Summary of Contents for Albercorp Cellcorder
- Page 1 Cellcorder Instruction Manual Revision 5.0 990 South Rogers Circle, Suite 11 Boca Raton, FL 33487 Tel: 561-997-2299 Fax: 561-997-5588 http://www.alber.com...
- Page 2 1. WARRANTY AND LIMITATION OF LIABILITY LIMITED WARRANTY Albércorp warrants that the software product will perform in accordance with the accompanying written materials for a period of ninety (90) days from the date of receipt. Some states and jurisdictions do not allow limitations on duration of an implied warranty, so the above limitation may not apply to you.
- Page 3 2. SOFTWARE LICENSE AGREEMENT THIS IS A LEGAL AGREEMENT. PLEASE READ BEFORE INSTALLING SOFTWARE. Any use of this media other than to review this Software License Agreement constitutes your acceptance of and agreement with the terms of this Software License Agreement with respect to the Albércorp Software.
- Page 4 Albércorp 990 South Rogers Circle, Suite 11, Boca Raton, FL 33487 Information in this document is subject to change without notice. Cellcorder Instruction Manual, Revision 5.0 1999, 2000 Albércorp., 990 South Rogers Circle, Suite 11, Boca Raton, FL 33487. This manual may not be copied in whole or in part without express written permission from Albércorp.
- Page 5 • Do not let unauthorized persons operate the equipment. • The maximum voltage the Cellcorder can read is 16V. Do not attempt to read Overall Volts. Use a separate meter, then enter the reading manually under the SG/TEMP/OV mode. •...
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Page 6: Table Of Contents
Data Extraction and Analysis ............6 1.4.6 System Display.................6 1.4.7 Power....................6 ............7 ECEIVING AND CCEPTANCE ESTING Unpacking....................7 Cellcorder Initial System Test ..............7 ................10 PERATING NSTRUCTIONS General Concepts...................10 Before Using the Cellcorder ..............11 General Operating Notes ...............11 Operation Notes ..................12 3.4.1 Multimeter Mode................13 3.4.2... - Page 7 Memory Management................27 Calibration .....................28 3.8.1 Entering the Calibration Screen............28 3.8.2 Entering the Password ..............28 3.8.3 Recording the Before Calibration Readings ........29 3.8.4 Calibrating the Cellcorder ..............31 3.8.5 Backing Up and Restoring the Calibration........35 A: C ............36 PPENDIX ELLCORDER ARTS B: S ............37...
- Page 8 (1) the Cellcorder voltage reading indicates zero to one-half of the cell voltage being tested, and (2) the Cellcorder displays a Low Current - Cell or Connect Problem error message. Although this modification...
- Page 9 Performing a Resistance Test The Test button must be pressed for longer than 1 second before the test will begin. WARNING The maximum voltage the Cellcorder can read is 16V. Do not attempt to read Overall Volts. Use a separate meter, then enter the reading manually under the SG/TEMP/OV mode.
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Page 10: Introduction
The Cellcorder may be used on a single cell or multicell module. Readings up to seven strings of 256 cells each or 28 strings of 64 cells can be stored and displayed on a bright fluorescent display. -
Page 11: Test Modes
This section describes the test modes of the Cellcorder. 1.3.1 Voltmeter In this mode, the Cellcorder is used with standard voltmeter probes to take monthly or quarterly float voltage readings. When the probes access the first cell, the reading is displayed and, within two seconds, the unit beeps and indicates on the display that the reading has been stored. -
Page 12: Specific Gravity And Temperature
Specific gravity (SG) and temperature readings can be entered manually or automatically from a compatible data storing hydrometer. In automatic mode, the user connects the hydrometer to the Cellcorder via an RS-232 cable and transfers the readings by pressing the appropriate function key. -
Page 13: Data Extraction And Analysis
1.4.5 Data Extraction and Analysis Upon completion of testing, the user connects the Cellcorder to a PC- compatible computer with the supplied RS-232 cable. The Albér data extraction program is executed and test results are imported into the program. Data is analyzed and displayed in an easy-to-read bar graph or tabulated format. -
Page 14: Receiving And Acceptance Testing
The CHARGE indicator should light. Do not connect any other leads to the unit at this time. Press the ON key on the front of the Cellcorder. After a series of beeps and a system self test, the unit defaults to the Cellcorder Main Menu:... - Page 15 Before you select the Relays diagnostic, verify that no leads are connected to the Cellcorder. A warning is displayed to ensure the leads are disconnected. Press and hold TEST to activate this diagnostic. A clicking noise will be heard as each relay is checked.
- Page 16 0 to 255 until ESC is pressed. If errors exist, the error count field increments. This completes Cellcorder diagnostic acceptance testing. Before beginning operation, turn the Cellcorder off by pressing the ON key on the keypad; the ON key operates as an ON/OFF key.
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Page 17: Operating Instructions
This section describes the operation of the Cellcorder. 3.1 General Concepts The Cellcorder is designed to improve the ease and accuracy of taking periodic maintenance readings. An effective maintenance program that meets the recommendations of most battery manufacturers calls for the following... -
Page 18: Before Using The Cellcorder
3.2 Before Using the Cellcorder Check that the Cellcorder carrying case contains two sets of test leads, the battery charger module, and the RS-232 cable. Prior to testing, charge the Cellcorder for at least eight hours to guarantee six hours of battery operation. -
Page 19: Operation Notes
Configuration setup screens. 3.4 Operation Notes To power on the Cellcorder, press the ON key. (The ON key operates as an ON/OFF key.) After the display shows the firmware revision level, the Main Menu appears. At the Main Menu, select option 3 - Setup, then select 3 - Memory Configs. -
Page 20: Multimeter Mode
SELECT AMP HOUR RATE 0 - 1000 AH MORE THAN 1000 AH After the amp hour selection is made, the Cellcorder checks if float voltage readings, using the voltmeter mode, were already taken. If they were, the following screen appears:... -
Page 21: Connecting The Test Leads
READINGS EXIST. USE VOLTMETER MODE FIRST [TEST] IGNORE VFLOAT After a choice of voltage readings is made, the Cellcorder is ready to take readings on Battery 1 cells. 3.4.2 Connecting the Test Leads The connection of the test leads for any type of resistance measuring instrument is very important and is directly related to the accuracy of the readings. -
Page 22: Taking The Readings
The leads are either connected wrong or there is a bad connection on one of the current leads. • The Cellcorder measures the current flow, cell voltage, and intercell voltage, and calculates both internal and external resistances. •... -
Page 23: Storing Data For More Than One String
Error Code 9 is displayed. 3.4.4 Storing Data for More Than One String The Cellcorder has two memory configurations available under the Setup selection on the Main Menu. One mode is 7 x 256 (7 batteries with 256 cells in each battery), and the other is 28 x 64 (28 batteries with 64 cells in each battery). -
Page 24: Voltmeter Mode
(Refer to Managing Battery Data Files in the Battery Analysis User's Guide.) After copying to the computer, either erase all Cellcorder memory locations or selectively erase one string at a time. To erase the strings, at the Main Menu, press F1. (Refer to Erasing String Data in Memory Management.) -
Page 25: Entering Specific Gravity, Temperature And Overall Volts
"Recorded in Memory." The unit ignores voltage polarity in this mode; therefore, you may connect the leads in either direction. When the leads are lifted and moved to the next cell, the Cellcorder increments to the next cell. During testing, you may review or retest previous readings. To return to a selected cell, press the UP or DOWN arrow keys (with the cursor in the Cell field) or enter a cell number and press ENTER. -
Page 26: Uploading Specific Gravity And Temperature Readings
3.4.6.2 Battery Selection To select another battery, the cell number must be cell 001. (Refer to Cell Selection.) Press ENTER until the cursor is at the Batt ID field. Select the desired battery number, then press ENTER. 3.4.6.3 Specific Gravity (SG) Entry When the cursor is in the SG field, a 12—... -
Page 27: Programming Test Parameters
ENTER. At the next menu, to load data, press ENTER. After the transfer starts, the Cellcorder displays the cell number that has been loaded. When the display reaches 64 or 256, depending on the configuration selected, all readings have been loaded. Note that all uploaded temperature values are rounded off to the nearest whole number. -
Page 28: Battery Charging
0000µ - 2000µΩ 3.4.9 Battery Charging Prior to doing any testing, charge the Cellcorder for at least eight hours to guarantee six hours of battery operation. The front panel CHARGE light indicates charging only and does not indicate when the battery is fully charged. -
Page 29: Error Codes And Warning Messages
This section covers error codes and warning messages. If an error message or error code cannot be resolved, contact Albércorp for assistance. On power up, the Cellcorder does a diagnostic check of several hardware parameters. If more than three errors occur, only the first three are displayed until the problems are resolved. - Page 30 The following error messages may appear at any time during use of the Cellcorder. The voltage error message (below) appears when the input voltage exceeds 16V. The maximum voltage the Cellcorder can read is 16V. Never exceed the maximum input voltage or permanent damage may occur. _*_VOLTAGE ERROR_*_ Input voltage must be less than 16V.
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Page 31: Resetting The Cellcorder
The reading error message appears when the test current exceeds 80 amps. This error may be the result of a hardware failure in the Cellcorder or an out-of- calibration condition. _*_READING ERROR_*_ EXCESSIVE LOAD CHECK CONNECTION [ANY KEY]... The low current message appears when the test current is below 20 Amps. This may be the result of a poor test lead connection, faulty cell, hardware failure in the Cellcorder, or an out-of-calibration condition. -
Page 32: Diagnostics
3.6 Diagnostics If the Cellcorder appears to have a malfunction, the diagnostic features of the unit can help isolate the fault. To access the diagnostics functions, select option 2 - Diagnostics from the Main Menu. The following is displayed: _ _DIAGNOSTICS MENU_ *... -
Page 33: Relays
Cellcorder can be permanently damaged. Before you select the Relays diagnostic, verify that no leads are connected to the Cellcorder. A warning is displayed to ensure the leads are disconnected. Press and hold TEST to activate this diagnostic. While TEST is pressed, the unit energizes each load relay one at a time. -
Page 34: Memory Management
7 x 256 or 28 x 64 configuration. After a configuration is selected, the Cellcorder always defaults to it. (That is, if you select 7 x 256, then every time the Cellcorder is powered on, the configuration will be in 7 x 256 mode until it is changed.) An asterisk ( * ) on the top right corner of a menu indicates... -
Page 35: Calibration
#### 3.8.2 Entering the Password When the Cellcorder is shipped from the factory or when software is updated via the RS-232 port, the password defaults to 1234. If the password is unknown, contact Albér for a password based on the randomly generated four numbers at the bottom right of the screen. -
Page 36: Recording The Before Calibration Readings
1) Select Multimeter mode on the Cellcorder so the actual voltage is being read. 2) Connect a 2V cell to the Cellcorder using the standard (two lead) voltage leads supplied with the Cellcorder. 3) Measure the voltage using the HP 5 ½ digit voltmeter (or equiv). - Page 37 Calibration Screen section. 2) Using the multimeter (three lead) test leads supplied with the Cellcorder, connect the Cellcorder to a 2V test cell with a 100 Amp/100 mV shunt in series with one of the load cables. Refer to the following figure.
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Page 38: Calibrating The Cellcorder
2) From the Calibration menu, select option 1 - 2V Cell. 3) Measure the voltage using the HP voltmeter. 4) Press the Cellcorder UP and DOWN arrow keys until the reading on the Cellcorder matches the input level (the HP DMM reading). - Page 39 Calibration Log under Cell: 2V After Calibration. 3.8.4.3 6V Cell Calibration 1) Using the two voltage leads, connect the Cellcorder across the same 6V source used in the Cell Readings section. 2) From the Calibration menu, select option 2 - 6V Cell.
- Page 40 WARNING: Current calibration should only be performed using a 2 volt source. Do not attempt to perform this procedure with a 6 volt or 12 volt module. The Cellcorder will report an error message and not allow calibration to continue.
- Page 41 Adjust RV3 until the value is within 30µV when changing polarity on the input. 5) Press the UP and DOWN arrow keys until the Cellcorder reading matches the input value. If the input is not a fixed 10mV standard source, then use the HP DVM to verify the input value.
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Page 42: Backing Up And Restoring The Calibration
The life of the battery is directly related to how well it is charged. 3.8.5 Backing Up and Restoring the Calibration Refer to the Battery Analysis User's Guide for information about backing up and restoring Cellcorder data. -
Page 43: Appendix A: Cellcorder Parts List
4 Appendix A: Cellcorder Parts List Quantity and Description Initial Cellcorder Unit Ser. No: _______________________ _____ Power Adaptor for Cellcorder _____ RS-232 Cable _____ Voltage Lead Cable Set (2 Leads) _____ Resistance Test Cable (3 Leads) _____ Cellcorder Operation Manual... -
Page 44: Appendix B: System Specifications
0.1% of reading ±1 LSD Voltage 0 - 16.00 volts Cell Resistance 0 - 99.99 milliohms Readings are repeatable from ±2% to ±5% (Refer to Albercorp Application Note CC-001 for details) 0.25% of reading ±2 Intercell Resistance 0 - 2.000 milliohms microhm Power Source... -
Page 45: Appendix C: Cellcorder Calibration Log
6 Appendix C: Cellcorder Calibration Log General Information: Customer: ______________________________________________________ P.O.# __________________________________________________________ Calibration Date: _________________________________________________ Serial Number:___________________________________________________ Approx. Input Actual Input Instrument Instrument Voltage Reading Reading Before Reading After Calibration Calibration Cell: 2V cell __________ __________ ___________ 6V cell __________... - Page 46 .........5 intercell resistance ......5, 15 batt ID field ........19 intercell type menu ......13 battery charging (Cellcorder) ..11, 21 internal cell resistance ....5, 14 battery low (Cellcorder) .....21 keypad diagnostic ......8, 25 battery maintenance ......10 loop back connector......
- Page 47 system reset........24 specific gravity ........ 5 system test..........7 temperature........5 temperature ......5, 18, 19 voltmeter.......... 4 temperature type C/F......19 test parameters........20 test initialization message ....16 test parameters menu ......20 test initialization screen......14 upload readings......6, 19 test leads..........14 voltmeter........
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