2. Getting Started CHAPTER 2 - BASIC OPERATION 1. Power Up 2. Analyzing Batteries 3. Evaluation of Battery Results & CHAPTER 3 - PROGRAMS TARGET CAPACITY 1.
  • Page 5 Table of Contents • CHAPTER 7 - PROGRAMMING BATTERY ADAPTERS 1. C-Code Definition 2. C-Code Structure 3. Quick View of Battery Parameters 4. Menu Tree 5. Menu Functions CHAPTER 8 - UTILITIES 1. Reset to Factory Default 2. Copy Settings 3.
  • Page 6 Table of Contents • CHAPTER 12 - DIAGNOSTICS 12-1 1. RAM/Clock/LCD Check 12-2 2. Start-up Messages 12-3 CHAPTER 13 - SERVICE 13-1 1. Static Precautions 13-2 2. Replacing Fuses 13-2 3. Replacing Back-up Battery 13-3 4. Replacing the EPROM 13-5 5.

  • Page 7: Introduction

    CHAPTER 1 INTRODUCTION • CHAPTER 1 INTRODUCTION • •...

  • Page 8: Overview Of Cadex C4000

    Introduction • Overview of Cadex C4000 -ON-OFF S . witch on the back panel Liquid Crystal Display (LCD) Station with out Battery Ad apters • Menu Key Display Key Target Selector S . witch Program Selector Switch Read~ Fail'Y~ LED Indicators (0 ne group per Station)

  • Page 9: Getting Started

    Introduction • 2. Getting Started Plug in and turn on Plug and on-off switch are located on the back of the C4000. Select the program The Program Selector Switch is on the front of the analyzer. Select: • PRIME for new or stored batteries prior to use •...

  • Page 10: Basic Operation

    CHAPTER 2 BASIC OPERATION • CHAPTER 2 BASIC OPERATION • •...

  • Page 11: Power Up

    Basic Operation • 1. Power Up Before connecting the C4000, check for the correct line voltage. The line voltage label is located on the bottom of the unit. The on-oft switch is on the back panel. When the power is turned on, the display (LCD) message briefly reads: :,gM9!:"(ll~'.::.B.~::.eEElmgrff:!~nISi:.:::.: Start-up messages...

  • Page 12: Analyzing Batteries

    Basic Operation • 2. Analyzing Batteries Set Program Before servicing a battery, select the desired program (refer to CHAPTER 3 - PROGRAMS & TARGET CAPACITY). Set Target Capacity Select the Target Capacity. If you are not certain what setting to use, select 80%. For more detail. refer to CHAPTER 3 - PROGRAMS &...
  • Page 13 Basic Operation • "Dead" batteries If the battery to be serviced has no voltage reading, an initial brief charge by a designated charger is required. The C4000 will not start the program if battery voltage is not detected. Connect battery After selecting the program and target capacity, you are now ready to connect the battery.
  • Page 14 Basic Operation • Example A fully-charged battery rated at 1000mAh must be able to provide a discharge current of 1000mA for one hour. If the battery can provide this current for that time, the derived capacity is 100%. If the battery can only provide the current for 30 minutes, the capacity 50%.

  • Page 15: Evaluation Of Battery Results

    Basic Operation • 3. Evaluation of Battery Results Evaluation by LEDs PRIME and AUTO Each Station is equipped with RUN, READY and FAIL LEOs. During service, the RUN LED is on. When the program is completed and the battery has met or exceeded the Target Capacity, the READY LED lights up.

  • Page 16: Programs & Target Capacity

    CHAPTER 3 PROGRAMS & TARGET CAPACITY • CHAPTER 3 PROGRAMS & TARGET CAPACITY • •...

  • Page 17: Application Table

    Programs & Target Capacity • Introduction The CADEX C4000 features user-selectable programs with decision-making capabilities that evaluate the bat- tery and apply an appropriate service to improve or restore a battery. This section explains the different applications, and recommends the best choice of program and target capacity settings to be used.

  • Page 18: Prime

    Programs Target Capacity & • 2. Prime When to use it • Prepare new batteries for field use. • Condition batteries that have been in storage. • Verify battery condition to support warranty • claim. PRIME is used to condition new batteries prior to use. A new (or stored) battery may require several charge/ discharge cycles until peak performance is reached.
  • Page 19 Programs Target Capacity & • Indicators Lights • READY if the battery meets or exceeds the Target Capacity. • FAIL if the battery cannot meet the Target Capacity . Display When the program is successfully completed, the Global Display shows the Final Capacity reading. By pressing the appropriate Display Key, the display shows additional information.

  • Page 20: Charge

    & Programs Target Capacity • 3. Charge When to use it • Top-up partially charged batteries. • Serves as a fast-charger. Program Time The time required may vary depending on the battery type. At a C-Rate of 1C, the charge time is: NiCd 90 minutes typically NiMH...

  • Page 21: Auto

    Programs & Target Capacity • Indicators LEDs Blinking READY if the battery is fully charged (blinking indicates that no capacity evaluation was taken). FAIL if the voltage is too low. Display When the program is successfully completed, the Global Display shows "DONE". If the battery failed, a Fail Code is shown (refer to CHAPTER 5 - FAULT -CODES).
  • Page 22 Programs & Target Capacity • How it works If Residual Capacity The battery is first discharged to one volt per cell during which the Residual Capacity is measured. If the meets target capacity meets or exceeds the target, a final charge is applied.

  • Page 23: Custom

    Programs & Target Capacity • 5. Custom The Custom Program is used if a special function or a sequence of functions is required, such as: • Discharge only for purpose of shipping or storage • Long-term reliability test by cycling the battery until the capacity drops below the set Target Capacity.

  • Page 24: Target Selector

    Programs Target Capacity & • 7. Target Selector Setting The Target Capacity is set through the Target Selector Switch. The setting is global and applies to all Stations. Individual Target Capacity settings are possible through the menu-driven interface. Refer to CHAPTER 8 - UTILITIES, "4.

  • Page 25: Calculation Of Target Capacity

    Programs & Target Capacity • 8. Calculation of Target Capacity To establish a workable target setting for your require- ment, the following evaluation is recommended: • Use a battery with a known working-capacity reading • Fully charge the battery and use it in a normal field situation •...

  • Page 26: Chapter 4 - Status Indicators

    CHAPTER 4 STATUS INDICATORS • CHAPTER 4 STATUS INDICATORS • •...

  • Page 27: Led Indicators

    Status Indicators • Introduction The light-emitting diode (LED) provides the user with a quick overview of the battery test results. The battery status is indicated for each Station by the LEOs as follows: (yellow) Program in progress READY (green) Program completed FAIL (red) Test results negative.

  • Page 28: Audible Tone Signals

    Status Indicators • 2. Audible Tone Signals The C4000 Analyzer produces a variety of audible signals to mark events such as buttons pressed or programs ending. The signals and the events are listed below. Single beep tone: • Battery connected (long beep) •...

  • Page 29: Status Indicator Tables

    Status Indicators • 3. Status Indicator Tables Table 4.1 summarizes the LED and sounder schedules. CONDITION LEOs SOUNDER MODE COMMENTS NO BATIERY Open terminal reset silent Station resets READY when battery FAIL removed. BATTERY Battery in single beep active Beep tone when INSERTED service READY...
  • Page 30 Status Indicators • Temperature Sensor The sensor inhibits fast charging outside the operational (optional) temperature range. Battery sensing is not required if the batteries are serviced within the specified temperature range. The temperature sensor measures the cell temperature of the battery. The sensor may be part of the battery assembly or installed externally.

  • Page 31: Display (Lcd)

    Status Indicators • LEOs CONDITION MODE SOUNDER COMMENTS OVER Heat rail too hot no charge Service resumes POWER ••••••••• TEMPERATURE silent when temperature discharge normal. SYSTEM ERROR System fault Any LEOs on or off at on or off non valid Micro-eontroller random fault.
  • Page 32 Status Indicators • Second line The second line displays the average cell voltages of the batteries in bar-graph form. Each battery occupies one line. The voltage range of the bars is divided into SHORT, ZONE 1, ZONE 2 and SOFT. While on charge, only batteries which enter and remain in Zone 2 are functioning correctly.

  • Page 33: Display Messages

    Status Indicators • Program Duration The elapsed program time is displayed on the lower right. This feature is only audible with the Option-Po Menu Display The Menu Display allows you to view and modify the battery parameters stored in the Battery Adapters. Refer to CHAPTER 7 - PROGRAMMING BATIERY...
  • Page 34 Status Indicators • Detailed Display Messages Message Explanation 1ST CHARGE [AUTO] First charge cycle in AUTO program 2ND CHARGE [AUTO] Second charge cycle in AUTO program 1ST DISCHARGE [AUTO] First discharge cycle in AUTO program 2ND DISCHARGE [AUTO] Second discharge cycle in AUTO program AUTO FAILED [AUTO] Battery failed in AUTO program BAD ADAPTER - RE-INSERT...
  • Page 35 Status Indicators • LOW VOLTAGE (ZONE 1 DELTA TEMP) (Code 52) NO ADAPTER No Battery Adapter, or adapter not recognized NOT ACTIVE - INSERT A BATTERY No battery connected, or battery not recognized NULL C-CODE - ENTER BATTERY CODE (Enter valid C-Code) OPEN FUSE OR BAD DRIVER (Code 60) OVER VOLTAGE...

  • Page 36: Chapter 5 - Fault Codes

    CHAPTER 5 FAULT CODES • CHAPTER 5 FAULT CODES • •...

  • Page 37: Application Tables

    Fault Codes • • 1. Application Tables The CADEX C4000 is capable of identifying battery deficiencies and faults. These characteristics categorized in Fault Codes. Explanation of the Fault Codes are shown on the display upon request. The Application Table on the following pages summarizes the Fault Codes.
  • Page 38 Fault Codes • Fault Definition Reason Battery What to Code Chemlstrv Discharge time-out Capacity exceeds 250% NiCd, NiMH Check battery rating within capacity C-Code Charge time-out Battery too large for allotted NiCd, NiMH Check battery rating within charge time C-Code Recondition time-out Allotted Recondition time is too NiCd, NiMH...

  • Page 39: Correctable Faults

    Fault Codes • 2. Correctional Faults Correctional Faults allow the program to proceed but result in a Fault Code as a caution to the user. Note Batteries with correctable faults may improve with the PRIME or AUTO program. If the battery is corrected as a result of the programs, the Fault Code changes to Corrected Fault Code.
  • Page 40 • What to do If a battery has been over-rated, select a lower charge and discharge current. Use your judgment in selecting a more appropriate current rating. CADEX recommends a current reduction of 10% to 15%. Code 18 Reason Battery terminal voltage rises too high during CHARGE CURRENT charging.

  • Page 41: Voltage Faults

    Fault Codes • 3. Voltage Faults Voltage faults are caused by shorted cells in the battery pack. If this occurs, the battery can no longer be used. Attempting to replace the faulty cells have failed in the past as the replacement cells are not matched with the existing cells.
  • Page 42 Fault Codes • Code 24 Reason Charge time-out in Zone 1 after 10 minutes VERY LOW VOLTAGE Battery has shorted cells. (ZONE 1 TIME-OUT) Battery type Code 24 is most common with NiCd and NiMH batteries. What to do Discard battery. Code 25 Reason Charge termination in Zone 1 through Plateau LOW VOLT (ZONE...
  • Page 43 Fault Codes • Code 28 Reason Battery voltage rises too high during charging. SOFT BATTERY The program terminates. Possible reasons: • Charge current is set too high for battery type • Battery has been in prolonged storage • Battery is too cold •...

  • Page 44: Timing Faults

    Fault Codes • 4. Timing Faults Each cycle is given a time limit in which to complete the task. If the task cannot be completed in the time frame allotted, a Fault Code is generated. Code 42 Reason Discharge time exceeds 250% (2:30h)' . DISCHARGE TIME-OUT Program is terminated.

  • Page 45: Temperature Criteria

    Fault Codes • 5. Temperature Criteria (Optional) If batteries are serviced under extreme temperature conditions, temperature sensing is recommended. Temperature sensing is optional and is not required under normal temperature conditions. Code 52 Reason Charge is terminated in Zone 1 through Delta LOW VOLTAGE (ZONE Temperature.

  • Page 46: Electrical Limitations

    Fault Codes • 6. Electrical Limitations The battery in service must be able to deliver the current being requested. Likewise, the C4000 must provide the charge and discharge requirements that is commanded. If, due to a weak battery or faulty power supply, the current cannot be delivered, a Fault Code is generated.

  • Page 47: Corrected Faults

    Fault Codes • Code 64 Reason CHARGE CURRENT Power supply, battery or driver cannot provide the NOT MET charge current required. Possible reasons: • Low line voltage • Power supply problem • Charging 12 cell battery packs at high current •...

  • Page 48: Chapter 6 - Battery Adapters

    CHAPTER 6 BATTERY ADAPTERS • CHAPTER 6 BATTERY ADAPTERS • •...

  • Page 49: Battery Adapter Styles

    The use of Battery Adapters enables the C4000 to accommodate a large variety of battery types. A list of current Battery Adapters is shown in the APPENDIX. an adapter is not listed, contact CADEX ELECTRONICS INC. • 1. Battery Adapter Styles...
  • Page 50 Battery Adapters • CONFIGURED CUP SMART ADAPTER SMART CABLE Configured or Universal Configured or Universal Figure 6.1 Battery slides into cup. Accommodates batteries Adapter is passive; the The C-Code may be that cannot fit into a cup. cable itself is pro- changed for batteries •...

  • Page 51: Installation

    Battery Adapters • Smart Cables Smart Cables differ from the Smart Adapter in that the memory chip is embedded in the cable. The cable is open-ended and may be terminated with appropriate battery connectors. Smart Cables are used with a Passive Adapter.

  • Page 52: Battery Adapter Errors

    Battery Adapters • 3. Battery Adapter Errors When a Battery Adapter is installed, the analyzer reads the C-Code in the adapter's memory chip. If the analyzer detects a fault, the LCD displays an appropriate message. The following table shows the most common messages.

  • Page 53: Chapter 7 - Programming Battery Adapters

    CHAPTER 7 PROGRAMMING BATTERY ADAPTERS • CHAPTER 7 PROGRAMMING BATTERY ADAPTERS • •...

  • Page 54: C-Code Definition

    Programming Battery Adapters • 1. C-Code Definition The C-Code is a set of battery parameters stored in the Battery Adapter. When the Battery Adapter is installed, the analyzer reads the C-Code and configures the Station to the appropriate battery parameters. The C- Codes can be altered by the user.

  • Page 55: C-Code Structure

    Programming Battery Adapters • 2. C-Code Structure The C-Code is made up of two parts: Basic C-Code and Extended C-Code. Basic C-Code The Basic C-Code contains the fundamental battery parameters consisting of: Battery type (NiCd, NiMH and SLA) Number of cells Battery rating in mAh.

  • Page 56: Quick View Of Battery Parameters

    Programming Battery Adapters • 3. Quick View of Battery Parameters The parameters programmed into the Battery Adapter can be viewed by pressing the Display Key when in "EMPTY" status. This feature allows you to verify the parameters before connecting the battery. Multi-frame display The parameters are contained in several frames, starting with the basic information in the first frame,...
  • Page 57 Programming Battery Adapters • GLOBAL DISPLAY 102'110 READY EMPTY ADAPTER? ,--------------------, To mClYll around In the Menu praa: EMPTY slIIliona have dirllct _ [!]fr W~ 0c:Q 0<? CCJ VIEW BATTERY PARAMETERS #1: VIEW BATTERY PARAMETERS? #1: SEALED MCd - 8 CEI.LS [7.5OV) (~:mAb.

  • Page 58: Menu Functions

    Programming Battery Adapters • 5. Menu Functions The menu is used to modify the existing battery parameters (C-Code), set DatelTime and Print Formats (Option-P only), or use any of the specific functions in the Utilities. Entering menu mode Press the Menu Key and select the Station with the from Global Display Battery Adapter you wish to modify.
  • Page 59 Programming Battery Adapters • The parameters are contained in several frames, starting with the basic information in the first frame, followed by more detailed definitions in the subsequent frames. Keys 1 and 2 let you scroll through the available menu options. Note To quick-view the battery parameters without going through menu mode, refer to "3.
  • Page 60 Programming Battery Adapters • Frame 2: DCM.;-oi5.G .. ( 26.OD.tnAh).:::..: .#.~kCM::Q~5.C:. (200omAb);; .. : :.:>.. ::: ...:". " TRICKUE:GH: REe08:.DCH"/t2!4.: .. . ;..:... :: rli;:: Explanation CH 0.5C (2000mAh) Charge C-Rate, current is 2000mA DCH 0.5C (2000mAh) Discharge C-Rate, current is...
  • Page 61 Programming Battery Adapters • Basic C-Code Extended C-Code Frame 6: with il~:~i:ii!.IIIII~~~!I~!llllllfi~~~!ii;ij!i!i!i:i:iiiliIlilliili Extended C-Code L-.J Selected Program Version Note The Extended C-Code is only shown if different than the default setting. Modify Battery Code Modifying the battery parameters (C-Code) is done with the MODIFY BATTERY CODE menu option.
  • Page 62 Programming Battery Adapters • Example 1 Change battery rating from current setting of : 10-06-060 • NiCd of 6 cells (7.5V) 1500mAh; C-Code • NiCd of 6 cells (7.5V) 1200mAh; C-Code 10-06-048. Cursor position at start :1111~' ! llill' I .I:I:::llljl::I:I!III!!II!:I!III:III::1jl~llllllllj~lj:lll:jllllll:lll:I:!III:I:::!I!I! Press 3 to go to the NUMBER OF CELLS Press 3...
  • Page 63 Programming Battery Adapters • Example Change battery type, cell count, -current rating and C-Rate to: • NiCd of 6 cells (7.5V) 4000mAh, C-Rate of 0.33; 11-06-160 :3333-06-500-3646. C-Code Repeat the keystroke procedure listed at the beginning of this section to enter the MODIFY BATTERY CODE menu option.

  • Page 64: Chapter 8 - Utilities

    CHAPTERS UTiliTIES • CHAPTER 8 UTiliTIES • •...

  • Page 65: Reset To Factory Default

    Utilities • Introduction The UTILITIES menu option includes the following options: • RESET TO FACTORY DEFAULT • COpy SETTINGS • SET PASSWORD • STATION TARGET CAPACITY • CENTER SWITCH POSITION* • MODIFY CUSTOM PROGRAM* • VIEW CUSTOM PROGRAM* • COMPANY NAME •...

  • Page 66: Copy Settings

    Utilities • 2. Copy Settings A Battery Adapter parameter's can be copied to another Battery Adapter with COpy SETTINGS. To copy settings Press Menu, select Station, scroll (Key 1 or 2) to UTILITIES, enter, scroll to COpy SETTINGS and enter. The display reads: Select the appropriate Station.
  • Page 67 To remove Password Select SET PASSWORD from UTILITIES; enter current password when prompted; at "EDIT PASSWORD" enter 000. Caution: Remember the Password If the password is unknown, the Battery Adapter is frozen. If this occurs, please contact CADEX ELECTRONICS INC. •...

  • Page 68: Station Target Capacity

    Utilities • 4. Station Target Capacity A Target Capacity for each Station can be set independently using any number from 1% to 199%. This Station Target Capacity is retained in the Battery Adapter and is applied instead of the Global Target Capacity set by the Target Selector Switch.

  • Page 69: Calibrate Station

    Utilities • The sequence is as follows: - 0, 1,2, 3, 4, 5, 6, 7, 8, 9, -(dash), . (period), [ ] (space), A, B, C, D, E, F, G, H, I, J, K, L, M, N, w, x, R, S, T, U, V, Y, Z.
  • Page 70 Utilities • Press the Display Key for the Station to start calibration. While calibrating, the LCD read: At the end of calibration, a triple beep is heard and the LCD reads: If the leads had opened during the test, the LCD reads: "CALIBRATION ERROR, PRESS ANY KEY".
  • Page 71 Utilities • Limitations on single cells Maximum 1000mA The maximum discharge current of a single cell is limited to 1000mA, even with calibration. The current for single cell may have to be set lower if cable length or contact resistance cause a problem. Possible problems are: Fail If the discharge current is set too high, FAIL 62 appears.

  • Page 72: Chapter 9 - Custom Programs

    CHAPTER 9 CUSTOM PROGRAMS • CHAPTER 9 CUSTOM PROGRAMS • •...

  • Page 73: Setting Up Custom Program

    Custom Programs • Introduction The Custom Program enables you to choose any desired sequence of charge, discharge, recondition or trickle charge. Rest periods, repeats and stop can also be added. This program allows long-term battery reliability tests, a self-discharge check, the priming of new batteries and more.
  • Page 74 Custom Programs • To continue to the next field setting, press Key 3; to step back, press Key 4; to apply changes to a Phase, scroll the number by pressing Key 1 or 2, then press Key 3 to accept and advance; to exit without changes, press the Menu Key.
  • Page 75 Custom Programs • Limitation Only one Custom Program configuration can be stored at any time within the analyzer. The program may be assigned to any or all Stations. It is not possible to assign various Custom Programs to different Stations. To change the Center Press Menu, select Station, scroll (Key 1 or 2) to UTILITIES, enter, scroll to CENTER SWITCH...

  • Page 76: Typical Applications

    Custom Programs • OPTION-P with dead If the back-up battery has been removed or is no longer functional, OPTION-P cannot retain the back-up battery Custom Program Code. In this case the function will be as per "Without OPTION-P". 2. Typical Applications Discharge only for NiCd Manufacturers-of NiCd batteries claim that it is best to battery...
  • Page 77 Custom Programs • Program Charge/discharge the battery until the derived capacity drops to below the set target setting. Custom-Code 2121-0000-0000-0000:00 Phase 1 [2121] 2=charge; 1=discharge; 21 =if target capacity is met, go-to Phase 1 (repeat as long as Target Capacity is met;...
  • Page 78 Custom Programs • Phase [4112] 4=trickle charge until fully charged (battery was unable to generate a capacity of 5% with fast-charge); 1=discharge; 12=proceed back to phase 2. Exit Phase [09] O=no cycle; 1=done, trickle charge. Self-discharge test After the battery has aged or has performed over 1000 charge-discharge cycles, the self-discharge of the rechargeable battery increases.

  • Page 79: Code Definition

    Custom Programs • The Custom Program is divided into four Phases and 3. Code Definition one Exit Phase. Each Phase can be programmed independently. The complete Custom Code is as follows: CCTG - CCTG - Phase 1 Phase 2 Phase 3 Phase 4 Exit Phase...
  • Page 80 Custom Programs • Test and Go-To The third and fourth digits of a Phase are assigned to "Test" and "Go-To". • Test provides further instructions after Cycles 1 and 2 have been completed. • Go-To executes these instructions . Table 9.2 illustrates the options of Test and Go-To. (n Test (G) Go-To Skip (T) Test...
  • Page 81 Custom Programs • Explanation of Test Advances to the next Phase. Provides an unconditional choice to either exit or advance to any of the 4 available Phases, regardless of the Target Capacity setting, capacity gains or other criteria. "Target Capacity met" lets you take a different route if the required Target Capacity is met.

  • Page 82: Program Variations

    Custom Programs • Exit Phase The Custom Program concludes with the Exit Phase. This Phase consists of Cycle and Ready. Cycle is identical to the Cycle 1 and 2 in the Phases. Ready completes the program. You have a choice of trickle charge or no trickle charge while in ready mode.
  • Page 83 Custom Programs • Faulty battery If a battery fails, the program is terminated. Example A battery with shorted cells unable to reach the required window voltage cannot continue to the next Phase. Cycles 1 and 2 After Cycles 1 and 2 are performed, the battery's count limit capacity may be less than 5%.

  • Page 84: Chapter 10 - Options

    CHAPTER 10 OPTIONS ~:-:,="."" " •. - • CHAPTER 10 OPTIONS • • 10-1...

  • Page 85: Data Retention

    Options • Introduction Your C4000 is equipped with OPTION-P if the model number reads "CDxx-xP". The firmware with OPTION-P is labelled "V3.xxP", Option-Pincludes:. Data Retention • Printer interface (RS-232 Port #2) • Computer interface (RS-232 Port #1 ). 1. Data Retention Power failure The Data Retention holds the battery test results in case of power failure.

  • Page 86: Dateltime

    Options • 2. DatelTime The DatelTime information maintains the year, month, day, hour, minute and seconds. This information appears on all print reports and is transferred to the computer, if interfaced. Back-up battery The date, time and other information is backed-up with a lithium battery.

  • Page 87: Printer Interface

    When using a parallel printer, a Serial-to-Parallel converter is required. For best results, use the SP-2 converter offered by CAD EX. • Note CADEX cannot guarantee proper function if another Serial-to-Parallel Converter is used. Interconnection Connect the cable from the SP-2 converter to Port 2.

  • Page 88: Print Formats

    The print formats are: • LABEL (2) • LABEL (4) • SERVICE REPORT. When printing labels, use the custom labels supplied by CADEX ELECTRONICS INC. The Service Report requires standard printer paper. Label Printing Set up Press Menu, select any Station, scroll (Key 1 or 2) to PRINT FORMATS, and press 3 to enter.
  • Page 89 Options • Sample of Battery Label Analyzer used - can be customized to read your Company Name or phone number (up to 15 digits) Month/DaylY ear Selected program and battery capacities (up to 5) ID Number (serialized) Battery Fault Codes (if available) Test Result Selected Station Serialized ID numbers...

  • Page 90: Computer Interface

    Options • Printing Service Report Set up Press Menu, select any Station, scroll (Key 1 or 2) to PRINT FORMATS, press Key 3, then press Key 1 or 2 to select SERVICE REPORT. To print Hold appropriate Display Key down until a beep tone is heard and the display reads: "PRESS KEY AGAIN TO PRINT".

  • Page 91: Event Log

    Options • 6. Event Log The event log of the C4000 system allows you to record the system's activity as the batteries are being serviced. The event log is formatted as follows: Station Number Program (1 Charge, 2 Prime, 3 Auto, 4 Standby) Present Cycle Status Program Duration (h:min:s) Average cell voltage...
  • Page 92 Options • Field Cycle Status The cycle status is composed of a number of 'bit fields'. Each bit field has a number and a condition attached to it. Discharge cycle 2 = Recondition discharge cycle Charge Trickle charge 16 = Battery passed Program completed 64 = Rest cycle Program interrupted (due to of battery, over...
  • Page 93 Options • Field 8 Battery Current The discharge current is marked with a minus (-) symbol in front of the number; the charge current has no symbol. Field 9 Temperature sensor Raw temperature input value for that Station. Field 10 Battery Capacity The reading shown represents the previous discharge.

  • Page 94: Chapter 11 - C-Code Tables

    CHAPTER 11 C-CODE TABLES CHAPTER 11 C-CODE TABLES • • 11-1...
  • Page 95 C-Code Tables • Introduction In CHAPTER 7 - PROGRAMMING BATTERY ADAPTERS we familiarized ourselves with the C-Code and its structure. This chapter examines each segment of the C-Code in detail. Pre-programmed Battery If a pre-programmed Battery Adapter is used, the Adapter complete C-Code has been entered at the factory and the adapter is ready for service.
  • Page 96 C-Code Tables • Sequence of C-Code The following list is a chapter guide. The C-Code items are listed in the order that they appear in the C4000's items C-Code (refer to Figures 11.1, 2 and 3). Some C-Code items of NiCd and NiMH batteries are shared with SLA batteries;...
  • Page 97 C-Code Tables • Structure of C-Code for NiCd (Default shown) 1. Battery Type 2. Number of Cells 3. Battery Rating 4. C-Rate, Charge 4. C-Rate, Discharge 5. Trickle Charge ~ __ 6. Recondition Discharge 7. Capacity Offset 8. Temperature Sensor (optional) •...
  • Page 98 C-Code Tables • Structure of C-Code for NiMH (Default shown) 1. Battery Type 2. Number of Cells 3. Battery Rating 4. C-Rate, Charge 4. e-Rate, Discharge 5. Trickle Charge 6. Recondition Discharge 7. Capacity Offset 8. Temperature Sensor (optional) • C-CODE: Basic Extended...
  • Page 99 C-Code Tables • Structure of C-Code for SLA (Default shown) 1. Battery Type 2. Number of Cells 3. Battery Rating 4. C-Rate, Charge 4. C-Rate, Discharge 7. Capacity Offset 8. Temperature Sensor (optional) • I: C-CODE: Basic Extended C-Code C-Code Figure 11.3 •...

  • Page 100: Battery Type

    C-Code Tables • 1. Battery Type Each unique battery type (chemistry) is assigned a Battery Type Code. This code sets the Station to the appropriate mode of operation for the selected battery type. BATIERY TYPE CODE C-RATE RESOLUTION Nickel Cadmium (NiCd) Standard Fine Nickel Metal Hydride (NiMH)

  • Page 101: Number Of Cells

    C-Code Tables • 2. Number of Cells CODE CODE CODE Number of cells specifies how many 1 cell 5 cells 9 cells cells a battery pack contains. 2 cells 6 cells 10 cells 3 cells 7 cells 11 cells 4 cells 8 cells 12 cells Table 11.2...

  • Page 102: Battery Rating

    C-Code Tables • 3. Battery Rating The battery rating is the manufacturer's specified capacity of the battery. We have encoded this rating into a three-digit number. The Battery Rating Code is the battery rating divided by 25 mAh. Battery Rating Code Code Code Code...
  • Page 103 C.Code Tables • Definition of battery Though the manufacturer specifies a battery capacity capacity (which we define as battery "rating"), the true capacity is a measure of how much energy the battery can actually hold. This capacity is measured in milliamperes per hour (mAh) or amperes per hour (Ah).

  • Page 104: C-Rate

    C-Code Tables • 4. C-Rate Definition C-Rate is a number representing the ratio of charge or discharge current to the battery rating. By lowering the C-Rate, the charge and discharge currents are reduced. The service time is prolonged accordingly. Example A discharge time of a battery with 100% capacity is one hour if discharged at 1C.
  • Page 105 C-Code Tables • How to set Battery • Always set the Battery Rating as specified by the batt. manufacturer. Rating and C-Rate • Set the recommended charge and discharge C-Rates afterwards. How accurate are the Battery manufacturers often over-rate their batteries by battery ratings specifying the peak rating rather than the more realistic average rating.

  • Page 106: Trickle Charge

    C-Code Tables • Standard C-Rate Resolution Fine C-Rate Resolution (Battery Type Codes 10, 20,30) (Battery Type Codes 11, 21, 31) CODE CODE CODE CODE CODE CODE CODE 0.1C 01 2.1C 21 0.01C 01 0.21C 21 0.41C 41 0.61C 61 0.81C 81 0.2C 02 2.2C 22 0.02C 02...

  • Page 107: Recondition Discharge

    C-Code Tables • 6. Recondition Discharge (NiCd, NiMH) Recondition Discharge is a slow deep discharge applied CODE below the end-of-discharge voltage threshold. During this gradual depletion of the remaining energy, the crystalline build-up (memory) on the cell plates dissolves and the NiCd battery is commonly restored. Definition The set figure in Table 11.6 is a percentage 12%*...

  • Page 108: Capacity Offset

    C-Code Tables • 7. Capacity Offset The Capacity Offset corrects the capacity readings when discharging the battery at a higher or lower rate than specified by the battery manufacturer. Negative Capacity Offset CODE CODE CODE CODE CODE -10% 40 -20% 30 -30% 20 -40% 10 -21 0/0 29...
  • Page 109 C.Code Tables • Example of Positive A SLA is specified to produce 100% capacity at a 20- hour discharge. If the battery is discharged in 5 hours, Capacity Offset at four times the current, the capacity will be 70% typical. A positive offset of 30% can be added to correct for the discrepancy.

  • Page 110: Temperature Sensor

    C.Code Tables • 8. Temperature Sensor (optional) Note The temperature sensor is recommended if the CODE battery is serviced outside the temperature range of 5°C Dlsabled* to 35°C (41°F to 95°F). If the battery is serviced at room N.T.C.,oC temperature, sensing of the battery temperature is not P.T.C.,oC required.

  • Page 111: End Of Discharge

    C-Code Tables • Recommended Setting Higher Increasing the Negative Slope delays termination of the fast-charge, causing the battery to heat up towards the end of the charge cycle. Lower Decreasing the Negative Slope may terminate the charge prematurely on the following conditions: •...

  • Page 112: End Of Recondition (Nicd, Nimh)

    C-Code Tables • 11. End of Recondition (NiCd, NiMH) The End-of-Recondition voltage is the threshold NICd CODe point at which the Recondition Discharge is undefined terminated. The battery voltage is measured in undefined average cell voltage. undefined undefined Recommended setting The minimum required setting O.4V/cell* to restore a NiCd battery affected by "memory"...

  • Page 113: Float Voltage (Sla)

    C-Code Tables • Reverse Load Code 2 through 9 apply the Reverse load Charge Method. The Reverse load Charge intersperses discharge currents between the charge pulses. This push-pull action promotes the recombination of gases generated during charge. Reverse Load is applied on fast-charge and trickle charge.

  • Page 114: Voltage Limit (Sla)

    C-Code Tables • 14. Voltage Limit (SLA) The SLA charge method is based on voltage limit. (In CODE comparison, the NiCd and NiMH are based on current undefined limit). The C4000 charges the SLA battery at the undefined specified current until the set voltage threshold is undefined reached.

  • Page 115: Topping Charge Plateau (Sla)

    C-Code Tables • Additional information For more information on charging of SLA batteries, refer "Analyzing to a separate manual entitled Rechargeable Batteries". Important Do not exceed the manufacturer's recommended charge current and voltage limit. Observe battery temperature range. 15. Topping Charge Plateau (SLA) Definition The topping charge Plateau is applied to CODE...

  • Page 116: Chapter 12 - Diagnostics

    CHAPTER 12 DIAGNOSTICS • CHAPTER 12 DIAGNOSTICS • • 12-1...

  • Page 117: Ram/Clock/Lcd Check

    Diagnostics • Introduction The C4000 performs a number of diagnostic checks on power-up and during service. A system failure is detected and displayed on the LCD. 1. RAM/Clock/LCD Check On power-up, the internal and external RAM, clock and LCD are checked. If the internal RAM or the LCD fails, all READY and FAIL LEOs flash;...

  • Page 118: Start-Up Messages

    Diagnostics • Reason Bad back-up battery. DatefTime and Company Name may also be affected. The system will try to correct the error and the message may not appear consistently. To clear the message, press any Display Key. 2. Start-up Messages Start-up with no battery When turning the C4000 on, the following messages are shown briefly:...

  • Page 119: Chapter 13 - Service

    CHAPTER 13 SERVICE • CHAPTER 13 SERVICE • • 13-1...

  • Page 120: Static Precautions

    Service • 1. Static Precautions The micro chips used in the C4000 may be damaged by static charge if not handled properly. Static charge is generated through the contact of non- conductive materials such as plastic bags, synthetic clothing and carpeted floors.
  • Page 121 Service • Approved Replacement Fuses Primary Fuse T1.5 Amp, 250 VAC (100 - 127V Line Voltage) TO.S Amp, 250 VAC (220 - 240V Line Voltage) Station Fuse 2.5 Amp fast blow, 250 VAC Caution Using an unapproved fuse may cause the device to fail.

  • Page 122: Replacing Back-Up Battery

    DANGER OF EXPLOSION IF BACK-UP BATIERY IS INCORRECTLY REPLACED. REPLACE ONLY WITH SAME OR EQUIVALENT TYPE RECOMMENDED BY CADEX. DISCARD USED BATIERY ACCORDING TO THE MANUFACTURER'S INSTRUCTIONS. Re-install the side plate. Turn unit on. Check for correct sign-on message. •...

  • Page 123: Replacing The Eprom

    Service • Non-volatile When the unit is first turned on after replacing the back- RAM ERROR Message up battery, a non-volatile RAM ERROR message will appear. To continue, press any Display Key. Pressing the Key initializes the clock chip. To verify correct operation, turn the power off and on again while batteries are being serviced.

  • Page 124: Installing Option-P

    Service • Move all toggle switches on the front to the center position (CHARGE). Re-install the lower housing. Make sure the toggle switches are seated properly by gently tugging them towards the bottom of the unit. Fasten screws. Turn unit on. Check for correct sign-on message. 5.
  • Page 125 DANGER OF EXPLOSION IF BACK-UP BATTERY IS INCORRECTLY REPLACED. REPLACE ONLY WITH SAME OR EQUIVALENT TYPE RECOMMENDED BY CADEX. DISCARD USED BATTERY ACCORDING TO THE MANUFACTURER'S INSTRUCTIONS. • Move all toggle switches on the front to the center position (CHARGE) Re-install lower housing and side plate.

  • Page 126: Motherboard Layout

    Service • 6. Motherboard Layout CLOCK CHIP Accessible removing plestlc floor section BACK.UP BATTERY Accessible removing right side plate Battery is on top of Motherboard Bottom View EPROM 256 CENTER 512 Aceeaalbls by removing pleatic floor section. • Clo..up of Jumper 4 Selects type of Eprom Figure 13.2 13-8...

  • Page 127: Chapter 14 - Specifications

    CHAPTER 14 SPECIFICATIONS • CHAPTER 14 SPECIFICATIONS • • 14-1...
  • Page 128 Specifications • System The C4000 services four batteries simultaneously. batteries are tested at user-specified voltage and currents. Short and reverse polarity protected. Battery Adapters The batteries interface through Configured Cups and Smart Cables. The Battery Adapters are mechanically and electrically configured for a battery type. For a list of Battery Adapters refer to APPENDIX- BATTERY ADAPTER LISTING.
  • Page 129 Specifications • Charge Method Reverse Load Charge to promote recombination gases generated during fast-charge (NiCd and NiMH batteries). Program Selection Prime Applies successive discharge/charge cycles until peak capacity is reached. Prepares new batteries for field use. Program duration is 4-8 hours. Charge Fast-charge only.
  • Page 130 Specifications • Data Ports Two RS-232C ports, one for printer output and one for computer interface. Requires Option-P to enable. Power Range ::t10%, load 180W max. Model CD44-1 , 115VAC, 60Hz (North American Version). Model CD44-2, 100/115/127VAC, selectable, 50-60Hz. Model CD44-9, 220/230-240VAC, selectable, 50-60Hz.

  • Page 131: Appendix

    • APPENDIX • •...
  • Page 132 C4000 Series D-CABLE w/ALIG. CLIP 0.00 UD-11 4-B005 Cadex C4000 Series D-CABLE w/BANANA PlG 0.00 UD-12 4-B007 Cadex C4000 Series D-CABlE w/MINI B PLG 0.00 UD-13 4-B008 If battery is not listed, please contact Cadex Electronics 01/03/1995 A - 1...
  • Page 133 344A4506 Pl 11.25 CC269B 10-09-024 4-1716 Ericsson/G.E. MONOGRAM 344A4506 P3 11.25 1200 CC269B 10-09-048 4-1717 Ericsson/G.E. 16105417 Gl 7.50 1700 CC105C 10-06-068 4-1035 Ericsson/G.E. 19A704850 P4 7.50 CC102A 10-06-032 4-1029 If battery is not listed, please contact Cadex Electronics 01/03/1995...
  • Page 134 Geodimeter Geodimeter 571132010 12.50 2000 CD200X 10-10-080 4-1491A Geodimeter Geodimeter 571143014 12.50 1000 CD201X 10-10-040 4-1492A H.P. Gl43100 12.00 2500 CA294X 30-06-100 4~1670 H.P. Gl43100 12.00 2500 CD294X 30-06-100 4-1670A If battery is not listed, please contact Cadex Electronics 01/03/1995...
  • Page 135 450 CC163B 10-09-018 4-1379-01 Maglite ML-5000 MA-5 6.25 2200 CA235P 10-05-088:0505-06-500-3646 4-1555 • Maglite ML-5000 MA-s 6.25 2200 CD235P 10-05-088:0505-06-500-3646 4-1555A Magnavox Video Camera AR8359BK01 12.00 2000 CC198C 30-06-080 4-1136 If battery is not listed, please contact Cadex Electronics 01/03/1995...
  • Page 136 700 CC101B 10-06-028 4- 1165 Mobira 500 Series BTH-5 7.50 1000 CC197B 10-06-040 4-1166 Mobira Cityman 100 7.50 700 CC179B 10-06-028 4-1454 Mobira Cityman 450 UL61 10.00 10-08-040 1000 CC180B 4-1453 If battery is not listed, please contact Cadex Electronics 01/03/1995...
  • Page 137 Fl ip Phone SNN-4058B 6.25 1050 CC126C 10-05-042 4-1412 Motorola Cell Flip Phone SNN-4059B 6.25 1300 CC126C 10-05-052 4-1488 Motorola Cell Fl ip Phone SNN-4102A 6.25 500 CC126C 10-05-020 4-1525 If battery is not listed, please contact Cadex Electronics 01/03/1995...
  • Page 138 NLN-6899A 15.00 CC115A 10-12-009 4-1198 Motorola Corrm Hl220 NLN-6900A 15.00 CC114A 10-12-018 4-1200 Motorola Corrm HT220 NLN-6900B 15.00 500 CC114A 10-12-020 4-1201 Motorola Corrm HT440 NLN-7401A 12.50 CC116C 10-10-020 4-1202 If battery is not listed, please contact Cadex Electronics 01/03/1995...
  • Page 139 4-1265 Motorola Conm P200, P210 NTN-5531A 10.00 CC117A 10-08-024 4-1263 Motorola Conm R8 ' s NTN-n62A 7.50 1200 CC361C 10-06-048:0707-06-500-3646 4-1807 Motorola Conm Radius P100 NTN-4817B 10.00 CC116C 10-08-026 4-1269 If battery is not listed, please contact Cadex Electronics 01/03/1995...
  • Page 140 NTT / Do Co Mo MO-VA F TZ-804 F (S) (400) 6.25 CC213X 10-05-016 4-1564 NTT / Do Co Mo MO-VA F TZ-804 F (S) 500 6.25 500 CC213X ZO-05-020 4-1605 If battery is not listed, please contact Cadex Electronics 01/03/1995...
  • Page 141 CC331C 10-05-028 4-1829 Nokia Nokia 900 7.50 CC179B 10-06-028 4-1455 Nokia • P-30 P-30-BP 7.50 1000 CC146B 10-06-040 4-1320 Nokia P4000, PT 612 P1BP 7.50 CC189A 10-06-028 4-1321 If battery is not listed, please contact Cadex Electronics 01/03/1995 A - 10...
  • Page 142 Racal Covert Cougar MA4736B (250) 10.00 CC190B 10-08-010 4-1445 Racal Covert Cougar MA4736B (330) 10.00 CC190B 10-08-013 4-1445-01 Racal Racal 4700 MA4705A 10.00 2000 CA346P 10-08-080 4-1344 If battery is not listed, please contact Cadex Electronics 01/03/1995 A - 11...
  • Page 143 Spi lSbury PMS 1210/1610 AC19R 11.25 CC163B 10-09-018 4-1379 • Standard CNB241 7.50 CC168A 10-06-028 4-1440 Standard CNB242 12.50 CC166A 10-10-024 4-1441 Standard CNB584A 10.00 CC295B 10-08-036 4-1663 If battery is not listed, please contact Cadex Electronics 01/03/1995 A - 12...
  • Page 144 Yaesu FTC2003, FTC703 FNB-2 11.25 500 CC152A 10-09-020 4-1407 Yaesu FTH-2008, FTH-7008 FNB-11 12.50 600 CC156A 10-10-024 4-1625 Yaesu FTH-2008, FTH-7008 FNB-12 12.50 500 CC156A 10-10-020 4-1410 If battery is not listed, please contact Cadex Electronics 01/03/1995 A - 13...
  • Page 145 CC155B 10-10-040 4-1409 Yaesu FTH2006 FNB-22 12.50 CC156B 10-10-020 4-1753 If battery is not listed, please contact Cadex Electronics 01/03/1995 Foot Print Code: ego CC155A Basic C-Code: ego 10-06-040 Configured Adapter ~ l-contact Tension rating * 25) NiCd Std ~ating...

  • Page 146: Glossary

    GLOSSARY • GLOSSARY • •...
  • Page 147 GLOSSARY • AUTO Automated program exercises batteries to prevent "memory" and reconditions those unable to reach the target capacity. Battery Specifies battery chemistry, voltage and mAh rating. Parameter Battery Voltage, Please see Nominal Battery Voltage. Nominal Capacity Offset Corrects the capacity reading of a battery when different discharge rates are applied.
  • Page 148 GLOSSARY • Discharge. Default Preset action taken if no other instructions are given; the parameters assumed by the C4000 unless explicitly specified. EEPROM Electrically Erasable Programmable Read Only Memory device located in the Battery Adapter. The code retained in the EEPROM can be changed within the C4000 by the user up to 100,000 times.
  • Page 149 RECON Recondition. Recondition A method proprietary to CADEX battery analyzers which reverses damage caused by "memory". Method consists of controlled deep- discharge applied below 1 volt per cell. Residual The amount of charge left in the battery after field use ...
  • Page 150 GLOSSARY • Smart Cable A battery cable with a memory chip built into it for storing the battery parameters. Standby Standby prevents memory if a NiCd battery must be kept on charge for operational readiness. Every 30 days, the battery is exercised by automatically restarting the program.

  • Page 151: Index

    .. I N D EX • ADAPTER, 6-5 Data Retention, 10-2 Analyzing Batteries, DatelTime, 10-3 Audible Tone Signals, Definition of battery capacity, 11-10 AUTO, 3-2, 3-6 Detailed Display, 2-6, 4-7 Auto Scale, 14-2 Detailed Display Messages, 4-9 Auto-Scale, 7-7,11-11 Display, 14-3 Display (LCD), 4-6 Bad Adap, 6-4, 6-5...
  • Page 152 .. 1 N D EX • Reverse Load Charge. 3-5 Menu Display, 4-8 Reverse polarity, 2-3 Menu Functions, 7-6 Menu Navigation, 7-6 11-10 Scaling, Menu Tree, 7-4 Self-discharge, 3-8 11-13 Minimum Trickle Charge. Self-discharge Test, 9-7 Modify Battery Code, 7-9 Serial Printer.

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