Cadex C7000 Series

Battery Analyzer

User’s Manual
Cadex C7200, C7400 & C7400ER

Cadex Electronics Inc.

22000 Fraserwood Way
Richmond, British Columbia
Canada V6W 1J6

Tel: +1 604 231-7777 Fax +1 604 231-7755

Web: www.cadex.com E-mail: info@cadex.com

Manual P/N: 89-307-1013 Rev 11

November 2005
Printed in Canada
Firmware Version 6.11

Cadex C7000 Series Battery Analyzer i

Safety Notice

Trademark

Cadex, BatteryShop, QuickLearn and QuickTest are registered trademarks of

Cadex Electronics Inc. All other trademarks mentioned herein are the property of
their respective owners.

Copyright

Copyright © 2005 by Cadex Electronics Inc. All rights reserved. No part of this
publication or the firmware controlling Cadex product(s) may be reproduced,
transmitted, transcribed, stored in a retrieval system, or translated into any
language or computer language in any form or by any means without the express
written permission of Cadex Electronics Inc.

Revision Rights

Cadex Electronics Inc. reserves the right to revise this publication and make
changes in the contents thereof without obligation to notify any person of such
changes. Please contact Cadex Electronics Inc. (service@cadex.com) for
suggestions or corrections.

Disclaimer

While every effort is made to ensure that the information contained in this manual
is accurate and up-to-date, Cadex Electronics Inc. does not warrant or guarantee
the accuracy of the contents of this manual. Further, Cadex makes no warranties,
either expressed or implied, as to the merchantability or fitness for a particular
purpose of the Cadex C7000 Series Battery Analyzers (C7200, C7400 and
C7400ER) equipment and/or its documentation.

In no event will Cadex or its officers or employees be responsible for any

consequential, incidental, or indirect damages (including damages for loss or
business profits, business interruption, and the like) arising out of the use or
inability to use the Cadex C7000 Series Battery Analyzers (C7200, C7400 and
C7400ER) Battery Analyzer equipment and/or its documentation.

ii Cadex Electronics Inc.

 Safety Notice

Safety Notice

Use of Equipment

The Cadex C7000 Series Battery Analyzers (C7200, C7400 and C7400ER) are
designed with adequate safeguards to protect the user from shock and other
hazards when used as specified within this document. However, if the equipment
is used in a manner not specified by this documentation, the protection provided
by this equipment may be impaired. Please read this document and equipment
labeling before using the equipment.

Modification of Equipment

CE, FCC, CSA and other approvals apply only to Cadex C7000 Series Battery
Analyzers (C7200, C7400 and C7400ER) in the factory-authorized configuration.
Changes or modification to the equipment not expressly approved by Cadex will
void the approvals and void the user’s authority to operate the equipment.

Disposal of Waste Electrical and Electronic Equipment (WEEE) in the

European Union

This symbol on the product and package indicates that this product must not
be disposed of with unsorted municipal waste. Instead, it is your responsibility
to dispose of WEEE by handing it over to a designated collection point for the
disposal. The separate collection and recycling of waste equipment will help
conserve natural resources and ensure that it is disposed of in a manner that
protects human health and the environment. For more information about
where you can drop off your waste equipment for disposal, please contact
your local municipal office, waste disposal service or wherever you
purchased the product.

Cadex C7000 Series Battery Analyzers iii

Safety Notice

Radio Interference

This equipment generates, uses and radiates radio frequency energy. If the
equipment is not installed and used in accordance with the instructions in this
manual, it may cause interference with radio communications. The equipment
has been tested and found to comply with the limits for a Class “A” digital
device pursuant to Subpart B of Part 15 of the FCC Rules, which are designed
to provide reasonable protection against such interference when operated in a
commercial environment. Operation of this equipment in a residential area may
cause interference, in which case the user is required to take whatever
measures needed to correct the interference, at their own expense.

EN55011/EN55022 Warning: This is a Class A product according to

EN55011/EN55022. In a domestic environment, this product may cause radio
interference, in which case the user, at their own expense, may be required to
take adequate corrective measures.

The equipment is designed with adequate safeguards to protect the user from
shock and other hazards when used as specified within this document. If the
equipment is used in a manner not specified by this documentation, the
protection provided by the equipment may be impaired. Please read the
documentation and equipment labeling before using the equipment.

The analyzer may be affected by interference from other devices. If the unit is
running abnormally, please ensure that the analyzer is moved away from any
source of radio interference.

iv Cadex Electronics Inc.

 Safety Notice

Explosion Hazard

Batteries can burst if treated improperly. Follow these precautions at all times.

Clean battery contacts before servicing. To clean battery contacts, use a lint-
free cotton swab dipped in 100% isopropyl alcohol.

Press the battery firmly into the adapter to ensure a good connection.

Ensure that the selected C-code is correct for the chemistry, voltage, and
rating of the battery being serviced.

Observe battery temperature. Service batteries between 5°C (41°F) and 50°C
(122°F). Stop service if battery becomes very hot. The temperatures cited
here are the battery temperatures, not ambient the ambient temperatures.
Fast charging outside this temperature range may damage or reduce the life
of the battery. Allow cold batteries to warm up and hot batteries to cool before
charging.

Do not attempt to charge non-rechargeable and primary batteries such as

alkaline, carbon-zinc, or non-rechargeable lithium batteries.

Do not short the positive and negative battery terminals together at any time.

Do not connect leads from one station to another, or to the case. An electrical
short to any point outside the station bypasses the current regulation loop and
may blow a fuse or cause permanent component damage.

Do not exceed the battery manufacturer’s recommended charge current and

voltage limits for batteries.

Do not remove the adapter from the analyzer while the battery is
running.

Cadex C7000 Series Battery Analyzers v

Safety Notice

Charging and Discharging Lithium-ion (Li-ion) Batteries

Lithium-ion (Li-ion) batteries are safe when used as directed. Battery safety cannot be
assured when a battery pack is built with individual cells of an unknown nature with a
serial and parallel connection. Not all Li-ion cells are suited for multi-cell packs. Only cells
that meet tight voltage and capacity tolerances can be used for serial and parallel
connection. Mismatched packs are subject to overcharge resulting in venting with flame
and fire. Check with the cell manufacturer to see if the cells are suitable for multi-cell
packs.

In the past, single Li-ion cells were only available to authorized battery manufacturers.
Today, imports are becoming readily available and often fall into the hands of the
inexperienced. While most brand name cells are equipped with an internal cell disconnect
that permanently opens the current path on high pressure, some brands do not provide
this safeguard. Many brands don’t’ use a separator that shuts down the battery when high
temperatures are reached. The internal safety features are omitted for cost reasons.

Please follow the following guidelines when charging and discharging

lithium-ion cell(s) and packs. Failing to follow these rules could result in
venting with flame, explosion, fire and personal injury.

• Never connect cells in parallel and/or series that are not designed for that
purpose. A cell mismatch may overcharge and vent with flames.
• Never charge or discharge the battery without connecting a working
protection circuit. Each cell must be monitored individually and the current
disconnected if an anomaly occurs.
• Always attach a temperature sensor when charging and discharging the
battery. The temperature sensor must disconnect the current on excess
temperature.
• Only connect cells that are matched and have the identical state-of-charge.
• Pay special attention when using an unknown brand. Not all brands contain
intrinsic safety features that protect the cell when stressed.
• During experiments, place the test battery into a well-ventilated fireproof
container. Never leave the battery unattended while under charge or
discharge.

vi Cadex Electronics Inc.

 Safety Notice

Shock Hazard

The Cadex Battery Analyzer contains high-voltage circuits, and can pose a
shock hazard when the upper cover is removed. Do not attempt to perform
any service procedures on the analyzer other than replacement of the
external fuse or internal backup battery (see Chapter 11, Services and
Upgrades, page 114).

To reduce the risk of electrical shock hazard, service batteries only when they
are removed and disconnected from their end-use equipment.

Use the analyzer only as specified in the documentation. Other uses may
impair the protection provided by the unit.

Use only a grounded AC outlet to power the analyzer.

Before attempting any internal service, remove all batteries from the battery
stations, turn the analyzer off and disconnect the power cord from the wall
socket. Wait a few minutes before opening the cover.

Replace fuses only with fuses of the same type and rating (see Replacing
the Primary (Input) Fuse, page 114).

Replace the internal backup battery only with the same type of battery (see
Replacing the Backup Battery, page 115). Observe the correct polarity
when installing the backup battery. Discard the used battery according to the
battery manufacturer’s instructions.

Cadex C7000 Series Battery Analyzers vii

Warranty & Service

Warranty & Service

Cadex Electronics Inc. warrants your Cadex Battery Analyzer against defective
materials and workmanship for a period of three (3) years from the original
purchase date.

The warranty does not cover:

• Damage caused by abusive operation, negligence, accident, or improper
installation.
• Damage caused by an attempted repair not authorized by Cadex.
• Cosmetic damage caused by normal wear and tear.
• Damage from external causes such as leakage spills, power fluctuations,
power failure or inadequate shipping.
• Product received without the appropriate model number, serial number, or
safety markings.
• Products used for rental purposes.

Warranty Service

Before sending the unit for service, contact Cadex Technical Support. If your
product requires warranty service, the representative will provide a Return
Authorization form or number and the location of the nearest service center.
• Ship the product to the service center with freight, insurance, and customs
duties prepaid. The Return Authorization form must be included to obtain
warranty service.
• Ensure that the unit(s) is properly packed before shipping, preferably in the
original Cadex boxes. Damage caused in transit due to improperly packed
items is not covered under warranty.
• Products returned from warranty service are shipped with freight prepaid by
Cadex.

viii Cadex Electronics Inc.

 Warranty & Service

Non-warranty Repairs

Before sending the unit in for service, contact Cadex Technical Support at 1 800
565-5228. If your product is not covered by warranty, the representative will
provide the contact information for the nearest service center. You may contact
the service center directly to arrange to send the product in for service. A Return
Authorization form or number will be provided only if the product is returning to the
Cadex Head Office.
• Ship the product to the service center with freight, insurance and customs
duties prepaid.
• Ensure that the unit(s) is properly packaged before shipping.
Note Cadex Electronics Inc. and Cadex authorized service centers require a
Purchase Order or written authorization to proceed with repairs.

Cadex C7000 Series Battery Analyzers ix

Table of Contents

Table of Contents

Chapter 1 Overview.................................................................................................1
Product Features...............................................................................................................1
Connecting to Cadex BatteryShop™................................................................................2

Chapter 2 Getting Started.......................................................................................1

Contents of the Box ..........................................................................................................1
Using this Manual .............................................................................................................1
Conventions ......................................................................................................................3
Direction Keys ...............................................................................................................3
Symbols.........................................................................................................................3
Abbreviations and Acronyms.........................................................................................4
Commonly Used Terms.................................................................................................5

Chapter 3 Operating Principles..............................................................................7

Components......................................................................................................................7
Front LCD Display Interface............................................................................................10
Lights (LEDs)...............................................................................................................12
Menu Structure................................................................................................................13
Battery Adapters .............................................................................................................14

Chapter 4 Basic Battery Service..........................................................................17

Chapter 5 Battery Service Programs...................................................................22

Basic Programs...............................................................................................................22
Auto .............................................................................................................................23
Charge.........................................................................................................................24
Prime ...........................................................................................................................25
QuickTest™.................................................................................................................25
Advanced Programs .......................................................................................................27
SelfDCH (Self-Discharge Test) ...................................................................................29
Life-Cycle.....................................................................................................................30
x Cadex Electronics Inc.
 Table of Contents

DCHOnly (Discharge Only) ........................................................................................ 31

ExtPrime (Extended Prime) ........................................................................................ 32
OhmTest ..................................................................................................................... 33
RunTime ..................................................................................................................... 34
Boost........................................................................................................................... 36
Learn........................................................................................................................... 37
Q-Learn (Quick Learn)................................................................................................ 39
Custom 1, 2, 3, and 4 ................................................................................................. 41
Battery Service Times .................................................................................................... 42

Chapter 6 C-codes (Configuration Codes)......................................................... 43

Basic C-code Parameters .............................................................................................. 44
Program ...................................................................................................................... 44
Target Capacity .......................................................................................................... 45
Chemistry.................................................................................................................... 45
Battery Voltage (Volts)................................................................................................ 45
Battery Rating (mAh) .................................................................................................. 46
C-code Setup Name ................................................................................................... 46
Scaled C-code ............................................................................................................ 46
C-code Matrix ............................................................................................................. 47
Locked C-code............................................................................................................ 47
Extended C-code Parameters........................................................................................ 47
Charge Rate (C-Rate)................................................................................................. 47
Discharge Rate (C-rate) ............................................................................................. 48
Trickle-Charge Rate (NiCd and NiMH only) ............................................................... 49
Recondition Discharge Rate (NiCd and NiMH only)................................................... 49
Capacity Offset ........................................................................................................... 49
Temperature Sensing ................................................................................................. 50
Negative Slope (NiCd and NiMH only) ....................................................................... 51
End of Discharge ........................................................................................................ 51
End of Recondition (NiCd and NiMH only) ................................................................. 52
Charge Method (NiCd and NiMH only)....................................................................... 53
Maximum Standby Voltage (SLA and Li-ion only)...................................................... 53
Maximum Charge Voltage (SLA and Li-ion only) ....................................................... 54
End of Charge (SLA and Li-ion only).......................................................................... 54
Default Extended C-code Settings ................................................................................. 55
Default Extended C-code for NiCd Batteries.............................................................. 55
Default Extended C-code for NiMH Batteries............................................................. 56
Default Extended C-code for SLA Batteries ............................................................... 56
Default Extended C-code for Li-ion Batteries ............................................................. 57
Extended C-code Settings for Special Cases ................................................................ 57
Intrinsically Safe Batteries .......................................................................................... 57

Cadex C7000 Series Battery Analyzers xi

Table of Contents

Hawker SLA Batteries .................................................................................................58

Gell SLA Batteries .......................................................................................................58
Managing C-codes..........................................................................................................58
Select a C-code...........................................................................................................58
Display a C-code .........................................................................................................59
Change Target Capacity or Program ..........................................................................59
Create or Edit a C-code...............................................................................................59
Add or Edit the C-code Setup Name...........................................................................61
Reset Extended C-code to the Default settings ..........................................................62
Delete a C-code ..........................................................................................................62
Copy a C-code (including QuickTestTM matrix) ............................................................63
Copy all C-codes (and matrices) from One Adapter to Another .................................63

Chapter 7 System Setup And Options ................................................................65

Date and Time.................................................................................................................65
Company Name ..............................................................................................................66
Sound Options ................................................................................................................66
Voltage Display ...............................................................................................................68
Battery Service Counter..................................................................................................69
Connecting to BatteryShopTM or a Printer.......................................................................70
Connecting to BatteryShopTM .......................................................................................70
Connecting Devices to the Serial Port ........................................................................71
Connecting Printers to the Parallel Port (C7400 and C7400ER only) ........................74
Security ...........................................................................................................................75
Security Level Functions .............................................................................................75
Program Parameters.......................................................................................................77
Starting Battery Service...............................................................................................78
Performing an Automatic OhmTest.............................................................................79
Optimizing Charge Time or Capacity ..........................................................................80
Termination Condition on dT/dt ...................................................................................80
Saving Program and Target Capacity Settings ...........................................................81
Resuming Service After Power Failure .......................................................................82
Short Key Functions ....................................................................................................84

Chapter 8 Reports and Labels .............................................................................85

Automatically Print Reports or Labels.............................................................................88
Automatic Report or Label printing..............................................................................88
Print Reports and Labels ................................................................................................89

Chapter 9 Events and Data Logs .........................................................................92

xii Cadex Electronics Inc.
 Table of Contents

Logging Events............................................................................................................... 92
Setting up the Event Log ............................................................................................ 92
Using the Event Log ................................................................................................... 93
Logging Data .................................................................................................................. 95
Sample text strings ..................................................................................................... 98
Setting up the Data Log.............................................................................................. 99
Using the Data Log ................................................................................................... 101

Chapter 10 Custom Programs ........................................................................... 104

Cycle 1 and Cycle 2 ..................................................................................................... 105
Test............................................................................................................................... 106
IF Statements ........................................................................................................... 107
THEN and ELSE Statements ................................................................................... 108
Phase Done.................................................................................................................. 109
Creating and Editing Custom Programs....................................................................... 109
Sample Custom Program ......................................................................................... 111

Chapter 11 Services and Upgrades................................................................... 114

Replacing the Primary (Input) Fuse ............................................................................. 114
Replacing the Backup Battery...................................................................................... 115
Replacing the Station Fuses ........................................................................................ 119
Upgrading the Firmware............................................................................................... 120
Resetting the System ................................................................................................... 120
Cleaning the Analyzer .................................................................................................. 121

Chapter 12 System Calibration.......................................................................... 122

Calibrating Voltage ....................................................................................................... 122
Servicing the Voltage Calibration Adapters.............................................................. 123
Calibrating Adapters..................................................................................................... 123
Adapter Calibration Values....................................................................................... 124
Calibration Values for QuickTestTM ........................................................................... 124

Chapter 13 Solving Problems and Getting Help .............................................. 126

Troubleshooting............................................................................................................ 126
Manual Updates and Other References....................................................................... 130
Technical Support ........................................................................................................ 131

Cadex C7000 Series Battery Analyzers xiii

Table of Contents

Appendix A Messages and Warnings ...............................................................132

Non-Coded Messages ..................................................................................................133
By Code ........................................................................................................................134
By Detailed Message ....................................................................................................137

Appendix B Charge Algorithms.........................................................................156

NiCd and NIMH batteries ..............................................................................................156
SLA and Li-ion batteries................................................................................................158

Appendix C Specifications.................................................................................160
Hardware.......................................................................................................................160

Appendix D Parts and Accessories...................................................................162

xiv Cadex Electronics Inc.

Chapter 1 Overview

The Cadex C7000 Series of Battery Analyzers includes the C7200, C7400 and
C7400ER.

Product Features

• Services rechargeable nickel-cadmium (NiCd), nickel-metal hydride (NiMH),

sealed lead-acid (SLA), lithium-ion (Li-ion) batteries and lithium-polymer (Li-
Poly). In this manual “Li-ion” refers to both), lithium-ion and lithium-polymer
batteries.

• Programmable with a total of 17 programs including:

o Four basic programs: Auto; Charge; Prime and Quicktest™.

o Nine advanced programs
o Four user-programmable programs.
• Battery Adapters allow convenient interface to all battery types. Over 1000
custom battery adapters are available and specialty adapters can be ordered.

• Adapters can be programmed with 10 C-codes. C-Codes contain the

chemistry, voltage and rating. Custom adapters are provided with C-Codes of
the most common batteries.

• A menu-driven interface with messages in plain English and status lights.

• Prints battery service reports and battery service labels.

• Analyzers can be connected to a PC and operated with BatteryShop™

software.

• BatteryShop™ software allows automated operation and networking of

multiple analyzers.

Cadex C7000 Series Battery Analyzer 1

Overview

Connecting to Cadex BatteryShop™

BatteryShop™ is a powerful Windows-based battery management software tool

that allows automation of the Cadex battery analyzer functions to increase
productivity.

• Provides control and monitoring of large-scale battery services by connecting

up to 120 Cadex analyzers to service up to 480 batteries simultaneously.

• Provides easy access to a database of information for over 1000 battery

models, including C-code settings. Even a novice user can perform a variety
of tests and programs.

To find out how Cadex BatteryShop™ can enhance your battery maintenance system,
contact Cadex Electronics Inc (see Connecting to BatteryShop™, page 70).

2 Cadex Electronics Inc.

Chapter 2 Getting Started

Contents of the Box

The Cadex Battery Analyzer package includes these items:

• One Cadex Battery Analyzer

• One IEC320 Power Cord (North American Version)
• One User’s Manual

Using this Manual

The Cadex C7000 Series Battery Analyzer User’s Manual contains the
concepts, procedures and other information necessary to operate the Cadex
battery analyzer equipped with firmware version 6.11 (see Upgrading the
Firmware, page 120). If you do not have version 6.11, contact Cadex to obtain
the upgraded version.)

Chapter 1 - Overview provides basic information about product features and

connecting the Cadex analyzer to a computer.

Chapter 2 - Getting Started goes through the items that are included with the
analyzer and how the manual works. It also explains common symbols,
abbreviations, acronyms and commonly used terms.

Chapter 3 - Operating Principles provides information about the Cadex analyzer,

components, display screen, interface and how to use battery adapters with the
analyzer.

Cadex C7000 Series Battery Analyzer 1

Getting Started

Chapter 4 - Basic Battery Service provides the basic procedures for servicing a
battery.

Chapter 5 – Battery Service Programs provides detailed information about all the
battery service programs.

Chapter 6 -C-codes (Configuration Codes) provides detailed information on

selecting and managing battery parameters (C-Codes).

Chapter 7 - System Setup and Options describes the analyzer’s menu system and
provides information about modifying the operation of the analyzer to suit your
needs. Refer to this chapter when connecting devices to the analyzer (i.e. printers
or a PC with BatteryShop™ software).

Chapter 8 - Reports and Labels provides information about printing battery service
reports and labels.

Chapter 9 - Events and Data Logs describes methods of obtaining and graphing
detailed voltage/current/temperature/impedance analysis.

Chapter 10 - Custom Programs describes how to create user-defined programs

for specialized or advanced applications.

Chapter 11 - Services and Upgrades provides information on servicing the Cadex

analyzer, including upgrading the firmware.

Chapter 12 - System Calibration provides instructions for calibrating the analyzer.

Chapter 13 - Solving Problems and Getting Help provides solutions for common
problems that may occur when operating the analyzer.

Appendix A - Messages and Warnings provides detailed information on fault

codes and messages that appear on the display.

2 Cadex Electronics Inc.

 Getting Started

Conventions
Typeface Meaning
SMALL CAPS Menu options to select
Default settings
LCD display text
BOLD SMALL CAPS Names of keys on the battery analyzer
Italics Emphasized words
Bold & Italic References to other sections in this manual

Direction Keys

Direction keys are represented in this manual as follows:

UP = 
DOWN = 
LEFT = 
RIGHT = 

Symbols

Caution
Information that, if ignored, can result in damage to the
Battery Analyzer, battery adapters or the battery.

Potential shock hazard.

Potential explosion hazard.

Cadex C7000 Series Battery Analyzers 3

Getting Started

Abbreviations and Acronyms

Abbreviation Name or Term

16k adapters These adapters have the extra memory to handle
matrices for QuickTest™. These adapters are marked
“16K” on the rear label.
AWG American wire gauge (a U.S. wire size standard)
LCD Liquid Crystal Display (also called display)
LED Light Emitting Diode (also called light)
Li Lithium-ion and Lithium-polymer battery chemistry
Li-ion Lithium-ion battery chemistry
Li-polymer Lithium-polymer battery chemistry. This chemistry is
treated in the same way as Li-ion.
mA Milli-ampere
mAh Milli-ampere hour
mOhm Milli-ohm
NiCd Nickel-cadmium battery chemistry
NiMH Nickel-metal-hydride battery chemistry
OEM Original equipment manufacturer
PC IBM compatible personal computer
RF Radio frequency
P/N Part number
SoC State of Charge
SoH State of Health
SLA Sealed lead acid battery chemistry
USB Universal Serial Bus

4 Cadex Electronics Inc.

 Getting Started

Commonly Used Terms

Term Explanation
Milliampere Hour Battery capacity or rating. A battery that provides a
(mAh) current of 1000 milliamperes for 1 hour is rated at
1000mAh (or 1Ah).
Battery A combination of cells.
Capacity The amount of energy that a fully charged battery is
capable of holding.
Configuration Battery parameters stored in battery adapters that tell
Code (C-code) the Cadex analyzer how to service a specific battery
type (see Chapter 6 - C-codes (Configuration Codes)
page 43).
Cells Individual items within the battery.
Cycle One charge and discharge sequence, even if the battery
is only partially charged or discharged.
C-Rate A “C” number is a value that is used to calculate charge
and discharge times.
A battery rated at 1000mAh provides 1000mA for one
hour if discharged at 1C. A discharge of 1C draws a
current equal to the rated capacity. The same battery
discharged at 0.5C would provide 500mA for two hours.
Battery cycle A charge followed by a discharge (or a discharge
followed by a charge). Even when batteries are partially
charged and discharged, a cycle is considered to have
occurred.
Intrinsically Safe Batteries with built-in safety protection circuitry. These
(I/S) batteries are used in volatile environments.
Memory Reversible capacity loss in NiCd and NiMH batteries
caused by an increase in the size of crystals formed
within the battery.
Matrix The set of battery parameters for a specific battery
model stored during the Q-Learn or Learn process and
used for testing batteries of the same model during
QuickTestTM. A matrix is stored with a C-Code.

Cadex C7000 Series Battery Analyzers 5

Getting Started

Term Explanation
Recondition A deep discharge below 1.0V/cell with a controlled
current. Reconditioning helps break down large crystals,
which develop as a result of memory, to more desirable
small sizes often restoring the battery to its full capacity.
Applies to NiCd and NiMH only.
Residual Capacity remaining in the battery when it is inserted in
Capacity an analyzer.
Resistance Also called internal resistance. Opposition to current
flow and dissipation of energy in the form of heat.
Self-Discharge Battery capacity lost during storage because of internal
leakage between the positive and negative cell plates.
Smart Battery Battery equipped with circuits that can communicate
with a charger.
State of Charge The current energy content of a battery.
State of Health The battery condition that takes into account its
capacity, resistance and self-discharge.
Target Capacity The capacity level (in percentage of manufacturer-stated
battery capacity) that a battery must display to pass a
test of battery capacity. The target capacity is an
arbitrary benchmark set by the user. By default it is set
to 80% but it can be changed.
Trickle Charge Maintenance charge to compensate for battery self-
discharge.
User Interface The front panel of the analyzer that provides information
about the status of the analyzer and any batteries being
serviced: It consists of the LCD display, the LED
indicators and the input keys.

6 Cadex Electronics Inc.

Chapter 3 Operating Principles

Components

Figure 1: Top and front panel of C7400 & C7400ER battery analyzer

Cadex C7000 Series Battery Analyzer 7

 Figure 2: Top and front panel of Cadex C7200 Battery Analyzer

Component Function
Battery stations Slots where the battery adapter is inserted. The C7400 and
C7400ER has four, the C7200 has two.
Station keys Displays C-codes or details of a service. The C7200 has two,
the C7400 and C7400ER has four
PRINT key Prints labels and reports.
EDIT key Edits the C-Code (battery parameters)
ESC key Used to exit menus, cancel changes, clear detailed displays.
FN key Provides shortcuts to common functions or special features.
ALT key Provides access to special services.
ENTER key To save settings, start battery service and enter sub-menus.
MENU key To access a list of options to set up the analyzer.
Numeric keypad To enter passwords or numeric values in a C-Code..

8 Cadex Electronics Inc.

 Component Function
Direction keys Navigate menus, move between fields, select values, view
service details.
LED indicators View current status of batteries in service (activated when a
service starts).
Ready (Green): Service complete and/or battery has passed.
Fail (Red): Battery service has failed or there is a fault.
Run (Yellow): Service in progress.
LCD display 2x40 character screen to display information on each station
and its details, to view Menu items.

Figure 3: Rear panel of Cadex battery analyzer

Component Function
On/Off Power To turn the analyzer On and Off.
switch
IEC 320 AC Connect the unit to an AC electrical power source with the IEC
input 320 power cord (North American version supplied).
Parallel port Not available on the C7200 analyzer.
Connects the unit to a printer or label printer.
RS232 serial Connects a serial printer or label printer. To connect to the
port (9-pin) serial port of a computer to upgrade the firmware, to use
BatteryShopTM or to monitor data.
USB port Not available on the C7200 battery analyzer.
Not functional with current product firmware.

Cadex C7000 Series Battery Analyzers 9

 Component Function
Cooling fan Operates continuously to keep the interior of the analyzer at
an optimum working temperature.
Do not restrict the airflow of the analyzer. Leave the fan
opening clear. Fan operation is automatic.
Primary input Protects the unit from internal short circuits. Can be replaced
fuse (see Replacing the Primary (Input) Fuse, page 114).

Front LCD Display Interface

The LCD display has 2 rows with 40 characters on each row. It has three main
states:

• The Global Display shows the general status of all four stations (or two
stations for the C7200) and any batteries being serviced. This is the default
view for the C7400 and C7400ER.

10 Cadex Electronics Inc.

 This is the default view for the C7200.

• The Detailed Display provides detailed data about one battery service or station
when the appropriate station key is pressed. For example, during a service in
Station 2, a display similar to this sample appears when you press 2 :

Note Press  or  to display additional details such as warning codes,

cycles, and program phases.

• The Menu Display provides access to various functions of the analyzer when
the MENU key is pressed (see Menu Structure, page 13).

Cadex C7000 Series Battery Analyzers 11

 Press the MENU key and select menu functions by pressing  or  to scroll
through the menu and pressing ENTER when the desired function is displayed.
For example, this message shows one option in the System Security menu:

Lights (LEDs)

Light Status Explanation

RUN (yellow) On Service in progress.
READY (green) On Service has completed; Battery has passed
the service.
Flashing Cold battery. Service resumes when battery
warms up (code 12).
FAIL (red) On Battery failed.
Flashing Hot battery. Service resumes when battery
cools (code 13).
All Flashing System failed. Turn the analyzer off and then
randomly on. Contact Cadex if the condition persists.

12 Cadex Electronics Inc.

Menu Structure

The menu-driven interface allows access to the various functions of the analyzer.
See sections on individual functions for details and instructions.

MENU

System ENTER Set Security

Security Change Password

System ENTER Date/Time

Setup Serial Port Device
Serial Port Settings
Parallel Port Device
Power Fail Resume Hours
Calibrate Adapter
Calibrate Voltage
Custom Programs
Program ENTER Self Discharge Rest
Settings LifeCycle Counter
Ohmtest Setpoints
Automatic Ohmtest
Runtime Settings
Charge Optimization
dT/dt Termination
Option ENTER Company Name
Controls Battery Startup
Program/Target Changes
Sound Control
Sound Check
Voltage Display
QuickTest Results
Set Service Counter
Clear Service Counter
Print Utilities ENTER Battery Service Report
Battery Label
System Setup Report
Adapter Setup Report
Auto-Print

Event Log ENTER View Event Log

Print Event Log
Clear Event Log
Events to Log

DOWN key T, S to scroll,

UP key ENTER to select,
ESC to exit.

Figure 4: Menu hierarchy of the Cadex Analyzer

Cadex C7000 Series Battery Analyzers 13

 Battery Adapters

Adapters are designed to fit specific battery types and shapes. The snap-lock
latch allows easy insertion and removal. There are two types of battery adapters:

• Custom Adapters accommodate a specific battery shape. There are over

1000 custom adapters available.

• Universal Adapters are used when a custom adapter is not available. Pins or
alligator clips attach to the positive and negative terminals and include a
magnetic temperature sensor.

Figure 5: Different types of battery adapters

ADAPTER HANDLING PRECAUTIONS

• Do not touch the adapter’s gold contacts at the rear or on

the analyzer station adapter connector. The static charge
can damage microcircuits on the adapter.

• Do not remove the adapter from the analyzer while it is

servicing a battery. Remove the battery first and then the
adapter.

• ESD HANDLING PRECAUTIONS: When the adapter is NOT

14 Cadex Electronics Inc.

 installed in analyzer:

o The battery should not be connected to the

adapter

o Do not allow anything to touch the gold

fingers on the adapter connector card

o Do not allow anything to touch the adapter

connector in the analyzer's adapter well

Each adapter contains up to ten battery service parameters called Configuration

Codes (or C-codes) in non-volatile memory. C-codes will not be lost when
adapters are removed and reinserted into any station on the analyzer or when the
analyzer is turned off.

Custom adapters are pre-programmed with C-codes for the most common
batteries. If a battery C-code is not available, you can program a new C-code or
reprogram an existing C-code into the analyzer.

Universal adapters, designed for generic batteries, are programmed with blank C-
codes and will display NULL CODE when inserted (see Create or Edit a C-code,
page 59). Battery adapters can be installed, removed or reprogrammed while
other stations are being used. Once the adapter is inserted, the battery station
receiving the adapter automatically uses the last selected C-code.

Cadex continuously designs and manufactures adapters for new battery models. A
list of current battery adapter models is available in the adapter catalog available inj
print or on the Cadex website. Contact Cadex for a current adapter catalog or
download a copy from our web site at www.cadex.com. Cadex also designs custom
adapters for a wide variety of applications. A Battery Adapter Design Form can be
downloaded from the Cadex website and used to order a custom adapter.

To insert an adapter

1. Place the empty battery adapter into the battery adapter station,
putting the front end in place first.

Cadex C7000 Series Battery Analyzers 15

 2. Press down on the back panel (with the label) until the adapter snaps
in place.

The LCD display for the station changes from NO ADAPT to EMPTY, indicating that
the battery adapter has been inserted but does not contain a battery. The second
line of the display indicates the program that was selected in the C-code. If the
adapter displays NULL CODE, the C-code has not been programmed, (see Create
or Edit a C-code, page 59).

OBSERVE POLARITY!

Do not connect the Universal adapter to the battery with the leads reversed
or insert the battery into the adapter in reverse.

To remove an adapter

1. Remove the battery from the adapter first.

2. Press the latch bar behind the label on the adapter and lift the
adapter upwards.

16 Cadex Electronics Inc.

Chapter 4 Basic Battery Service

This chapter covers the basic procedures for servicing a battery including: turning
on the unit; inserting the battery adapter; selecting the correct C-code and
program; inserting the battery; confirming the setting; starting service and
recording the results.

To service a battery

1. Turn the power on using the ON/OFF power switch on the rear panel.
A boot-up screen appears for 5 seconds: It displays the firmware
version on the bottom left (in this case, it is V6.00) and the security
level (in this case, it has not been set). This screen can also be
cleared after 5 seconds by pressing the ESC key.

2. Insert the battery adapter into a station by sliding the lower-front part
of the adapter into the station towards the display. Press the back end
down to close with a click. If adapters are inserted in Stations 1 and 4,
a display like this appears:

Cadex C7000 Series Battery Analyzer 17

 If a Universal adapter is used for the first time, NULL CODE appears on
the display. You must create a custom C-code (see Create or Edit a
C-code, page 59).

3. Insert a battery into the adapter.

BATTERY CONTACTS MUST BE CLEAN BEFORE INSERTING THE

BATTERY.

Dirty contacts can increase the resistance in the connection between the
adapter and the battery, causing false voltage and current readings and in
extreme cases, melting of the contacts. To clean the battery contacts, use a
lint-free cotton swab dipped in 100% isopropyl alcohol.

The following message appears when the battery is detected:

Note You can set up the Cadex analyzer not to display this
message and start service (see Starting Battery Service,
page 78).

If the display continues to display an Empty message, this means that

the Cadex analyzer is not recognizing the battery. There are a
number of reasons this may happen:

• Battery is not inserted correctly. Verify that the battery is

correctly and firmly inserted into the adapter. Make sure that the
contacts on the battery connect with the contacts on the adapter
and check for any switches on the battery.
• Battery is completely discharged or protection circuits are
open. Run the Boost program by pressing the station key and
holding it for two seconds (see Boost, page 36).

18 Cadex Electronics Inc.

 4. Press ENTER to display the C-codes (see Chapter 6 - C-codes
(Configuration Codes), page 43).

5. If the active C-code (indicated by “*”) is the correct one for the battery
you are servicing and all settings in the C-code are correct, go to step
8 to start service otherwise continue to the next step.

6. Select another C-code.

a) Press  or  to scroll through the C-codes in the adapter.

b) Press ENTER when the correct C-code is displayed. Press ENTER

again to confirm the changes. The selected C-code is now active,
and is indicated by “*”.

If you want to change any of the settings in the C-code, you

should do it now (see Create or Edit a C-code, page 59).

Always use the correct C-code, especially the correct chemistry. Failure
to do so may damage the battery or cause fire or explosion.

7. If the C-Code is correct, press ENTER to confirm the settings.

8. Press ENTER again to start the battery service. The yellow (run) light
appears.

Once the service starts, the display will show the current program status
as in the following diagram. For detailed information about messages that
appear, (see Appendix A - Messages and Warnings, page 132).

Cadex C7000 Series Battery Analyzers 19

 Depending on the battery chemistry and the program selected,
service may take anywhere from a few seconds to a few hours. Some
programs can take several days or weeks.

If the battery passes after service has completed, the green Ready
light comes on. If a battery failed, the red Fail light appears with a Fail
code (see Appendix A - Messages and Warnings, page 132):

9. To display details about an ongoing or completed battery service:

a) Press the station key to see the detailed display:

b) Press  to see any applicable warning codes:

20 Cadex Electronics Inc.

 For more information about message codes, including reasons for
battery failure and possible solutions (see Appendix A, Messages
and Warnings, page 132).

c) Press  to see additional information:

REMOVING LARGE BATTERIES WHILE IN SERVICE

It is NOT recommended to remove very large batteries while it is in

service. Large batteries may create arcs that may degrade the
performance of the analyzer. If it is necessary, follow these
instructions:

Press and release the Alt key and the station key holding the battery.
On the screen that appears, press  to select ‘Interrupt’ and press
Enter. Remove the battery within 5 seconds.

Cadex C7000 Series Battery Analyzers 21

 Chapter 5 Battery Service Programs

The Cadex analyzer comes with four basic programs, nine advanced programs
and four custom programs. These programs measure the battery state of health
(SoH), the battery’s capacity and find any anomalies that may affect battery
performance. If the battery passes the Auto, Prime or Charge service programs,
the battery can stay on the charger and stay fully charged until it is used. If the
battery fails, the program terminates with the appropriate fault code.

Basic Programs

The basic programs are Auto, Charge, Prime, and QuickTest™ (for 16K battery
adapters only). These programs cannot be edited. Each program performs
functions for different purposes:

Program Does this Is used for this

Auto Exercises batteries to • Restoring batteries affected by
maintain optimum “memory”.
performance. If the Target
Capacity cannot be • Performing routine battery
reached, the battery is maintenance.
reconditioned. • Identifying marginally
performing batteries.
• Servicing batteries in unknown
condition.
• Verifying battery condition for
warranty claim.

Charge Applies fast charge only. • Charging batteries quickly.

No capacity readings are
taken and no discharge is • Topping up partially discharged
applied. batteries.

22 Cadex Electronics Inc.

 Program Does this Is used for this

Prime Repeatedly cycles battery • Preparing new batteries for

until maximum capacity is field use.
reached. If capacity
improvement is more than • Conditioning batteries that
5% over previous reading, have been in storage.
an additional cycle is
applied.

QuickTest™ Tests battery SoH by • Gives an estimate of battery

comparing battery data to SoH to help sort batteries.
data from other batteries of
the same model stored in • 16K battery adapters only
the QuickTest™ matrix in (adapters are identified with a
the C-code. “16K” sticker on the back)
• A matrix is required to run this
program (see Q-Learn
Procedure, page 41).

Auto

Function: Exercises batteries to maintain optimum performance. This is the

recommended program for routine maintenance of batteries. It reconditions NiCd
and NiMH batteries that do not reach Target Capacity. Li-ion and SLA batteries
are not reconditioned, only exercised. Batteries in use are typically cycled every
three months on Auto. If batteries are failing prematurely, increase the frequency
of service on the Auto program.

Sequence: The battery is first cycled (charged and then discharged) to determine
it’s true capacity. If NiCd and NiMH batteries do not meet the target capacity at
the end of the discharge cycle, they are reconditioned to reduce battery memory.
Following recondition, the battery is cycled again to determine the recovered or
final capacity. The battery is fully charged when the program completes.

SLA and Li-ion batteries are cycled once. If the target capacity is not reached in
the first cycle, it is cycled again. Recondition is not performed for Li-ion and SLA
batteries.

Cadex C7000 Series Battery Analyzers 23

 Results: Global display shows battery capacity as a percentage of manufacturers
stated capacity for the battery model. Detailed display shows average battery or
cell voltage, analyzer charge or discharge current in mA, OhmTest results, battery
temperature (if applicable), and duration of service

Batteries in good condition should be greater than the target capacity (by default
this is 80%). If batteries fail, check the fault codes for details.

Duration: Approximately 2.5 to 10 hours for NiCd and NiMH, 20 to 40 hours for
SLA and 6 to 20 hours for Li-ion using default C-codes.

Charge

Function: Fast charge a battery.

Sequence: A charge cycle is applied to the battery. No capacity readings are

taken (capacity is only obtained if there is a discharge). Because Charge does
not perform a full analysis, bad batteries may not be caught and can affect a
mission critical application. Use the Auto or Prime program to fully
diagnose a battery.

Results: The global display alternates between current average battery, cell
voltage and analyzer charge or discharge current (mA) during service and after
service. Detailed display also shows OhmTest results, battery temperature (if
applicable) and duration of service.

Look for the green Ready LED. It indicates that the battery has been charged.
There is no capacity reading taken during a charge. To diagnose faulty batteries
the user is required to run Prime, Auto, etc.

Duration: Approximately 1.5 hours for NiCd and NiMH, 10 hours for SLA, and 4
hours for Li-ion using default C-codes.

24 Cadex Electronics Inc.

 Prime

Function: Prepares new or stored batteries for use. A new or stored battery may
require several charge/discharge cycles to form the cells to achieve peak
performance.

Sequence: The program cycles (discharges and charges) the battery until the
difference between capacities from one cycle to the next is less than 5%. Up to
four cycles are applied until the 5% capacity difference is reached. This allows for
batteries that cannot accept a full charge on the first cycle. If the battery is fully
discharged, the program starts with a charge. No reconditioning is applied. Some
batteries may require several Prime cycles to fully form the cells.

Results: Global display shows final battery capacity percentage. Detailed display
shows battery capacity percentages for the last three cycles performed as well as
average battery or cell voltage, analyzer charge or discharge current in mA,
OhmTest results, battery temperature (if applicable) and duration of service.

Batteries in good condition should be greater than 80% or your target capacity. If
batteries fail, check the fault codes for details. If the capacity is low, the battery
should be Primed again. In some cases, two or three Prime programs may be
required to fully form a battery.

Duration: Approximately 5 to 10 hours for NiCd and NiMH, from 40 to 80 hours

for SLA, from 12 to 25 hours for Li-ion using default C-codes.

QuickTest™

This firmware (version 6.11) will not display or use a matrix made with
firmware version 5.00 or below. Therefore, you will have to run the
Learn program again to create a new matrix. Any old matrix will not be
displayed if the adapter is used in version 6.11.

Ensure that battery contacts and adapter contacts are clean. Dirty
contacts will affect QuickTestTM readings.

Note: QuickTest is available only when you are using 16k battery adapters.
These adapters are marked ‘16K’ on the rear of the adapter.

Cadex C7000 Series Battery Analyzers 25

 Function: Before running QuickTestTM, create a matrix for the battery using the
Learn program (see Learn, page 37). QuickTestTM determines the battery SoH
(state of health) that is an approximation of the battery capacity and resistance. If
a matrix does not exist for the C-code, (i.e. no batteries of the same model have
gone through the Q-Learn or Learn programs) a message appears stating that no
QuickTestTM matrix has been found, and that the Learn program should be run
first. QuickTestTM can still run without a matrix but results are unreliable.

Sequence: The battery is tested to ensure that it has 20% - 90% State of Charge.
If not, it applies a charge or discharge for five minutes. The program then
performs a sequence of resistance tests, partial charges, discharges and rest.
Test results are compared to the matrix to determine the battery state of health.

Results: The Global and detailed display shows the battery condition as
“Excellent”, “Good”, “Marginal” or “Poor”. Detailed display also shows average
battery or cell voltage, analyzer charge or discharge current in mA, OhmTest
results, battery temperature (if applicable) and duration of service.

Duration: Approximately 5 minutes if the battery SoC (state of charge) is between

20% and 90%. Batteries with a lower or higher SoC require additional time to
bring their SoC to between 20% and 90%. For most batteries, this takes about 5
minutes. However, with high-capacity batteries, it may take longer.

26 Cadex Electronics Inc.

Advanced Programs

Advanced programs include OhmTest; RunTime; Self-Discharge; Life-Cycling;

Discharge Only; Extended Prime; QuickLearn (Q-Learn); Learn; Boost and the
four programmable custom programs. Unlike basic programs, some advanced
programs have settings that can be edited.

Program Does this Is used for this

Self- Reads fully charged battery • Identifying batteries that may

Discharge capacity; recharges and have good capacity but have
reads the capacity after a high self-discharge.
programmable wait period.

Life-Cycle This is a destructive test • Verifying battery life cycle. For

that continuously cycles a example, is for use with a
battery until it fails. single battery to determine the
Life Cycle of an entire batch of
Continuously cycles battery batteries.
until capacity drops below
target capacity. Displays • To verify the life of a new
initial and final capacity, constructed cell.
OhmTest result.
• Estimating performance time.

Discharge Discharges a battery to its • Determining residual capacity

Only end-of-discharge voltage. of battery.
(DCHOnly)
• Preparing batteries for storage.
• Determining battery
performance under load.

Extended Applies a 16-hour trickle • Preparing new batteries or

Prime charge, followed by cycling to batteries that have been in
obtain peak capacity. extended storage for use.

OhmTest Tests internal resistance. • Checking battery condition.

Passes or fails the battery
based on the target • Determining if the battery
resistance. needs to be analyzed further.

Cadex C7000 Series Battery Analyzers 27

 Program Does this Is used for this

RunTime Simulates a 5/5/90 discharge. • Testing battery runtime for

Programmable time and communications equipment.
discharge rates per phase.

Boost Applies a 100mA trickle • Reactivating batteries that are

charge for 3 minutes. not recognized by the Cadex
analyzer because of low
voltage or an open protection
circuit.

Quick This program assumes that a • Rapidly establishing an

Learn battery has 100% capacity. It accurate QuickTest™ matrix
(Q-Learn) profiles the battery and saves based on the SoH of a new
the data to the QuickTest™ battery that is known to be
matrix in the C-code. good.
• 16K battery adapters only.
(16K adapters have an
identifying sticker on the back.)

Learn Applies a charge-discharge- • Establishing or modifying

charge cycle to determine QuickTest™ matrix using a
battery capacity, profiles the spectrum of batteries with
battery, saves the data to the various SoH.
QuickTest™ matrix in the C-
code. • Increasing QuickTest™
accuracy (confidence grade)
for a given battery type.
• 16K battery adapters only.
(16K adapters have an
identifying sticker on the back.)

Custom Allows the user to create • Accommodates specialized

1,2,3,4 specific programs (see requirements.
Chapter 10 - Custom
Programs, page 104).

28 Cadex Electronics Inc.

 SelfDCH (Self-Discharge Test)

Function: Identifies the self-discharge or the amount of charge a battery loses if it

is left alone for a period of time. The standard time is 24 hours.

Sequence: The battery is charged and discharged to obtain its first capacity. The
battery is then charged and left for a 24-hour rest period (instructions to change
this time are given below). During this time, the battery loses energy through self-
discharge. After 24 hours, the battery is discharged to determine the second
capacity. The difference between the second and first capacity is the self-
discharge.

Results: Press the station key to view the detailed display then press  to view
the self-discharge rate (given as a percentage). A battery with low self-discharge
has less than 15% self-discharge. A battery that has more than 15% self-
discharge may have soft cells and may not be able to provide the required use-
time.

Global display shows battery capacity percentage. Detailed display shows battery
capacity percentages for the last three cycles performed. It also displays average
battery or cell voltage; analyzer charge or discharge; current in mA; OhmTest
results; battery temperature and duration of service.

Duration: Approximately 30 hours for a NiCd battery using default C-codes.

To change the Self-Discharge time

1. From the global display, press MENU.

2. Press  or  to scroll to PROGRAM SETTINGS, then press ENTER.

3. Press  or  to scroll to SELF DISCHARGE REST, then press ENTER.

4. Press  or  or use the number pad to select the self-discharge

period.

Cadex C7000 Series Battery Analyzers 29

 5. Press ENTER.

6. Press  or  to scroll to YES to accept changes and press ENTER.

7. Press ESC twice to return to the global display.

Life-Cycle

This is a “destructive” test that continuously cycles a battery until it

fails. Do not run this program on a battery you need to use.

Function: Determines total battery life by the number of cycles. Checks whether
the battery meets the standard life for its chemistry. This is an accelerated aging
test and the battery cannot be renewed after this test.

Sequence: The battery is charged and discharged continuously until the battery
fails (i.e. battery capacity falls below target capacity) or the maximum number of
cycles has been reached.

Results: Global display shows failure-warning message. Detailed display shows

percentage capacity for the first cycle and the last three cycles run. It also
displays: average battery or cell voltage; analyzer charge or discharge current
(shown in mA); OhmTest results; battery temperature and duration of service.

An additional display screen (press  from detailed display) shows cycle number,
percentage of battery capacity achieved and OhmTest results for the first and last
cycles run.

Look for the number of cycles (a cycle is a charge followed by a discharge).

Batteries should provide the number of cycles as specified by the manufacturer.
Typically, with a target capacity of 80%, NiCd batteries should provide about 1500
cycles, NiMH 500 cycles, Li-ion 500 cycles, and SLA 300 cycles.

Duration: Approximately one month or more depending on the chemistry.

30 Cadex Electronics Inc.

 To edit the Life Cycle Test settings

The program uses the target capacity set in the C-code to determine when the
program should end (see Target Capacity, page 45). To terminate the program
after a certain number of cycles, do the following:

1. From the global display, press MENU.

2. Press  or  to scroll to PROGRAM SETTINGS, then press ENTER.

3. Press  or  to scroll to LIFECYCLE COUNTER, then press ENTER.

4. Press  or  or use the number pad to select the number of cycles.

5. Press ENTER. Press  or  scroll to YES to accept changes and

press ENTER.

6. Press ESC twice to return to the global display.

DCHOnly (Discharge Only)

Function: The DCHOnly program determines the residual capacity of a battery,

prepares batteries for storage and checks battery performance under load.

To determine battery capacity, fully charge the battery using the Charge program
before running the Discharge only program.

Sequence: The battery is discharged until its voltage reaches the END OF
DISCHARGE setting in the C-code.

Results: Detailed display shows battery capacity as a percentage of

manufacturer’s stated capacity for the battery model. It also shows average
battery or cell voltage; analyzer charge or discharge current (in mA); battery
temperature and duration of service. Look for the green ready LED. The battery
capacity is measured during a discharge and if the battery is partially discharged,
the capacity may be lower than the target capacity. This may give a Fail Code 115
or 116. The battery is not necessarily poor.

Cadex C7000 Series Battery Analyzers 31

 Duration: Approximately 1 hour for a NiCd battery discharged at default C-code
settings.

To edit the Discharge Only settings

The Discharge Only test settings cannot be edited. However, the program uses
the END OF DISCHARGE setting in the C-code (see End of Discharge, page 51).

Smart batteries (often used in laptops) should not be stored in a fully

discharged state.

If the battery’s voltage drops below the level required by the processor within
the battery, information can be lost. In some cases, this data loss can leave
the battery permanently unusable.

ExtPrime (Extended Prime)

Function: Exercises a battery that has been in storage or unused for a long time
(typically three months or more).

Sequence: The battery is charged for 16 hours on the TRICKLE CHARGE setting in the
C-code. The battery is then continually cycled (charged and discharged) up to five
times until the difference between the capacities achieved from one cycle to the next is
less than 5%.

Results: Global display shows final battery capacity percentage. Detailed display
shows battery capacity percentages for the last three cycles performed. It also
shows average battery or cell voltage; analyzer charge or discharge current (in
mA); OhmTest results; battery temperature and duration of service.

Batteries in good condition should be greater than 80% or your target capacity. If
batteries fail, check the fault codes for details. If the capacity is low, the battery
should be Primed again. In some cases, two or three Prime programs may be
required to fully form a battery.

Duration: Approximately 24 hours for a NiCd battery charged and discharged at

1.00 C.

32 Cadex Electronics Inc.

 OhmTest

This OhmTest program uses a method similar to the IEC “DC” method
to determine the battery resistance. The results tend to be higher than
analyzers with firmware version 5.00 and below. Therefore, the
OhmTest results cannot be compared with results from analyzers with
older firmware versions.

Ensure that battery contacts and adapter contacts are clean. Dirty
contacts will affect OhmTest readings.

Ensure battery has a high state of charge (SoC). If battery SoC is less
than 50%, OhmTest readings become less consistent.

Calibrate the adapter before performing an OhmTest.

Function: This program is similar to the IEC “DC” method of resistance

measurement. It is recommended to have the battery with a high state of charge
(i.e. fully charged) to provide values. Low state of charge may produce poor or low
values. The OhmTest program determines the internal resistance of a battery and
passes or fails the battery based on the OHMTEST SETPOINTS. It provides an
estimate of the battery capability to handle load. Setting an OHMTEST SETPOINT is
described below.

Sequence: The program tests battery resistance and compares the result with the
analyzer’s OHMTEST SETPOINTS for the battery chemistry. If the result is below this
threshold, the program fails the battery.

Results: Global display shows internal resistance in milliohms (mΩ). Detailed

display also shows average cell voltage; analyzer charge or discharge current (in
mA); battery temperature and duration of service.

If the value is above the analyzer’s OhmTest setpoint threshold, the battery fails
the OhmTest and should be replaced. If the battery passes, run the Auto or Prime
program on the battery to determine whether there are other faults.

Compare several good and bad batteries to determine a suitable OHMTEST

SETPOINT. Some industries use 500milliohms as a pass/fail mark.

Cadex C7000 Series Battery Analyzers 33

 Duration: 15 seconds for all chemistries.

To edit the OhmTest Setpoint

1. From the global display, press MENU.

2. Press  or  to scroll to PROGRAM SETTINGS and then press ENTER.

3. Press  or  to scroll to OHMTEST SETPOINTS and then press ENTER.

4. Press  or  or use the number pad to set the OhmTest setpoint for
the first battery chemistry type.

The default setpoint is 1000mΩ but you can choose any setting
between 0 and 4000mΩ.

5. Press  or  to move to the next battery chemistry type.

6. Repeat steps 4 and 5 until the OhmTest setpoint for all battery
chemistries are set appropriately.

7. Press ENTER.

8. Press  or  to scroll to YES to accept changes and press ENTER.

9. Press ESC twice to return to the global display.

RunTime

Function: The RunTime program simulates battery run-time by repeatedly

running three different loads until the battery reaches the end-of-discharge setting
in the C-code. These loads are often called the standby, talk and receive time.
You can set the load current (as a percentage of the Discharge Rate) and time (in
minutes) for each of the three loads so that the load cycles simulate the
equipment in which the battery is used.

34 Cadex Electronics Inc.

 Sequence: The battery is charged. The program then repeatedly runs three
different loads (see instructions below to set these loads) until the battery is fully
discharged (i.e. The end-of-discharge setting in the C-code is reached).

Results: The detailed display shows the battery run-time (hours and minutes). It
also shows battery or cell voltage; analyzer charge or discharge current (in mA);
OhmTest results; battery temperature and duration of service.

Duration: Approximately 8 – 10 hours for a NiCd battery using default C-codes.

To edit the RunTime settings

1. From the global display, press MENU.

2. Press  or  to scroll to PROGRAM SETTINGS and then press ENTER.

3. Press  or  to scroll to RUNTIME SETTINGS and then press ENTER.

4. The cursor is at Discharge 1 (the first load).

5. Press  or  or use the number pad to set a load between 1 and

100 for the Discharge %. This is a percentage of the Discharge Rate
in the C-Code. The default is 100.

6. Press  to move to Minutes – the time this load is applied. Press 

or  or use the number pad to set the time between 1 and 59
minutes. The default is 1.

7. Press  to move to the load setting for the Discharge 2 (second

phase). Repeat steps 4 and 5.

8. Press  to move to the load setting for the Discharge 3 (third phase).
Repeat steps 4 and 5.

9. Press ENTER to save the settings.

10. Press  or  to scroll to YES to accept changes and press ENTER.

Cadex C7000 Series Battery Analyzers 35

 11. Press ESC twice to return to the global display.

Boost

Warning!

The Boost program overrides some of the analyzer’s built-in safety measures
to recognize a battery. Do not attempt to Boost a battery if the polarity,
chemistry, voltage and capacity (mAh) are not known. You must also ensure
that battery polarity is correct before you attempt to run Boost. For this reason,
it is NOT recommended to use a Universal Adapter with Boost.

Failure to follow these precautions may result in serious damage to the

Cadex unit and/or the battery.

Function: Reactivates batteries with open or shorted protection circuits or with

voltage so low that the Cadex analyzer does not recognize them or gives a
‘Shorted’ (Code 121) message when they are inserted in battery adapters.

Sequence: The battery is trickle-charged for three minutes at 100mA. The

Program can be terminated at any time by pressing the Esc key. Look for stable
current and voltage readings during the Boost program. If they are intermittent,
the battery may be poorly connected, battery protection circuit may be damaged
or the battery is inoperable. Normal battery service will start after Boost has
reached more than 0.30V/cell on NiCd and NiMH batteries and more than 2.5V for
Li-ion batteries. If Boost does not raise the voltage to detectable levels, apply the
Boost program again.

Results: If the Boost is successful, the Cadex analyzer recognizes the battery
and indicates on the global display that a battery is inserted in the battery adapter.

Duration: 3 minutes (user may repeat if unsuccessful).

To run the Boost program

1. Insert the battery adapter in a battery station.

2. Insert the battery in the battery adapter.

36 Cadex Electronics Inc.

 If the battery needs to be boosted, the global display for the station
may show one of two things:

i. It may continue to display the EMPTY message, indicating that the

Cadex analyzer has not recognized the battery.
ii. It may display a SHORTED (Code 121) message for the battery.

3. Press the station key and hold until a warning message appears
reminding you to check battery polarity (about 2 seconds).

4. If polarity is correct, press ENTER to continue.

Depending on how your analyzer is set up (see To set user input

required by the Cadex analyzer before battery service begins,
page 78), you may need to press ENTER again to accept the C-code
settings.

The Boost program starts, and BOOST appears as the active program.
The program runs about 3 minutes and provides a 100mA charge.

5. Press ESC any time during the Boost to terminate the program.

If the Boost is successful, the global display changes to the active program name
to show that the Cadex analyzer now recognizes the battery.

If the Boost is unsuccessful, you can repeat this procedure until it is successful or
until you are convinced that the battery cannot be restored.

To edit the Boost settings

The Boost test program has no settings that can be edited. Boost current is fixed
at 100mA for three minutes.

Learn

This firmware (version 6.11) will not display or use a matrix that was
made in firmware version 5.00 or below. Therefore, you will have to run

Cadex C7000 Series Battery Analyzers 37

 the Learn program again to create a new matrix. Any old matrix will not
be displayed if the adapter is used in version 6.11.

Ensure that battery contacts and adapter contacts are clean. Dirty
contacts will affect QuickTestTM readings.

Function: Learn creates and stores a modifiable matrix into a C-code for use by
QuickTestTM.

Sequence: The Learn program applies several charges, discharges and

OhmTests to obtain a battery profile. The profile contains the battery’s C-code.
The C-code is then saved as a matrix used for running the QuickTestTM program.

Results: Detailed display shows three decreasing capacity percentages as well

as average cell voltage; analyzer charge or discharge current (in mA); OhmTest
results; battery temperature and duration of service. The C-code display screen
shows a T in the upper right-hand corner to indicate that a C-code, saved as a
matrix, has been stored for using with the QuickTestTM program.

Duration: 4 – 8 hours depending on battery capacity and default C-codes.

Learn Limitations

• Learn is available only on 16K battery adapters. ‘16K’ is marked on the rear
label of the adapter.
• Only custom adapters should be used. Universal adapters such as the
Universal Alligator Clips Adapter (07-110-0115), the Claw (07-110-0170) and
the FlexArm (07-110-0180) are NOT recommended. These adapters can
create inaccurate results due to resistance errors.
• Learn and QuickTestTM cannot be used with the following batteries:
o SLA batteries greater than 2Ah (2000mAh).
o Some 1-cell (1.20V) and 2-cell (2.40V) NiCd and NiMH batteries.
o Batteries with resistance above 800mΩ (as measured by OhmTest). It is
advisable to run an OhmTest to determine battery resistance prior to
running the Learn program.

38 Cadex Electronics Inc.

 o Batteries that disconnect, reset or give failures while running the Learn
program.
o Batteries that cannot accept a charge rate and discharge rate of at least
1.00C. These batteries tend to give errors if they are serviced on the
analyzer using the Auto or Prime programs.

Learn Procedure

If you are using a battery that has not been used for two months or more, run the
Prime program on the battery prior to running the Learn program.

Calibrate the adapter and ensure that the C-Code for the battery is correct. Take
a good battery (over 80% capacity) and run through the Learn program. After the
Learn program is complete, take the battery and while it is in the same adapter,
run the QuickTestTM program. The final SoH (state of Health) result should be
within the range of the actual battery capacity. If not, erase the battery matrix
(press FN and then press 2) and start over. Once successful, test other batteries
with the same capacity, if possible, to ensure that the SoH readings are within an
acceptable range.

To create the most effective matrix, repeat the above steps with more batteries. It
is recommended to run the Learn program on at least three batteries: one with a
capacity above 90%; one with a 70-80% capacity and finally one at 70% capacity.
The batteries can be run through the Learn program in any order.

The battery matrix will be erased if anything in the C-code is changed except for
the target capacity and the actual program (i.e Auto, Charge, Prime, QuckTestTM
or any of the other programs).

Q-Learn (Quick Learn)

Function: Q-Learn creates and stores a matrix into a C-code for use by
QuickTestTM. The Q-Learn program is only run once on a battery. For more
accurate results, running the Learn program is recommended.

Sequence: This program assumes that the battery has 100% capacity. If a
battery has lower capacity, it will not make a correct matrix. The program consists

Cadex C7000 Series Battery Analyzers 39

 of a charge and a discharge and the OhmTest. The data obtained from the
program profiles the battery’s SoH, saving the battery’s C-code as a matrix.

Results: Detailed display shows the battery’s average cell voltage; analyzer
charge or discharge current (in mA); OhmTest results; battery temperature and
duration of service. If Q-Learn is successful, the C-code will display a T in the
upper right-hand corner to indicate that a QuickTestTM matrix has been created.

Duration: Approximately 5 minutes for all batteries with a SoC (state of charge)
level between 20% and 90% of battery capacity. Batteries with a SoC level lower
than 20% or greater than 90% require additional time to bring their SoC to
between 20% and 90%. For most batteries, this takes an additional 5 minutes but
in some cases, especially with high-capacity batteries, it may take longer.

Q-Learn Limitations:

• Q-Learn assumes that the battery’s capacity is 100%. If a battery’s capacity is

less than 100%, it will give erroneous results.
• Q-Learn should only be used for one battery. For more accurate results, run
the Learn program on three different batteries with varying capacities.
• Q-Learn is available only on 16K battery adapters. ‘16K’ is marked on the rear
label of the adapter.
• Only custom adapters should be used. Universal adapters such as the
Universal Alligator Clips Adapter (07-110-0115), the Claw (07-110-0170) and
the FlexArmTM (07-110-0180) are NOT recommended. These adapters will
give inaccurate results due to resistance errors.
• Q-Learn and QuickTestTM cannot be used with the following batteries:
o SLA batteries greater than 2Ah (2000mAh).
o 1-cell (1.20V) and 2-cell (2.40V) NiCd and NiMH batteries.
o Batteries with resistance above 800mΩ (as measured by OhmTest). It is
advisable to run OhmTest on any battery that is run through the Q-Learn
program.
o Batteries that disconnect, reset or give failures while running the Learn or
Q-Learn programs.

40 Cadex Electronics Inc.

 o Batteries that cannot accept a charge rate and discharge rate of at least
1.00C. These batteries tend to give errors if they are serviced on the
analyzer using the Auto or Prime programs.

Q-Learn Procedure

Calibrate the adapter and ensure that the C-Code for the battery is correct. Take
several batteries with 100% capacity or over. Confirm the capacity by servicing
the batteries on the Prime program. Note the final capacity and resistance
readings. Take the battery with the highest capacity (ensure that it is 100% or
greater) and the highest resistance and run this battery through the Q-Learn
program. After the Q-Learn program is complete, take the same battery in the
same adapter and run it through the QuickTestTM program. The final SoH (state of
Health) result should be 100%. If the result is less than 100%, erase the battery
matrix (press FN and then press 2) and start over. When a successful result has
been obtained (100%), test the other batteries with the same capacity to ensure
that the SoH readings are within an acceptable range.

The battery matrix will be erased if anything in the C-code is changed except for
the target capacity and the actual program (i.e Auto, Charge, Prime, QuckTestTM
or any of the other programs).

Custom 1, 2, 3, and 4

By default, custom programs are blank when the Cadex analyzer is shipped from
the factory (see Chapter 10 - Custom Programs, page 104).

Cadex C7000 Series Battery Analyzers 41

 Battery Service Times

The following table displays the approximate service times at default charge and
discharge rates.

NiCd, NiMH SLA Li-ion

Auto 2.5 – 10 hours 20 – 40 hours 6 – 20 hours
Charge 1.5 hours 10 hours 4 hours
Prime 5 – 10 hours 40 – 80 hours 12 – 25 hours
QuickTest™ All chemistries: approximately 5 minutes
OhmTest 15 seconds 15 seconds 15 seconds
Runtime Duration depends on settings
Self- 30 hours 60 hours 50 hours
Discharge
LifeCycle 1500 cycles (NiCd) 200 – 500 1000 cycles
cycles
500 cycles (NiMH)
Discharge 1 hour 20 hours 4 hours
Only
Extended 21 – 26 hours 56 – 96 hours 28 – 41 hours
Prime
Quick Learn All chemistries: 2-5 minutes
Learn All chemistries: 4 – 8 hours
Boost All chemistries: 3 minutes
Custom Duration depends on settings
1, 2, 3, 4

42 Cadex Electronics Inc.

Chapter 6 C-codes (Configuration Codes)

Battery information such as chemistry, voltage and rating needs to be

programmed into the adapter so the analyzer knows how to service A battery.
This information is called the C-code. Up to 10 C-Codes can be stored on each
adapter. Once a C-Code has been entered, the information is stored permanently
in the adapter memory where it can be displayed; selected; created; copied;
edited and deleted (see Managing C-codes, page 58). The adapter can be
moved between stations*and the C-Code remains within the adapter.

Note A C-code cannot be edited or changed while a battery is serviced.

Custom battery adapters come pre-programmed with the most common battery C-
codes compatible with the adapter. Universal adapters such as 07-110-0115
(Smart Cable) and 07-110-0180 (FlexArmTM) are shipped with no C-Codes and will
display NULL CODE when inserted into the analyzer. Create a C-code to clear the
NULL CODE message (see Managing C-codes, page 58).

Each C-code is divided into three parts:

• Basic C-codes include program; target capacity; chemistry; voltage and

capacity. The C-code setup name, if specified, is displayed on the LCD
screen along with basic parameters. If a C-code is locked, scaled or has a
matrix, it is indicated on the display by an ‘L’, ‘S’ or ‘T’ respectively. The
battery chemistry, voltage and capacity are required in order to start servicing
a battery.
• An extended C-code, which consists of charge/discharge C-rate, trickle-
charge rate, recondition settings and other parameters are needed to service

* It is recommended to calibrate battery adapters whenever they are moved from one
analyzer to another (see Calibrating Adapters page 132).

Cadex C7000 Series Battery Analyzers 43

 a battery. The types of parameters depend on the battery chemistry described
in the following table. In general, extended parameters can be left at their
default settings.
• A matrix contains the battery C-Code information for running the QuickTestTM
program. Running the Learn or Q-Learn program produces the matrix. Matrix
information cannot be seen on the analyzer, however, an inverse T in the top
right hand corner of the LCD screen, when the Basic C-code is displayed, will
indicate that a matrix has been stored. The matrix is deleted if any part of the
C-code, apart from the target capacity or program and is changed (i.e. Auto,
Charge, Prime, QuickTestTM or any of the other programs).
• An adapter can save up to 10 C-Codes. Each C-Code is unique and has the
following characteristics:

C-Code # Basic C-Code Extended C-Code Matrix

C1 CC1 EEEE1 MMMMMMM1
C2 CC2 EEEE2 MMMMMMM2
C3 CC3 EEEE3 MMMMMMM3
C4 CC4 EEEE4 MMMMMMM4
C5 CC5 EEEE5 MMMMMMM5
C6 CC6 EEEE6 MMMMMMM6
C7 CC7 EEEE7 MMMMMMM7
C8 CC8 EEEE8 MMMMMMM8
C9 CC9 EEEE9 MMMMMMM9
C10 CC10 EEEE10 MMMMMMM10

Basic C-code Parameters

Basic C-code parameters appear on the first detailed screen whenever a battery
adapter is inserted in a station and the station key is pressed.

Program

The Program parameter specifies which of the programs is to be run (see Battery
Service Programs, page 22).
44 Cadex Electronics Inc.
 Target Capacity

The target capacity parameter (displayed as TARGET on the analyzer LCD screen)
is displayed as a pass/fail mark. Batteries must achieve the target capacity to
“pass”. In the Auto program, if a battery capacity is less than the Target Capacity,
the battery is reconditioned.

You can set the target capacity anywhere from 50% to 150% of nominal capacity.
These values are recommended for most uses:

90% Maintains batteries for critical applications that require maximum

energy reserve and high reliability. Fewer batteries will pass.
80% Recommended (default) setting that provides a balance
between adequate energy reserve and long service life.
70% Recommended for less stringent applications where battery
power demand is not critical or is of brief duration. More
batteries will pass.

Target capacity is a pass/fail benchmark only. It does not determine the level to
which a battery is charged; it only provides an arbitrary point to which to compare
actual battery capacity. For example, a battery with a 90% capacity will pass if the
target capacity is set at 80% but fail if the target capacity is 100%. The batteries
are always fully charged.

Chemistry

The chemistry parameter refers to the battery chemistry. The chemistry is labeled
on the battery. The analyzer works with: NiCd (Nickel-cadmium); NiMH (Nickel-
metal-hydride); Li-ion (for Lithium-ion and Li-Polymer) and SLA (Sealed Lead
Acid). For Lithium Polymer batteries, use Li-ion.

Battery Voltage (Volts)

The Battery Voltage parameter refers to the terminal voltage of the battery. The
voltage is often labeled on the battery. On the C7200 and C7400, the maximum
voltage is 14.4V for NiCd, NiMH and Li-ion batteries. The maximum voltage is 14V
for SLA batteries. The C7200 and C7400 cannot be modified to handle batteries
greater than 14.4V. The maximum voltage on the C7400ER is 28.8V for NiCd and

Cadex C7000 Series Battery Analyzers 45

 NiMH batteries and 36V for SLA and Li-ion batteries. The voltage is based on a
nominal cell voltage of 1.2V/cell for NiCd and NiMH batteries, 2V/cell for SLA
batteries, and 3.6V/cell for Li-ion batteries.

On some NiCd and NiMH batteries, manufacturers may rate the voltage based on
1.25V/cell rather than 1.2V/cell. For example, the batteries may have a stated
voltage of 7.5V or 12.5V. To obtain the correct voltage, multiply this voltage by
0.96. These voltages are definitions only (in fact, battery voltage varies depending
on the state of charge) and do not affect test results. You can also set the Cadex
analyzer to display voltage as either 1.2V/cell or 1.25V/cell (see Voltage Display,
page 68).

Some manufacturers may state the number of cells of their batteries. To get the
correct voltage, multiply the number of cells by the chemistry type. For example,
the voltage of a 6-cell NiCd would be 6 x 1.2V = 7.2V. Use 7.2V on the analyzer.

Battery Rating (mAh)

The battery rating parameter is the nominal capacity or the capacity specified by
the manufacturer. These are also indicated on the battery or may be obtained
from the manufacturer.

Available settings: 100 – 24,975mAh in increments of 25mAh.

If a battery rating is provided in Watt-Hours (Wh), divide it by the battery voltage to

obtain the mAh rating. For example, a 5Wh battery is 0.7Ah (700mAh).

C-code Setup Name

The C-code setup name might be the battery model number or some other name
that helps users identify the C-code or the battery it defines. Use ALT-EDIT to
access the C-code name and FN-0 to clear the text.

Scaled C-code

Due to the power limitations on the analyzer, if a C-code requires a higher charge
or discharge rate than the analyzer is capable of, it automatically scales the C-

46 Cadex Electronics Inc.

 code. An inverse S on the top-right hand corner of LCD screen when the basic C-
code is displayed will indicate a scaled C-code.

C-code Matrix

When a C-code matrix has been stored to perform a QuickTestTM, an inverse T in

the top-right-hand corner of the LCD screen will display along with the basic C-
code.

Locked C-code

Cadex locks some C-codes at the request of the battery manufacturer. An inverse
L on the top-right hand corner of the basic C-code display indicates a locked C-
code. These C-codes cannot be edited but they can be deleted.

Extended C-code Parameters

In general, extended C-Code parameters can be left on their default settings. If,
however, you are creating or editing C-codes for Smart Cable Adapters or certain
types of batteries (for example, intrinsically safe batteries or Hawker SLA
batteries), you should pay close attention to the extended C-code parameter
settings (see Extended C-code Settings for Special cases, page 55).

Charge Rate (C-Rate)

A battery with 1000mAh capacity that is charged at 500mA has a charge C-Rate
of 0.50C. A lower charge C-rate reduces the charge current and increases service
time. Maximum current is 4000mA (6000mA for the C700ER) for batteries with a
stated cell voltage of up to 7.2 V. Maximum current is reduced for batteries with
higher nominal voltage. For example, on the C7200, the charge rate for a 14.4V
battery will be automatically scaled to 2000mA. An inverse S (scaled C-code) will
be displayed on the basic C-code screen.

Cadex C7000 Series Battery Analyzers 47

 Discharge Rate (C-rate)

A battery with 1000mAh capacity that is discharged at 500mA is discharged at

0.50C. A lower discharge C-rate reduces the discharge current and increases
service time. Maximum current is 4000mA (6000mA for the C7000ER). The
discharge rate is reduced for batteries with higher nominal voltage (for example,
2400mA for a 14.4V battery on the C7200). For a single-cell NiCd or NiMH
battery, the maximum discharge is 2500mA.

Default Charge and Discharge Rates

NiCd: Standard NiCd batteries up to 1800mAh can be charged and discharged at

rate of 1.00C. Cadex recommends a C-rate of 0.70C or 0.50C for batteries above
these mAh ratings. The default setting for NiCd is 1.00C. For 1.2V and 2.4V
batteries, the default charge rate is 0.30C to maintain normal temperatures.

NiMH: NiMH batteries produce heat during Charge and Discharge. The default
charge rate is 0.50C if Temperature Sensing is Disabled. In addition, due to the
very fine negative slope, the current is cut in half twice towards the end of the
charge cycle to ensure that the battery is fully charged (the current is not reduced
if the Charge rate is at 0.10C). If temperature sensing is Disabled, a rest period is
applied before the current is cut to allow for the battery to cool. This lengthens the
service time. For 1.2V and 2.4V batteries, the default rate is 0.30C to maintain
cooling. If the battery gets hot during charge, reduce the Charge rate to 1000mAh
or less.

SLA: Battery manufacturers rate the SLA at a 20-hour discharge (0.05C). This
slow discharge is not practical when analyzing SLA batteries so the analyzer uses
a default 0.30C Charge and 0.10C (10-hour) discharge. Due to this higher
discharge rate, the battery will give a lower capacity. Refer to the manufacturers
specification for the battery rating at the 10-hour discharge and adjust the battery
rating (capacity) or Capacity Offset to compensate for the higher discharge rate.

Li-ion: Most Li-ion (and Li-Polymer) batteries can accept a 1.00C Charge and
Discharge rate. This is the default Charge and Discharge Rate.

48 Cadex Electronics Inc.

 Trickle-Charge Rate (NiCd and NiMH only)

The Trick Charge Rage parameter defines the charge level required to maintain
the charge on a NiCd or NiMH battery after service is complete.

Available settings: 1% – 10% of the rated capacity.

Default Trickle Charge Rate

The recommended and default rate for NiCd and NiMH is 2%. This rate
compensates for any self-discharge and maintains temperature. During Trickle
Charge, the battery should remain cool and battery temperature should be less
than 5oC above ambient temperature. If the battery feels warm, reduce the trickle
charge.

Recondition Discharge Rate (NiCd and NiMH only)

The Recondition Discharge Rate parameter refers to a slow, gradual discharge

applied during reconditioning after the battery reaches the end-of-discharge
voltage. During this process, the crystalline build-up (memory) on the cell plates
dissolves and the battery often restores itself.

Available settings: 2% – 20% of discharge rate setting, in increments of 2%.

Default Recondition Discharge Rate

The recommended Recondition and Discharge default rate for NiCd and NiMH is
12%. This provides the best compromise between speed, effectiveness and
safety. The setting is small enough to avoid damage if cell reversal occurs and is
large enough to achieve a reasonable, short Recondition Discharge time.

Capacity Offset

The Capacity Offset parameter adds its value to the capacity readings. It is used
for SLA batteries to compensate for capacity variation when a battery is
discharged at a higher or lower rate than specified by the manufacturer. This

Cadex C7000 Series Battery Analyzers 49

 offset is changed based on manufacturer recommendations. It is not mandatory to
add the Capacity Offset.

Available settings: -50% to +49%

Default Capacity Offset

SLA batteries are often rated based on a 20-hour (0.05C discharge). This
discharge is slow and is not practical when analyzing SLA batteries. The default
setting for Discharge is 0.10C (10-hours). Since this is a higher value, the capacity
will be less. Refer to the manufacturer specifications for the battery rating at the
10-hour discharge and adjust the Capacity Offset or battery rating (capacity) to
compensate for the higher discharge rate. The Capacity Offset merely adds to the
capacity if the battery and does not improve battery capacity in any way. The
default capacity offset is 00% for all chemistries.

Temperature Sensing

For safety purposes, temperature sensing cannot be disabled for Li-ion batteries.
If disabled is selected, temperature is not displayed during service.

The Temperature Sensing parameter defines the temperature range within which
the battery is serviced (effective only for batteries or adapters equipped with a
temperature sensor). The temperature sensor measures the battery temperature
either internally or externally. If battery temperature exceeds the maximum
threshold, service is suspended until the battery’s temperature drops to 5oC below
the threshold. If the battery’s temperature is below the minimum threshold, service
is suspended and the battery is trickle charged until minimum temperature is
reached.

Default Temperature Sensing

Adapters with temperature sensor: 5oC-45oC.

Adapters without a temperature sensor: Disabled (not for Li-ion batteries)

50 Cadex Electronics Inc.

 The recommended setting is 5oC-45oC, which is the ideal battery service
temperature range. For NiMH batteries, it is recommended to activate
temperature sensing to speed up service. If temperature sensing is disabled, the
analyzer automatically applies resting periods to allow NiMH batteries to cool
down, which lengthens the service time.

Negative Slope (NiCd and NiMH only)

The Negative Slope parameter is a measure of the voltage drop that occurs when
the battery reaches full charge. The charge cycle is terminated when the voltage
drop reaches the set value.

Available settings: 8mV/cell – 64mV/cell

Default Negative Slope

For 1.2V - 2.4V batteries: 24mV/cell

For 3.6V – 36V batteries: 8mV/cell

Always use the lowest possible negative slope setting. Increasing the negative
slope setting delays charge termination causing the battery to heat up at the end
of charge. Decreasing the negative slope may terminate charge prematurely if the
battery has voltage fluctuations due to instability.

End of Discharge

The End of Discharge is a parameter that is chemistry-dependent. It defines the

threshold point at which the discharge cycle is terminated.

Available settings:

• 0.76 – 1.12V/cell (NiCd, NiMH)

• 1.36 – 1.95V/cell (SLA)
• 2.30 – 3.20V/cell (Li)

Cadex C7000 Series Battery Analyzers 51

 Default End of Discharge

Most battery-powered devices are designed to operate at the default settings

provided below. However, some devices may have a higher or a lower cut-off
value, so these values may have to be adjusted if the battery capacity is being
compared to the device it’s being used in. Refer to the manufacturer settings for
these cases.

NiCd and NiMH: 1.00V/cell.

SLA: 1.75V/cell. This value can vary depending on the Discharge rate used. Refer
to the manufacturer specifications.

Li-ion: 3.00V/cell. A good number of Li-ion batteries have 2.50V/cell as the End of
Discharge setting. Refer to the manufacturer specifications.

End of Recondition (NiCd and NiMH only)

The End of Recondition parameter defines the threshold point at which the
reconditioning cycle is complete. This recondition is most effective on NiCd
batteries. This threshold point leaves the battery discharged.

Available settings:

• DISABLED

• 0.40 – 0.80 V/cell

Default End of Recondition

The minimum required setting to restore a NiCd battery affected by “memory” is

0.60V/cell. The Cadex analyzer uses 0.40V/cell. SLA and Li-ion batteries cannot
be conditioned with a deep discharge.

SMART BATTERIES SHOULD NOT BE RECONDITIONED.

Select DISABLED for the End of Recondition when servicing a smart battery.

52 Cadex Electronics Inc.

 If the battery’s voltage drops below the level required by the processor within
the battery, valuable information can be lost. In some cases, this data loss
can leave the battery permanently unusable.

Charge Method (NiCd and NiMH only)

This parameter determines how NiCd and NiMH batteries are charged. The
reverse load method intersperses discharge pulses during charge and trickle
charge to keep batteries cool and promote the recombination of gases.

Available settings:

• DC CHARGE

• NO REV LOAD

• Reverse Load 5% – 12%

Default Charge Method

Best results have been achieved using the default Rev. Load 9%. DC Charge is
used for batteries that cannot accept a pulse charge (some intrinsically safe
batteries fall into this category). NO REV LOAD is a charge pulse without the
reverse pulse.

Maximum Standby Voltage (SLA and Li-ion only)

The Maximum Standby Voltage parameter determines the voltage that SLA and
Li-ion batteries are maintained at when fully charged, after service is complete. A
charge current of approximately 0.10C maintains the Maximum Standby Voltage.
If the battery voltage exceeds the Maximum Standby Voltage, the current is
reduced or eliminated until battery voltage drops below the Maximum Charge
Voltage. This parameter must be set to be lower than the Maximum Charge
Voltage.

Available settings:

• 2.15 – 2.45V/cell (SLA)

• 3.90– 4.35V/cell (Li-ion)

Cadex C7000 Series Battery Analyzers 53
 Default Maximum Standby Voltage

SLA: 2.25V/cell

Li-ion: 4.05V/cell

Refer to the manufacturer’s specifications for proper settings. If the battery

generates heat during prolonged storage on the analyzer after service has been
completed, remove the battery from the analyzer.

Maximum Charge Voltage (SLA and Li-ion only)

The Maximum Charge Voltage parameter defines the voltage threshold of SLA
and Li-ion batteries that must be maintained until the End of Charge conditions
are reached. The charge current drops while the maximum charge voltage is
maintained.

Available settings:

• 2.20 – 2.65V/cell (SLA)

• 3.90 – 4.35V/cell (Li-ion)

Default Max. Charge Voltage

SLA: 2.40V/cell.

Li-ion: 4.2V/cell.

Refer to the manufacturer’s specifications for proper settings as these values vary
depending on the charge rate used and the ambient temperature.

End of Charge (SLA and Li-ion only)

The End of Charge parameter defines the rate of charge the analyzer uses to
determine if the battery is fully charged. When the charge current drops below the
End of Charge setting while maintaining the Maximum Charge Voltage, the
battery is considered fully charged.

54 Cadex Electronics Inc.

 The Charge Optimization setting affects the way the end-of-charge setting is used
during a charge (see Optimizing Charge Time or Capacity, page 80).

Available settings: 0.01 C – 0.10 C

Default End of Charge

SLA and Li-ion: 0.05C. Refer to the manufacturers specification for proper setting
as these values vary depending on the charge rate being used. For some
batteries, a lower setting is required to ensure adequate charge.

Default Extended C-code Settings

This section lists the default extended C-code parameter values for each of the
four battery chemistry types.

Default Extended C-code for NiCd Batteries

Parameter Default Setting

Charge 1.00 C
Trickle 5%
Discharge 1.00 C
Recondition 12%
Capacity Offset 0%
Temperature Sensing 0ºC – 45 C
Negative Slope 8mV/cell, 16mV/cell for 1.2V and 2.4V
batteries
End of Discharge 1.00V/cell
End of Recognition 0.40V/cell
Charge Method Reverse Load 9%

Cadex C7000 Series Battery Analyzers 55

 Default Extended C-code for NiMH Batteries

Parameter Default Setting

Charge 1.00 C
Trickle 2%
Discharge 1.00 C
Recondition 12%
Capacity Offset 0%
Temperature Sensing 0ºC – 45 C
Negative Slope 8mV/cell, 16mV/cell for 1.2V and 2.4V
batteries
End of Discharge 1.00V/cell
End of Recognition 0.40V/cell
Charge Method Reverse Load 9%

Default Extended C-code for SLA Batteries

Parameter Default Setting

Charge 0.30 C
Discharge 0.10 C
Capacity Offset 0%
Temperature Sensing 0 C – 45 C
Max. Standby Voltage 2.25V/cell
Max. Charge Voltage 2.40V/cell
End of Charge 0.05 C
End of Discharge 1.75V/cell

56 Cadex Electronics Inc.

 Default Extended C-code for Li-ion Batteries

Parameter Default Setting

Charge 1.00 C
Discharge 1.00 C
Capacity Offset 0%
Temperature Sensing 0 C – 45 C
Max. Standby Voltage 4.05V/cell
Max. Charge Voltage 4.20V/cell
End of Charge 0.05 C
End of Discharge 3.00V/cell

Extended C-code Settings for Special Cases

This section lists recommended parameter settings for specific types of batteries,
where the recommended settings are different from the default settings.

Intrinsically Safe Batteries

Before servicing intrinsically safe (I/S) batteries, set the following C-code
parameters as specified:

Parameter Setting
Charge 0.10 C*
Discharge 0.10 C*
Charge Method DC charge
End of Discharge 0.96V/cell

* Recommended settings. You can try setting the charge and discharge rates to higher
values to speed up servicing; however, if fault codes appear, you must lower the rates.

Cadex C7000 Series Battery Analyzers 57

 Hawker SLA Batteries

Before servicing Hawker SLA batteries, set the following C-code parameters as
specified below (any parameters not listed here should be left at their default
settings):

Parameter Setting
Discharge 0.40 C
Max. Standby Voltage 2.35V/cell
Max. Charge Voltage 2.60V/cell
End of Discharge 1.62V/cell

Gell SLA Batteries

Use the SLA default settings for Gell batteries.

Managing C-codes

If the ASK FOR BATTERY C-CODE option is set to YES, the desired C-code must be
selected and the appropriate parameters entered before a battery is inserted or
before battery processing begins (see To set the user input required by the
Cadex analyzer before battery service begins, page 78).

Note QuickTestTM matrices created by the Q-Learn and the Learn programs are
stored in battery adapters as part of the C-code and can be copied to
other adapters. However, any change made to the C-code (except target
capacity and selected program) erases the stored QuickTestTM matrix.

Select a C-code

1. From the global display, press the station key.

2. Press  or  to scroll to the C-code you want to select.

3. Press ENTER.

4. Press  or  to scroll to YES to accept changes and press ENTER.

58 Cadex Electronics Inc.
 5. Press ESC twice to return to the global display.

The “*” appears beside the C-code number on the display to indicate that the C-
code is active.

Display a C-code

1. From the global display, press the station key.

2. Use the  or  key to scroll to the C-code you want to display. Basic
C-code parameters appear on the same screen.

3. Press  or  to scroll through the extended C-code parameters.

4. When you are finished viewing the C-code parameters, press ESC
once or twice to return to the global display.

Change Target Capacity or Program

1. From the global display, press the station key.

2. Press EDIT.

3. Press  or  to scroll to the desired program.

4. Press  or  to move to the target capacity field.

5. Press  or  or use the keypad to enter the desired target value.

6. Press ENTER.

7. Press  or  to scroll to YES to accept changes and press ENTER.

8. Press ESC twice to return to the global display.

Create or Edit a C-code

1. From the global display, press the station key.

Cadex C7000 Series Battery Analyzers 59

 2. Use the  or  key to scroll to an empty C-code or to the C-code
you want to edit.

An empty C-code contains no battery chemistry (TYPE) and VOLTS and

mAh are set to 0.

3. Press EDIT.

4. Select the program you want to run:

a) Press  or  to scroll to the basic program you want to run.

b) Press  to select the program and move to TARGET.

Or

a) Press  or  to scroll through the basic programs to ADVANCED.

b) Press .

c) Press  or  to scroll to the advanced program you want to run.

d) Press  to select the program and move to TARGET.

At any time from this point, you can press ENTER to save your
changes and stop editing the C-code parameters.

5. Press  or  or use the keypad to enter the required target capacity

(see Target Capacity, page 45).

6. Press  to move to TYPE.

7. Press  or  to scroll to the appropriate battery chemistry for the C-

code.

8. Press  to move to VOLTS.

9. Press  or  or use the keypad to enter the voltage (VOLTS) of the

battery to be serviced (see Battery Voltage (Volts), page 45).
60 Cadex Electronics Inc.
 10. Press  to move to mAh.

11. Press  or  or use the keypad to enter the battery capacity in

milliampere hours (mAh) (see Battery Rating, page 46).

12. Press ENTER.

13. To leave the extended C-code parameters at the default settings:

a) Press ENTER again.

b) Press  or  to scroll to YES to accept changes and press

ENTER.

To edit the extended C-code parameters (not usually required):

a) Press .

b) Edit the extended C-code settings (see Extended C-code

Parameters, page 47).

• Press  or  to move between C-code settings.

• Press  or  or use the keypad to change the settings as

required.

c) Press ENTER.

d) Press  or  to scroll to YES to accept changes and press

ENTER.

14. Press ESC twice to return to the global display.

The message CHANGES ACCEPTED appears on the display.

Add or Edit the C-code Setup Name

1. From the global display, press the station key.

Cadex C7000 Series Battery Analyzers 61

 2. Press  or  to scroll to the C-code for which you want to edit or add
the setup name.

3. Press ALT, and then press EDIT.

4. Press  or  to scroll through upper case letters, lower case letters,

punctuation marks, numbers, and a space (which looks like an
underscore) to select characters for the setup name.

5. Press  or  to move the cursor between character positions within

the setup name. There are ten positions available.

6. Press ENTER.

7. Press  or  to scroll to YES to accept changes and press ENTER.

8. Press ESC twice to return to the global display.

Reset Extended C-code to the Default settings

1. From the global display, press the station key.

2. Use the  or  key to scroll to the C-code whose extended

parameters you want to reset.

3. Press FN and then press 1.

4. Press  or  to scroll to YES to accept changes and press ENTER.

5. Press ESC twice to return to the global display.

(see Default Extended C-code Settings, page 55).

Delete a C-code

1. From the global display, press the station key.

2. Use the  or  key to scroll to the C-code you want to delete.

62 Cadex Electronics Inc.

 3. Press FN and then press 0.

4. Press  or  to scroll to YES to accept changes and press ENTER.

5. Press ESC twice to return to the global display.

Copy a C-code (including QuickTestTM matrix)

1. Ensure both adapters are inserted in the Cadex analyzer. Neither

adapter should contain a battery. The source adapter (the adapter
with the C-code to be copied) can also be the target adapter (the
adapter that will receive the copied C-code.)

2. From the global display, press the station key for the source adapter.

3. Use the  or  key to scroll to the C-code you want to copy.

4. Press FN, and then press 3.

5. Press the station key for the target adapter. (This can be the same as
the source adapter.)

6. Use the  or  key to scroll to the C-code you want to overwrite

(usually an empty C-code).

An empty C-code contains no TYPE information and VOLTS and MAH

are set to 0.

7. Press ENTER.

8. Press  or  to scroll to YES to accept changes and press ENTER.

9. Press ESC twice to return to the global display.

Copy all C-codes (and matrices) from One Adapter to Another

1. Ensure that both adapters are inserted in the Cadex analyzer. Neither
adapter should contain a battery.

Cadex C7000 Series Battery Analyzers 63

 2. From the global display, press FN, and then press 6.

3. Press the station key for the station containing the Target adapter.

4. Press  or  to scroll to YES to accept changes and press ENTER.

5. Press ESC twice to return to the global display.

64 Cadex Electronics Inc.

Chapter 7 System Setup And Options

You can customize a number of global settings on the Cadex analyzer. You can
set the date, time, company name, view the event log and print reports or labels.

Date and Time

1. From the global display, press MENU.

2. Press  or  to scroll to SYSTEM SETUP and then press ENTER.

3. Press  or  to scroll to DATE/TIME and then press ENTER.

4. Enter the date and time information:

5. Press  or  to move between fields (year, month, day, hour,

minute, and second).

6. Press  or  or use the number pad to enter the correct date and
time information for each field.

7. Press ENTER.

8. Press  or  to scroll to YES to accept changes and press ENTER.

9. Press ESC twice to return to the global display.

Note The analyzer is shipped with the date and time set for the Pacific
Standard Time (PST) (GMT-8).

Cadex C7000 Series Battery Analyzers 65

 Company Name

1. From the global display, press MENU.

2. Press  or  to scroll to OPTION CONTROLS and then press ENTER.

3. Press  or  to scroll to COMPANY NAME and then press ENTER.

4. Enter the company name:

5. Press  or  to scroll through upper-case letters, lower-case letters,

punctuation marks, numbers, and a space (which looks like an
underscore) to select characters for the program name.

6. Press  or  to move the cursor between character positions within

the program name. There are twenty positions available.

7. Press ENTER.

8. Press  or  to scroll to YES to accept changes and press ENTER.

9. Press ESC twice to return to the global display.

Sound Options

The Cadex analyzer uses several sounds to alert users to various events. You
can control whether or not sounds are played and you can assign sounds to
specific events when the sound control is on.

There are two kinds of events sound alerts can be assigned to. These are key
press events and alert events. When key press sounds are on, you hear a click
every time you press a key on the Cadex analyzer and you hear one or more
tones every time an action or program is completed.

To turn sounds ON or OFF

1. From the global display, press MENU.

66 Cadex Electronics Inc.

 2. Press  or  to scroll to OPTION CONTROLS, and then press ENTER.

3. Press  or  to scroll to SOUND CONTROL and then press ENTER.

4. Press  or  to turn the key press sound on (YES) or off (NO).

5. Press  or .

6. Press  or  to turn the alert sounds on (YES) or off (NO).

7. Press ENTER.

8. Press  or  to scroll to YES to accept changes and press ENTER.

9. Press ESC twice to return to the global display.

To hear sounds assigned to events

1. From the global display, press MENU.

2. Press  or  to scroll to OPTION CONTROLS and then press ENTER.

3. Press  or  to scroll to SOUND CHECK and then press ENTER.

4. Press  or  to scroll to the event for which you want to hear the
assigned sound, and press ENTER.

The Cadex analyzer plays the sound or tone(s) assigned to the

selected event. If you do not hear anything, sounds have been turned
off.

5. Repeat step 4 for all events whose assigned sounds you want to
hear.

6. Press ESC twice to return to the global display.

Cadex C7000 Series Battery Analyzers 67

 Voltage Display

You can choose to display voltage as total battery (terminal), voltage (volts) or
individual cell voltage (V/Cell). If voltage display is set to V/cell, you must multiply
the displayed voltage by the number of cells in the battery to find the voltage for
the battery.

On some NiCd and NiMH batteries, manufacturers may rate their batteries based
on 1.25V/cell rather than 1.2V/cell. You can specify whether you want voltage
displayed as 1.2V/cell or 1.25V/cell, (see Battery Voltage (Volts), page 45).

To set the voltage display mode

1. From the global display, press MENU.

2. Press  or  to scroll to OPTION CONTROLS and then press ENTER.

3. Press  or  to scroll to VOLTAGE DISPLAY and then press ENTER.

4. Press  or  to scroll to the required setting:

• YES sets the Cadex analyzer to display the voltage of individual

cells within the battery (V/Cell).
• NO sets the Cadex analyzer to display the terminal voltage for the
battery as a whole (Volts).

5. Press  or  to move to the NiXX field.

6. Press  or  to select 1.20 or 1.25 volts per cell to display for NiCd
and NiMH batteries.

7. Press ENTER.

8. Press  or  to scroll to YES to accept changes and press ENTER.

9. Press ESC twice to return to the global display.

68 Cadex Electronics Inc.

Battery Service Counter

You can program the Cadex analyzer to notify you after it has serviced a specified
number of batteries. This can be useful, for example, as a prompt to remind you to
perform routine maintenance tasks such as voltage calibration.

You can also restart the count from 0 (zero).

To set the battery service counter

1. From the global display, press MENU.

2. Press  or  to scroll to OPTION CONTROLS and then press ENTER.

3. Press  or  to scroll to SET SERVICE COUNTER and then press

ENTER.

4. Press  or  or use the number pad to enter the number of batteries

you want the Cadex analyzer to service before it notifies you.

Set the number to 0 to disable the battery service counter.

5. Press ENTER.

6. Press  or  to scroll to YES to accept changes and press ENTER.

7. Press ESC twice to return to the global display.

To restart the battery service count

1. From the global display, press MENU.

2. Press  or  to scroll to OPTION CONTROLS and then press ENTER.

3. Press  or  to scroll to CLEAR SERVICE COUNTER and then press

ENTER.

4. Press ENTER.

Cadex C7000 Series Battery Analyzers 69

 5. Press  or  to scroll to YES to accept changes and press ENTER.

6. Press ESC twice to return to the global display.

Note This option is not the same as setting the battery service counter to 0.
When the service counter is set to 0 using the SET SERVICE COUNTER
option, it is disabled. When you use this option to clear the battery service
counter, you are restarting the service count from 0.

To display the number of batteries serviced

This option displays both the total number of batteries serviced and the number of
batteries serviced in a session (a session is ended when the service counter is
cleared).

1. From the global display, press FN, and then press 5.

2. Press ESC to return to the global display.

Connecting to BatteryShopTM or a Printer

The Cadex analyzer has a parallel port and an RS232 DB-9-pin female serial port,
which you can use to connect the battery analyzer to a printer, label printer or
computer. You may need to use a customized cable to connect to the analyzer.
The USB port is only available on the C7400 and C7400ER but it is currently not
activated.

Other devices may work with the Cadex analyzer but they are not guaranteed to
do so. Cadex is not responsible for any problems or technical support arising from
trying to use any printing devices other than those supported.

Connecting to BatteryShopTM

To set the analyzer up for BatteryShopTM, do the following:

70 Cadex Electronics Inc.

 Connect the cable that is provided with BatteryShopTM to the 9-pin serial RS-
232 port on the analyzer. If necessary, use a 25-9 pin converter that is
supplied with BatteryShopTM to connect the other end to the PC serial port.

Change the analyzer from STANDALONE mode to BATTERYSHOP mode,

Press FN and then press 9 and select TERMINAL.

Press ENTER to save the settings.

These steps are sufficient to set up the analyzer for use with BatteryShopTM.
Refer to the BatteryShopTM users manual for details.

Connecting Devices to the Serial Port

The serial port on the Cadex analyzer connects the unit to a computer so you can
run BatteryShop™ or transfer service data to a computer. You can also connect
supported label printers through the serial port.

The Cadex analyzer supports the following devices on the serial port:

• Dymo-CoStar SE250 or SE300 label printer (choose LABEL MAKER device

setting) for printing bar-code labels and battery labels. This is the only label
printer that is supported. Use the cable that comes with the printer to connect
to the analyzer serial port and set the port to LABEL MAKER. Instructions on
setting the port are provided below.

• Set the analyzer to BATTERYSHOP mode to use the unit with BatteryShop™
software. Use the cable that comes with the software to connect to the
analyzer serial port and set the port to BATTERYSHOP. Instructions on setting
the port are provided below.

Note: To toggle between BATTERYSHOP mode and STANDALONE mode press FN,
and then press 9.

• A PC can be used to manually monitor battery data. Use the cable supplied
with BatteryShop™ to connect to the analyzer serial port or make one using
the configuration described shown in Typical Serial Cable Pin
Cadex C7000 Series Battery Analyzers 71
 Configurations, page 73. A standard serial cable will not work. Set the
serial port settings to match the PC port.

The Cadex analyzer offers these settings for the serial port:

Option Available Settings Default

Baud Rate 1200, 2400, 4800, 9600, 19200 9600
Handshake NONE, CTS/RTS, X ON/X OFF CTS/RTS
Data Bits 7, 8 8
Stop Bits 1, 2 1
Parity NONE, ODD, EVEN NONE

To specify and set up the device connected to the Cadex analyzer serial port

1. From the global display, press MENU.

2. Press  or  to scroll to SYSTEM SETUP and then press ENTER.

3. Press  or  to scroll to SERIAL PORT DEVICE and then press ENTER.

4. Press  or  to scroll to the device to connect to the serial port:

• Use BATTERYSHOP to use the unit with Cadex analyzer

BatteryShop™ software.
• Use TERMINAL to connect to a computer you want to use to
display and analyze service data (see Logging Data, page 95)
• Use LABEL MAKER to connect to a Dymo-CoStar SE300 label
printer.
• Use PRINTER to connect to a serial dot matrix Epson compatible
printer. Since serial printers are no longer available, use the
parallel port or use a SP-2 converter if the parallel port is not
available (see Appendix D - Parts and Accessories, page 162)
• DISABLED if you do not want to connect a device using the serial port.

5. Press ENTER.

72 Cadex Electronics Inc.

 6. Press  or  to scroll to YES to accept changes and press ENTER.

7. Press  to scroll to SERIAL PORT SETTINGS and then press ENTER. This
step is not required if connecting to BatteryShopTM or using the Dymo-
CoStar SE300 label printer.

8. Enter the required settings as specified in the device user’s manual

(see above for available options):

• Press  or  to move the cursor from option to option.

• Press  or  to scroll through available settings.

9. Press ENTER.

10. Press  or  to scroll to YES to accept changes and press ENTER.

11. Press ESC twice to return to the global display.

Typical Serial Cable Pin Configurations

Note: Do not use these configurations for the Dymo SE300 printer. Use the cable
that is supplied with the printer instead.

DB-9 to DB-25
Note When connecting to a serial
DB-9 DB-25
printer, it may also be necessary to
RD 2 — 2 TD jumper pins 6 (DSR), 8 (DCD), and 20
TD 3 — 3 RD (DTR) together on the printer’s DB-25
CTS 8 — 4 RTS connector. Other jumpers may also be
required. Check your printer manual for
RTS 7 — 5 CTS
specific information.
SG 5 — 7 SG

Cadex C7000 Series Battery Analyzers 73

 DB-9 to DB-9
Note When connecting to a serial
DB-9 DB-9
printer, it may also be necessary to
RD 2 — 3 TD jumper pins 6 (DSR), 1 (DCD), and 4
TD 3 — 2 RD (DTR) together on the printer’s DB-9
CTS 8 — 7 RTS connector. Other jumpers may be also
required. Check your printer manual for
RTS 7 — 8 CTS
specific information.
SG 5 — 5 SG

Connecting Printers to the Parallel Port (C7400 and C7400ER only)

Supported printers can be connected directly to the analyzer’s parallel using a

parallel cable. You must specify which device is connected to the Cadex analyzer
parallel port.

The Cadex analyzer supports the following device on the parallel port:

• Epson-compatible dot matrix parallel printers for printing reports and labels
using the Parallel port (choose printer device setting).

To specify the device to connect to the Cadex analyzer parallel port

1. From the global display, press MENU.

2. Press  or  to scroll to SYSTEM SETUP and then press ENTER.

3. Press  or  to scroll to PARALLEL PORT DEVICE and then press

ENTER.

4. Press  or  to scroll to the device you want to connect to the

parallel port:

• Use PRINTER to connect to an Epson FX-850-compatible parallel

printer.
• Use DISABLED if you do not want to connect a device using the
parallel port.

74 Cadex Electronics Inc.

 5. Press ENTER.

6. Press  or  to scroll to YES to accept changes and press ENTER.

7. Press ESC twice to return to the global display.

Security

The Cadex analyzer offers three security levels for protection against tampering:
Level 0 (off), Level 1 (low), and Level 2 (high). Level 0 is the default. Depending
on the security level chosen, you may have to enter the password for some
features.

A password must have at least three digits.

Security Level Functions

The table below shows functions that require a password at each of the three
security levels:

Functions Level 0 Level 1 Level 2

(Off) (Low) (High)
Services Start Services

C-code Edit C-codes

Select C-codes

System Change Time/date

Setup
Select Serial and
Parallel Port
devices
Perform
Calibration
Program Change Program
Settings Settings

Cadex C7000 Series Battery Analyzers 75

 Functions Level 0 Level 1 Level 2
(Off) (Low) (High)
Option Change Battery
Controls startup options
Change Company
name
Change Sound
control options
Change Voltage
display options
Print Select battery
Utilities service report
Select battery
label
Select System
setup report
Set Auto-print
options
Print All Reports

Event Log Clear event log

Set up events to
log

To set the level of security

1. From the global display, press MENU.

2. Press  or  to scroll to SYSTEM SECURITY and then press ENTER.

3. Press  or  to scroll to SET SECURITY and then press ENTER.

4. Press  or  or use the number pad to enter the desired security

level (0, 1, or 2).

76 Cadex Electronics Inc.

 5. If required, enter the password using the number pad and press
ENTER.

6. Press  or  to scroll to YES to accept changes and press ENTER.

7. Press ESC twice to return to the global display.

To change the password

1. From the global display, press MENU.

2. Press  or  to scroll to SYSTEM SECURITY and then press ENTER.

3. Press  or  to scroll to CHANGE PASSWORD and then press ENTER.

4. Enter the old password using the number pad and then press ENTER.

5. Enter the new password, and then press ENTER.

6. Enter the new password again to confirm and then press ENTER.

The message PASSWORD ACCEPTED appears on the display if your

password change was successful.

7. Press ESC twice to return to the global display.

If you lose or forget your password, contact Cadex Technical Support at 1 800
565-5228 ext. 315 with your company name and the serial number of your Cadex
analyzer.

Program Parameters

There are a number of settings available that affect the way the Cadex analyzer
functions in most or all of its programs.

Cadex C7000 Series Battery Analyzers 77

 Starting Battery Service

By default, when you insert a battery in a battery adapter in the Cadex analyzer,
you must verify the C-code settings before the service is performed. This
verification can be turned off so users can run a battery service as soon as a
battery is inserted. You can set the options as follows:

• The Cadex analyzer asks for Battery ID number and asks you to verify
settings.

• The Cadex analyzer asks for Battery ID number only.

• The Cadex analyzer asks you to verify C-code settings only (default).

• The Cadex analyzer starts the program in the active C-code without asking for
input.

To set user input required by the Cadex analyzer before battery service
begins

1. From the global display, press MENU.

2. Press  or  to scroll to OPTION CONTROLS and then press ENTER.

3. Press  or .to scroll to ASK FOR BATTERY ID #

4. Press  or  to scroll to the required setting:

• YES sets the Cadex analyzer to ask for the Battery ID number.

• NO (default) sets the Cadex analyzer not to ask for Battery ID

number.

5. Press  or .to scroll to ASK FOR BATTERY C-CODE

5. Press  or  to scroll to the required setting:

• YES sets the Cadex analyzer to ask the user to verify C-code
settings.

78 Cadex Electronics Inc.

 • NO (default) sets the Cadex analyzer not to ask for the battery
C-code.

6. Press ENTER.

7. Press  or  to scroll to accept changes and press ENTER.

8. Press ESC twice to return to the global display.

Performing an Automatic OhmTest

Every time the Cadex analyzer runs a charge cycle, it can automatically perform
an OhmTest on the battery as well (except when the charge cycle is being
performed as part of a custom program). You can choose whether or not to
perform the automatic OhmTest.

Note Automatic OhmTest cannot be turned on or off using the following

programs: QuickTestTM, Q-Learn, Learn and Life-Cycle. OhmTest is
included in these programs and the settings cannot be changed.

To turn Automatic OhmTest on or off

1. From the global display, press MENU.

2. Press  or  to scroll to PROGRAM SETTINGS and then press ENTER.

3. Press  or  to scroll to AUTOMATIC OHMTEST and then press ENTER.

4. Press  or  to scroll to the required setting:

• YES (default) sets the OhmTest to run automatically before every

charge cycle (except during custom programs).
• NO turns off the automatic OhmTest.

5. Press ENTER.

6. Press  or  to scroll to YES to accept changes and press ENTER.

Cadex C7000 Series Battery Analyzers 79

 7. Press ESC twice to return to the global display.

Optimizing Charge Time or Capacity

The end of charge conditions can be modified, (see Appendix B – Charge

Algorithms, page 156).

To select the charge optimization option

1. From the global display, press MENU.

2. Press  or  to scroll to PROGRAM SETTINGS and then press ENTER.

3. Press  or  to scroll to CHARGE OPTIMIZATION and then press ENTER.

4. Press  or to move to between NICD AND NIMH OPTIMIZATION and

SLA AND LI OPTIMIZATION:

5. Press  or  to the required setting (see Appendix B – Change

Algorithms, page 156)

• TIME (default).
• CAPACITY.

6. Press ENTER.

7. Press  or  to scroll to YES to accept changes and press ENTER.

8. Press ESC twice to return to the global display.

Termination Condition on dT/dt

The Termination Condition on DT/DT parameter sets the temperature a battery can
reach before it will terminate or reduce the charge current. If a battery temperature
rises more than the DT/DT the charge current is either reduced or charge is
completed (see Appendix B – Charge Algorithms, page 156).

80 Cadex Electronics Inc.

 To select the charge optimization option

1. From the global display, press MENU.

2. Press  or  to scroll to PROGRAM SETTINGS and then press ENTER.

3. Press  or  to scroll to DT/DT TERMINATION and then press ENTER.

4. Press  or  to the required setting (see Appendix B – Charge

Algorithms, page 156)

• 2OC RISE PER: 2 MINUTES

• 2OC RISE PER: 3 MINUTES (default)

• 2OC RISE PER: 4 MINUTES

5. Press ENTER.

6. Press  or  to scroll to YES to accept changes and press ENTER.

7. Press ESC twice to return to the global display.

Saving Program and Target Capacity Settings

By default, when you make changes to program and target capacity settings, they
are saved as part of the C-code stored in the battery adapter.

You can choose to have the Cadex analyzer save these changes to the battery
station rather than to the C-code. Settings saved to the station are independent of
setting battery adapter inserted in the station. Program and target capacity
settings programmed into the analyzer station will override the C-codes
programmed in the adapter.

Saving program and target capacity is useful if you have several Cadex analyzer
units and want to dedicate a unit to one or two specific programs and target
capacities.

Cadex C7000 Series Battery Analyzers 81

 To set the method of saving changes to program and target capacity

1. From the global display, press MENU.

2. Press  or  to scroll to OPTION CONTROLS and then press ENTER.

3. Press  or  to scroll to PROGRAM/TARGET CHANGES and then press

ENTER.

4. Press  or  to scroll to the required setting:

• C-CODE (default) saves any changes made to the program

settings or the target capacity to the active C-code.
• STATION saves any changes made to the program settings or the
target capacity to the battery station. These changes override any
settings in the active C-code.

5. Press ENTER.

6. Press  or  to scroll to YES to accept changes and press ENTER.

7. Press ESC twice to return to the global display.

Note If you want to use all of the settings from the active C-code, this option
must be set to C-CODE. Setting it to C-CODE will erase all settings saved to
the stations.

Resuming Service After Power Failure

If there is a power failure, the back-up memory in the analyzer keeps service data
for one hour. If the power failure lasts less than an hour, battery service resumes
from where it left off. If the power failure lasts longer than one hour, the battery
resumes from the beginning. This time can be modified:

To change the Power Failure Resume Hours

1. From the global display, press MENU.

82 Cadex Electronics Inc.

 2. Press  or  to scroll to SYSTEM SETUP, press ENTER.

3. Press  or  to scroll to POWER FAILURE RESUME HOURS, press

ENTER.

4. Press  or  to scroll to the required setting:

5. Press ENTER. Press ENTER again to save the settings.

6. Press ESC twice to return to the global display.

Cadex C7000 Series Battery Analyzers 83

 Short Key Functions

Common functions can be set with the Fn or Alt with number key.

From Edit Display From Global Display

Fn-0 Deletes C-Code Fn-5 Views Service Counter

Fn-1 Resets extended C-Code Fn-7 Views Firmware Version

to default settings
Fn-8 Calibrates Station

Fn-2 Erases QuickTestTM matrix Fn-9 Toggles between stand alone

and BatteryShopTM mode
Fn-3 Copies single C-Code

Fn-6 Copies all C-Codes from Alt-0 Resets defaults and

one adapter to another restarts unit

Fn-9 Protects a Matrix from Stn Key 3 second key press

changes. Indicated by ‘P’ starts Boost
in C-Code

Alt- Enters unique names Alt-Stn Select ‘Restart’ to restart

Edit for C-Codes Key service. Select ‘Interrupt’ – the
station will interrupt to remove
a battery while it is in service.

84 Cadex Electronics Inc.

Chapter 8 Reports and Labels

The Cadex analyzer prints labels and service reports. using either Auto-Print or
Manual settings. When Auto-Print is active, a label or service report will print
immediately after servicing the battery, when the battery is removed from the
analyzer. When the battery is removed, the label or service report is printed and
the station will reset (the service information will not be saved). Manual print
settings allow you to print a label or service report after a battery is serviced and
before it is removed from the analyzer. The Cadex analyzer supports specific
types of printers (see Connecting to BatteryShopTM or a Printer, page 70). In
order to use other types of printers or save service data, Cadex recommends
using BatteryShop™.

There are three reports available:

• The Battery Service Report includes: the battery ID number; detailed status
information; battery parameters (including chemistry, number of cells, rating,
and cell voltage); the C-code description; the cycles performed on the battery;
charge and discharge rates; any applicable fault codes and final capacities.
For a sample battery service report see Figure 6, page 87.

• The System Setup Report. includes: the time; date; company name; serial
port settings; device selected; event log setup; adapter setup and custom
program information (the System Setup Report must be printed on a dot-
matrix printer).

• The Adapter Setup Report report includes: the adapter header information;
each C-code and program stored in the adapter and all parameter settings
(the Adapter Setup Report must be printed on a dot-matrix printer).

There are also two types of labels:

Cadex C7000 Series Battery Analyzers 85

 • Battery ID label. This label contains the company name; date of service; test
results with any fault codes and the battery ID number (if the battery ID has
been programmed into the program parameters ). The label is attached to the
battery after it is serviced.

• Bar-code label. This label contains a bar code representing either the battery
ID number or the C-code. For samples of bar code and battery labels, see
Figure 7, page 88.

86 Cadex Electronics Inc.

 BATTERY SERVICE REPORT
Company: CADEX ELECTRONICS
Date: 01/19/2000
Time: 16:47:11

BATTERY STATUS
Battery: STATION 2
Battery ID: 1234567890

Current Cycle: PROCESS COMPLETE

Cycle Capacities: 30% 82% 98%
Battery Resistance: 122m Ω
Cell Voltage: 3.91V/cell
Charge Cycles: 3
Discharge Cycles: 3
Recondition Cycles: 0
Elapsed Time: 0 Days 6 Hours 40 Minutes

BATTERY PARAMETERS
Battery C-Code: 40-02-016:0505-505-3407
Program: Auto
Target Capacity: 80%

Battery Type: 42 - Lithium Ion

Number of Cells: 2 (7.2V)
Battery Rating: 400mAh

Charge Rate: 0.50C ( 200mA) Max. Charge Voltage: 4.10V/Cell

Discharge Rate: 0.50C ( 200mA) End Discharge: 4.10V/Cell
End of Charge: 0.10C ( 40mA) Max. Standby Voltage: 4.05V/Cell
Capacity Offset: 0% Temperature Sensing: 5oC - 45oC

FAULT CODES

FINAL STATUS

Ready

Figure 6: Battery service report

Cadex C7000 Series Battery Analyzers 87

 Bar code label with C-code

Bar code label with battery ID

Service date Battery ID labels with capacity

and resistance readings
Battery ID

Figure 7: Battery ID and bar code labels

Automatically Print Reports or Labels

You can set up the Cadex analyzer to print battery service reports or battery
labels automatically whenever a battery is removed from an adapter after
servicing.

Automatic Report or Label printing

1. Make sure you have connected a printer or a label printer to the

Cadex analyzer’s parallel port or serial port and made any required
changes to the serial port settings (see Connecting to
BatteryShopTM or a Printer, page 70).

2. From the global display, press MENU.

3. Press  or  to scroll to PRINT UTILITIES and then press ENTER.

4. Press  or  to scroll to AUTO-PRINT and then press ENTER.

88 Cadex Electronics Inc.

 5. Press  or  to scroll to LABEL or REPORT, as required. If you want to
cancel automatic printing, scroll to NEITHER.

6. Press ENTER.

7. Press  or  to scroll to YES to accept changes and press ENTER.

8. Press ESC twice to return to the global display.

Print Reports and Labels

If you don’t have the Cadex analyzer set up to print battery labels or battery
service reports automatically, you can still print them for individual batteries that
have been serviced. You can also print bar-code labels for individual batteries.

Note Before you can print any report or label, a printer or label printer must be
properly set up and connected to the parallel port or the serial port of the
Cadex analyzer (see Connecting to BatteryShopTM or a Printer, page
70).

Tip You can also print reports and labels by selecting that option from the
menu under PRINT UTILITIES.

Print a battery service report

1. Perform the required service on the battery. Do not remove the

battery from the adapter.

2. Press PRINT.

3. Press the station key of the station that contains the battery.

4. Press  or  to scroll to BATTERY SERVICE REPORT.

5. Press ENTER.

Cadex C7000 Series Battery Analyzers 89

 Print an adapter setup report

1. Press PRINT.

2. Press the station key of the station that contains the battery.

3. Press  or  to scroll to ADAPTER SETUP REPORT.

4. Press ENTER.

Print a system setup report

1. From the global display, press MENU.

2. Press  or  to scroll to PRINT UTILITIES and press ENTER.

3. Press  or  to scroll to SYSTEM SETUP REPORT and press ENTER.

Print a battery label

1. Perform the required service on the battery. Do not remove the

battery from the adapter.

2. Press PRINT.

3. Press the station key of the station that contains the battery.

4. Press  or  to scroll to BATTERY LABEL.

5. Press ENTER.

Print a label with a battery ID bar code

1. Perform the required service on the battery. Do not remove the

battery from the adapter.

2. Press PRINT.

3. Press the station key of the station that contains the battery.
90 Cadex Electronics Inc.
 4. Press  or  to scroll to ID # BAR CODE LABEL.

5. Press ENTER.

Print a label with a bar code for the active C-code

1. Press PRINT.

2. Press the station key of the station that contains the battery.

3. Press  or  to scroll to BAR CODE FOR ACTIVE C-CODE.

4. Press ENTER.

Cadex C7000 Series Battery Analyzers 91

 Chapter 9 Events and Data Logs

Logging Events

The event log stores data concerning the fifty most recent eligible events. This
allows tracking of general battery service trends as well as identification of
potential problems.

DATE TIME STN CODE DESCRIPTION

01/18/2000 14:07 0 200 POWER ON
01/18/2000 14:07 0-1 201 ADAPTER INSERTED
01/18/2000 14:07 0-2 201 ADAPTER INSERTED
01/18/2000 18:57 0-1 115 TARGET CAPACITY NOT MET
01/18/2000 19:00 0-1 26 BATTERY REMOVED
01/19/2000 10:25 0-2 18 PROCESS SUSPENDED
01/19/2000 10:25 0-2 188 SUSPENDED PROCESS ABORTED
01/19/2000 10:25 0-2 17 BATTERY REMOVED

Figure 8: Sample event log

Setting up the Event Log

There are several types of events that the Cadex analyzer can log.

Event Description
Errors Problems that stop the service.
Warnings Problems that do not stop the service, but may affect
battery performance.
System Events Events recorded by the system.
Battery Events Completed actions or programs in a battery service cycle.
Battery Cycles Detailed events in a battery service cycle.
92 Cadex Electronics Inc.
 Event Description
Echo to Printer Instruction to send events to the printer.

You can specify which of these events to include in the event log.

To set up the types of events to be logged

1. From the global display, press MENU.

2. Press  or  to scroll to EVENT LOG and then press ENTER.

3. Press  or  to scroll to EVENTS TO LOG and then press ENTER.

4. For each event type:

a) Press  or  to scroll to YES to include it in the event log or NO

not to include it.

b) Press  to move to the next event type.

5. Press ENTER when you have set up all events to be logged.

6. Press  or  to scroll to YES to accept changes and press ENTER.

7. Press ESC twice to return to the global display.

Using the Event Log

If you have a printer connected to the serial port of the Cadex analyzer, you can
print the event log. Alternatively, you can display the 50 most recently logged
events on the LCD display.

At any time, you can clear all events from the event log.

Cadex C7000 Series Battery Analyzers 93

 To print the event log

1. Make sure you have connected a printer to the serial port of the
Cadex analyzer and made the appropriate changes to the serial port
settings (see Connecting to BatteryShopTM or a Printer, page 70).

2. From the global display, press MENU.

3. Press  or  to scroll to EVENT LOG and then press ENTER.

4. Press  or  to scroll to PRINT EVENT LOG and then press ENTER.

To display the event log on the LCD display

1. From the global display, press MENU.

2. Press  or  to scroll to EVENT LOG and then press ENTER.

3. Press  or  to scroll to VIEW EVENT LOG and then press ENTER.

4. Press  or  to scroll through the events in the log.

5. Press ESC when you are finished viewing the log events.

6. Press ESC twice more to return to the global display.

To remove all logged events from the event log

1. From the global display, press MENU.

2. Press  or  to scroll to EVENT LOG, and then press ENTER.

3. Press  or  to scroll to CLEAR EVENT LOG and then press ENTER.

4. Press  or  to scroll to YES to accept changes and then press

ENTER.

5. Press ESC twice to return to the global display.

94 Cadex Electronics Inc.

Logging Data

When the Cadex analyzer is connected to a computer, you can create data logs
that can be used for detailed analysis of your battery services. The log displays
the data as text strings on the computer screen. Each text string appears on a line
by itself. For an example of data logged with Microsoft’s HyperTerminal program
(see Figure 9, page 96).

Note If you are using the Cadex analyzer with Cadex BatteryShopTM, the
software’s Data Monitor function is similar to the Data Log. A more
powerful and flexible alternative to both the Data Log and Data Monitor, is
Cadex’s BatteryShopTM Real-time data-collection functionality.

Two types of text strings are created when you log data. The first is the “event
string”, which is generated whenever a specific event occurs. Some examples of
specific events that would generate this type of data string are the start or end of a
specific phase in a program; a battery or adapter insertion or removal and errors
and warnings. The second, and most common event string is the “processing
string”, which updates battery data once a minute and indicates normal battery
processing.

Text strings have seven or eight fields, which are separated by commas. The first
six fields in both types of text strings are identical and represent these data
elements:

• Analyzer number. This number is always “0”.

• Station number. This is the number of the battery station that reported the
data string.

• Battery ID. This field displays the battery ID, if it was entered in the Cadex
analyzer. The Battery ID field always has 10 characters but some or all of
them may be blank spaces.

• Date. This is the date the data string was created, in the format mm/dd/yyyy.
This string reflects the Cadex analyzer date settings, not those of the
computer.

Cadex C7000 Series Battery Analyzers 95

 • Time. This is the time the data string was created, using the 24-hour clock
and in the format hhmmss. This string reflects the Cadex analyzer time
settings, not those of the computer.

• Event Code. This number indicates which event has been reported.
Processing strings always display event code 250, which indicates normal
processing. Event strings can display any event code other than 250. For a
list and explanation of event codes, see Messages and Warnings, page 132.

Figure 9: Sample data logged to HyperTerminal.

The content of the final part of the strings depends on the string type. Processing
strings (Code 250) contain two additional fields:

• Battery data. This field displays four different data elements, in this order:

• Process or status. This number represents the process or status

of the current program as listed in Appendix A, Messages and
Warnings (see By Code).

96 Cadex Electronics Inc.

 • Voltage. This is the terminal voltage of the battery in mV.
• Current. This is the charge or discharge current being applied to
the battery in mA. If the current number is positive, the battery is
being charged; if it is negative, the battery is being discharged.
• Battery temperature. This is battery temperature in degrees
Celsius. If temperature sensing is disabled in the C-code, this
value is always 0.

Back-slash characters separate the four elements.

• Battery capacity. In most cases, this field displays the current (or most
recent) battery capacity and the previous battery capacity, both as
percentages of the nominal battery capacity in the C-code. A back-slash
character separates the two capacities. Current battery capacity is updated
(increased) during discharge cycles.

Note If you were running QuickTest, this field displays the battery SoH
(State of Health) as a percentage, followed by the ASCII value of the
confidence grade for the matrix (A = 65, B = 66, C = 67). For more
information about confidence grades, see QuickTest™, page 25.

The bottom text string in Figure 9 is a processing string. It indicates that the
battery in station 1 (ID CDX0095468) is processing normally (event 250), charging
(process 2) with a terminal voltage of 1345mV, a charge current of 801mA, and a
battery temperature of 28°C. The most recent battery capacity achieved was 74%;
the previous capacity was 68%.

Event strings contain one or two fields in addition to the first six:

• Program and target capacity. This field displays a one- or two-digit number
representing the current program and the target capacity from the C-code. A
back-slash character separates the two elements.

Program codes are as follows:

0 = Auto 8 = RunTime
1 = Charge 9 = Self-Discharge
Cadex C7000 Series Battery Analyzers 97
 2 = Prime 10 = LifeCycle
3 = Custom1 11 = Discharge Only
4 = Custom2 12 = Extended Prime
5 = Custom3 13 = Boost
6 = Custom4 14 = QuickTest
7 = OhmTest 15 = Q-Learn
16 = Learn

• Battery data. In certain cases, event strings also contain a battery data field.
For example, when an automatic OhmTest is run as part of a program, the
event string generated includes the OhmTest results in mΩ.

Sample text strings

Here are some sample data logging text strings followed by explanations.

0,2," ","01/24/2001","085120",201,"0\80"

A battery adapter was inserted (Code 201) in station 2 on January 24, 2001 at
8:51 a.m. The current C-code specifies the Auto program with a target
capacity of 80% (0\80 in the final field). Battery ID is not yet available.

0,2," ","01/24/2001","085121",20,"0\80"

A battery was inserted in the adapter (Code 20).

0,2,"CDX01 ","01/24/2001","085140",11,"0\80"

Processing of the current program began (Code 11). The battery ID is CDX01.

0,2,"CDX01 ","01/24/2001","085140",250,"2\1416\398\21",""

Normal processing (Code 250) of battery CDX01. The battery is charging

(process = 2), terminal voltage is 1416mV, charge current is 398mA, and
battery temperature is 21°C. Battery capacity has not yet been determined.

98 Cadex Electronics Inc.

 0,2,"CDX01 ","01/24/2001","085456",27,"0\80", 341

An OhmTest was performed (Code 27). Resistance is measured at 341mΩ.

0,2,"CDX01 ","01/24/2001","100200",250,"7\1419\-401\35","85\37"

Normal processing (Code 250). The battery is discharging (process = 7), terminal
voltage is 1419 mV, discharge current is 401mA, and battery temperature is
35°C. Current battery capacity is 85%; previous capacity was 37%.

0,2,"CDX01 ","01/25/2001","090500",250,"5\1694\7\28","89\87"

Normal processing (Code 250). The battery is ready (process = 5), terminal
voltage is 1694 mV, charge current is 7mA (trickle charge), and battery
temperature is 28°C. Final battery capacity achieved is 89%; previous
capacity was 87%.

0,2,"CDX090 ","04/11/2001","151600",250,"35\3943\0\23","76\67"

Normal processing (Code 250) of battery ID CDX090. A QuickTest has been

completed (status code 35). Terminal voltage is 3943mV, no current is being
applied, and battery temperature is 23° C. The battery SoH is 76% with a
confidence grade of 67, the ASCII code for “C”. (“A” is 65, and “B” is 66).

Setting up the Data Log

To log data to your computer, you must connect the Cadex analyzer to the serial
port of your computer (see Connecting to BatteryShopTM or a Printer, page
70), set the Cadex analyzer to log data, and set up a program to read the data
from the serial port. The procedure outlined here assumes you are using
Microsoft’s HyperTerminal communications program, which comes with most
versions of Microsoft Windows; however, you can use any compatible
communications program that can read data through the computer serial port(s).

To set the Cadex analyzer to log data to a computer

1. From the global display, press MENU.

Cadex C7000 Series Battery Analyzers 99

 2. Press  or  to scroll to SYSTEM SETUP and then press ENTER.

3. Press  or  to scroll to SERIAL PORT DEVICE and then press ENTER.

4. Press  or  to scroll to TERMINAL and then press ENTER.

5. Press  or  to scroll to YES to accept changes and press ENTER.

6. Press  to scroll to SERIAL PORT SETTINGS and then press ENTER.

7. Pressing  or  to move the cursor between options and  or  to

scroll through available settings, enter these serial port settings:

• BAUD RATE: 9600

• HANDSHAKE: NONE

• DATA BITS: 8
• STOP BITS: 1
• PARITY: NONE

8. Press ENTER.

9. Press  or  to scroll to YES to accept changes and press ENTER.

10. Press ESC twice to return to the global display.

To set HyperTerminal to read Cadex analyzer data

1. Click Start on the Windows Task Bar, point to Programs, then point
to Accessories, and then click HyperTerminal.

2. Double-click the HyperTrm or HyperTrm.exe icon.

3. Type a name for your data log connection, such as Cadex analyzer
connection, and then click OK.

4. In the dialog box that appears, enter these settings:

100 Cadex Electronics Inc.

 • Connect using. From the list, select Direct to Comx, where x is the
number of the serial port to which your Cadex analyzer is connected.
• Bits per second: 9600
• Data Bits: 8
• Parity: None

• Stop Bits: 1
• Flow Control: None

5. Click OK.

The HyperTerminal screen appears. The bottom left-hand corner of

the screen should display the message “Connected h:mm:ss”.

6. Check that HyperTerminal is communicating with the Cadex analyzer

by inserting an adapter in any station on the analyzer. A text string
similar to this one should appear on-screen:

0,2," ","01/25/2001","095126",201,"0\80"

If nothing appears on-screen, check the HyperTerminal properties:

a) Click File, and then click Properties.

b) Verify that the serial communication port number is correct.

c) Click Configure, and verify that the serial port settings match the
Cadex analyzer serial port settings.

If the Properties settings are correct, check the serial cable and
connections, and verify the serial port settings on your computer and
your battery analyzer.

Using the Data Log

Once you have set up a connection file, you can use that file to open
HyperTerminal and log Cadex analyzer data. You can also save Cadex analyzer
Cadex C7000 Series Battery Analyzers 101
 data logs by capturing them as text files, which you can import into a spreadsheet
program such as Microsoft Excel for graphing and analysis.

To log and save data to a text file

1. Click Start on the Windows Task Bar, point to Programs, then point
to Accessories, and then click HyperTerminal.

2. Double-click Cadex analyzer Connection (or the name you gave the
connection when you first set it up).

HyperTerminal opens and starts displaying data sent from the Cadex
analyzer.

3. Click Transfer, and then click Capture Text.

4. Type a name for your data log text file, giving it a .txt extension.

To change the file location, click Browse and specify a different

folder.

5. Click Start.

Data starts to be saved from the highlighted point on-screen.

6. When all the data you want to include in your file has been captured,
click Transfer, then point to Capture Text, and then click Stop.

The text file is created. You can now import it into a spreadsheet
program for further analysis.

To open the data log in Microsoft Excel

1. Start Microsoft Excel.

2. Click File, and then click Open.

102 Cadex Electronics Inc.

 3. In the dialog box that appears, navigate to the folder in which you
saved your data log text file.

4. In Files of Type, select Text Files (*.prn; *.txt; *.csv).

5. Click the name of the text file you want to open in Microsoft Excel.

6. Click Open.

You can now use Microsoft Excel functions to analyze, graph, or create a report of
the Cadex analyzer BatteryShop data.

Note You are not limited to spreadsheet programs. Depending on what you
want to do with the data, you can open your data log in any software
program that recognizes comma-separated-values files. This may include
word processing programs and database programs, among others.

Cadex C7000 Series Battery Analyzers 103

 Chapter 10 Custom Programs

These features are recommended for advanced users only.

Creating a custom program requires a good understanding of rechargeable

batteries and the analyzer. Applying routines that conflict with the battery
manufacturer’s specifications or recommendations can damage a battery.

If you regularly modify custom programs, the use of Cadex BatteryShop™ is

strongly recommended. The graphical user interface of Cadex BatteryShop™
allows easy programming and monitoring of battery performance. See
Cadex’s BatteryShop™ online Help for detailed instructions.

Custom programs can run virtually any sequence of service cycles. They are
stored in the analyzer to be globally used by any adapter.

A custom program consists of phases 1 through 5, followed by phase DONE.

Each of the first five phases consists of two cycles, a test, and the TRUE and FALSE
statements, as shown in the flow chart in
Previous
Phase

Cycle 1 Cycle 2 Test (IF Fail Result (ELSE

(Action) (Action) statem ent) (False) statem ent action)

Pass (True)

Result (THEN
statem ent action)

• Figure 10.

104 Cadex Electronics Inc.

 Previous
Phase

Cycle 1 Cycle 2 Test (IF Fail Result (ELSE

(Action) (Action) statem ent) (False) statem ent action)

Pass (True)

Result (THEN
statem ent action)

Figure 10: Custom program process, phases 1 through 5

• Phase Done consists of Cycle 1 only and does not proceed to any other
cycle.

The analyzer goes through the first phase, then follows the paths prescribed by
the IF, THEN, and ELSE statements in the test cycle of each phase.

Cycle 1 and Cycle 2

There are seven different actions that can be performed as Cycle 1 or Cycle 2 of
phases 1 through 5.

Action Description
Skip Cycle Skips the cycle and goes to the next cycle or the
TEST statement.

Discharge Time Discharges the battery for the specified time period
(for 000:00:00 (hhh:mm:ss)* at the discharge rate set in the
at 100%) extended C-code.
A setting of 50% gives a discharge current that is
50% of the C-code discharge rate (see Discharge
Rate (C-rate), page 48).

Cadex C7000 Series Battery Analyzers 105

 Action Description
Charge Time Charges the battery for the specified time period (in
(for 00:00:00 hhh:mm:ss format)* at the charge rate set in the
at 100%) extended C-code.
Recondition Time Reconditions (deep discharges) the battery for the
(for 000:00:00) specified time period (hhh:mm:ss)* at the recondition
discharge rate set in the extended C-code.
This cycle is skipped for SLA and Li batteries
because these chemistries cannot be reconditioned.
This cycle can be applied only after a discharge
cycle.
Trickle-Charge Time Charges NiCd and NiMH batteries for the specified
(rest for 000:00:00) time period (hhh:mm:ss)* at the trickle-charge rate
set in the extended C-code.
This cycle is skipped for SLA and Li batteries.
Rest Time Applies no current for the specified time period
(rest for 000:00:00) (hhh:mm:ss)*.
The time must be specified or the cycle is skipped.
OhmTest Performs the OhmTest on the battery.

Test

The test cycle has three parts:

• The IF statement, which describes a condition that must be either true or

false for the battery being tested.

• The THEN statement, which describes the action to be taken if the battery
passes the test (the condition is true).

• The ELSE statement, which describes the action to be taken if the battery fails
the test (the condition is false).

* If the default time period of 000:00:00 is used, the analyzer services the battery according
to end-of-charge, end-of-discharge or end-of-recondition settings in the extended C-code.
The maximum allowable is 200:59:59.

106 Cadex Electronics Inc.

 IF Statements

You can choose from ten different test conditions, or IF statements, when you are
setting tests for phases 1 through 5.

IF Statement Description
Skip Test Selects the TRUE statement. The FALSE statement is
ignored.
IF Target Capacity Met Selects the TRUE statement if the capacity during the
last discharge cycle meets the target capacity;
otherwise, selects the FALSE statement.
IF Target Capacity Not Selects the TRUE statement if the capacity during the
Met last discharge is below the target capacity;
otherwise, selects the FALSE statement.
IF < 5% Capacity Selects the TRUE statement if the improvement in
Increase capacity during the last two discharge cycles is less
than 5% (for example, the last one is 88% and the
one before is 85%); otherwise (for example, if the
last one is 90% and the one before is 80%), selects
the FALSE statement.
IF > 5% Capacity Selects the TRUE statement if the improvement in
Increase capacity during the last two discharge cycles is
more than 5% (for example, the last one is 90% and
the one before is 80%); otherwise (for example,
88% and 85%) selects the FALSE statement.
IF Total Capacity < 5% Selects the TRUE statement if the capacity during the
last discharge cycle is less than 5%; otherwise,
selects the FALSE statement.
IF Total Capacity > 5% Selects the TRUE statement if the capacity during the
last discharge cycle is greater than 5%; otherwise,
selects the FALSE statement.
IF User Defined Timeout Selects the TRUE statement if the time period set in
Cycle 1 or Cycle 2 expires before the battery is fully
charged, discharged or reconditioned; otherwise,
selects the FALSE statement. For Trickle Charge and
Rest, the program selects the TRUE statement only.

Cadex C7000 Series Battery Analyzers 107

 IF Statement Description
IF Loop Count < Max Selects the TRUE statement if the number of cycles
(the loop count) is less than the value set in THEN
REPEAT X TIMES of the TRUE statement or ELSE
REPEAT X TIMES in the FALSE statement; otherwise,
selects the FALSE statement.
IF Loop Count > Max Selects the TRUE statement if the number of cycles
(the loop count) is more than the value set in THEN
REPEAT X TIMES of the TRUE statement or ELSE
REPEAT X TIMES in the FALSE statement; otherwise,
selects the FALSE statement.

THEN and ELSE Statements

There are ten possible responses to the results of the IF statement. Each of these
responses is available as a THEN statement (for when a battery meets the
condition, or passes) or as an ELSE statement (for when a battery does not meet
the condition, or fails).

THEN/ELSE Statement Description

Starts the next phase. Starts the next phase.
Go to Phase 1 Starts Phase 1.
Go to Phase 2 Starts Phase 2.
Go to Phase 3 Starts Phase 3.
Go to Phase 4 Starts Phase 4.
Go to Phase 5 Starts Phase 5.
Go to Done Starts Phase Done.
REPEAT 0 times Repeats actions in the current phase the number of
times specified.
Available settings:
• 1 to 8
• FOREVER. The program continues forever. See
the “IF Loop Count<Max” and “IF Loop
Count>Max” statements, above.

108 Cadex Electronics Inc.

 THEN/ELSE Statement Description
REST for 000:00:00 Applies no current for the specified time period (in
hhh:mm:ss format). The RESTING message (code
19) is displayed with time counting down.
After resting, the program goes to the next phase.
FAIL Fails the battery. The battery is electrically
disconnected, the FAIL light comes on, and the
WARNING message (code 16) appears.

Phase Done

You can perform one of three different actions in the final phase of the custom
program.

Action Description
Ready—No Charge Ends the program. The green READY light is on, and
no trickle charge is applied.
Ready—Trickle Charge Trickle-charge the battery using the trickle-charge
rate in the extended C-code. Includes the standby
maintenance cycle, which performs a discharge/
charge every 30 days (180 days for SLA).
Trickle Charge Trickle-charge the battery using the trickle-charge
rate in the extended C-code.

Creating and Editing Custom Programs

To create or edit a custom program

1. From the global display, press MENU.

2. Press  or  to scroll to PROGRAM SETTINGS and then press ENTER.

3. Press  or  to scroll to CUSTOM PROGRAMS and then press ENTER.

4. Press  or  to scroll to the program you want to create or edit, for

example, CUSTOM 1.

Cadex C7000 Series Battery Analyzers 109

 5. Press EDIT. The cursor appears on Phase 1.

6. Press  to move the cursor to the Cycle 1 field.

7. Program the action to be completed during this cycle:

a) Press  or  to select the action.

b) Press .

c) If necessary, use the direction keys or the number pad to enter

any additional settings required for the cycle and then press .

8. Repeat step 7 for Cycle 2 of the phase.

9. Program the test for the phase:

a) Press  or  to select the IF statement, the test to be performed.

(see Test, page 106).

b) Press .

c) Press  or  to select the THEN, or TRUE, statement (the action

to be performed if the battery passes the test). Available THEN
and ELSE statements are described on page 108.

d) Press .

e) Press  or  to select the ELSE, or FALSE, statement (the action

to be performed if the battery fails the test).

f) Press .

10. Press  to move to the next phase.

11. Repeat steps 6 – 10 for phases 2 – 5.

Once Phases 1 through 5 have been programmed, the cursor

appears on Phase Done.
110 Cadex Electronics Inc.
 12. Program the action for Phase Done:

a) Press  to move to Cycle 1.

b) Press  or  to select the action to be performed. (There is only

one cycle for Phase Done.)

13. When you have finished entering the settings, press ENTER.

14. Enter a name for the program, if desired:

• Press  or  to scroll through upper case letters, lower case

letters, punctuation marks, numbers, and a space (which looks
like an underscore) to select characters for the program name.
• Press  or  to move the cursor between character positions
within the program name. There are seven positions available.

15. Press ENTER.

16. Press  or  to scroll to YES to accept changes and press ENTER.

17. Press ESC twice to return to the global display.

Sample Custom Program

NiCd or NiMH batteries that do not meet the target capacity should always be
reconditioned. If the battery does not meet the target capacity after reconditioning,
the program fails the battery.

Phase Action
Phase 1 Charge the battery.
Phase 2 Discharge to find the battery capacity. If the capacity meets the target
capacity, complete the program (Phase Done). If the target capacity is
not met, apply the recondition cycle (Phase 3).
Phase 3 Recondition and charge the battery.
Phase 4 Discharge to find capacity after the recondition cycle. If the capacity
meets the target capacity, charge the battery (Phase 5). If the target

Cadex C7000 Series Battery Analyzers 111

 capacity is not met, fail the battery.
Phase 5 Fully charge the battery.
Phase Done Complete the program with a trickle charge to maintain capacity.

The flowchart in Figure 11 on the next page demonstrates how this program
works.

112 Cadex Electronics Inc.

 Phase 1 Cycle 1 Charge

Cycle 2 Skip

Test Skip

True
True/False (Go to Phase 2)

Phase 2 Cycle 1 Discharge

Cycle 2 Skip

Test Meets target

capacity

True False
True/False (Go to Done) (Go to Phase 3)

Phase 3 Cycle 1 Recondition

Cycle 2 Charge

Test Skip

True
True/False (Go to Phase 4)

Phase 4 Cycle 1 Discharge

Cycle 2 Skip

Meets target
Test capacity

True False
True/False (Go to Phase 5) (Fail)

Phase 5 Cycle 1 Charge

Cycle 2 Skip

Test Skip

True
True/False (Go to Done)

Phase Done Done Done Done

Ready Ready Fail

Trickle charge Trickle charge

Figure 11: Flow chart for sample custom program

Cadex C7000 Series Battery Analyzers 113

 Chapter 11 Services and Upgrades

Caution!

There are no internal user-serviceable parts in the Cadex analyzer other

than the internal backup battery.

Except for changing the battery, unauthorized disassembly and/or

repair of the analyzer by other than an authorized Cadex Service Center
will void the warranty.

See Appendix D - Parts and Accessories, page162 for information about

ordering replacement parts.

Replacing the Primary (Input) Fuse

If the analyzer does not power up but the input line is okay and power cord is
firmly inserted, the primary (input) fuse may need to be replaced (see Appendix D
- Parts and Accessories, page 162).

To replace the primary fuse

1. Remove all batteries and adapters, turn off the analyzer and unplug
the power cord. Wait one minute before continuing.

2. Locate the fuse holder below the power cord socket.

3. Open the fuse cover by turning it counterclockwise with a small coin

or screwdriver.

114 Cadex Electronics Inc.

 Figure 12: Replacing the fuse

4. Remove and examine the fuse carefully.

If the filament inside the glass tube is broken, replace the fuse. Be
aware that the filament can sometimes appear intact even when it is
broken.

5. Close the fuse cover by pushing and turning it clockwise with a small
coin or screwdriver until it locks in place.

6. Insert the power cord and turn on the analyzer.

Replacing the Backup Battery

The C7000 Series Battery Analyzer uses a 3-volt lithium coin battery (type
CR2032 or equivalent) to save settings while the analyzer is turned off. With
ordinary use of the C7000 Series Battery Analyzer, you should have to replace
the battery only every seven to ten years.

You need the following:

• A small Phillips screwdriver.

• A new 3-volt lithium battery.

• A wrist strap or other device to eliminate electrostatic discharge.

Cadex C7000 Series Battery Analyzers 115

 ELECTROSTATIC SENSITIVE DEVICE!

Do not open the C7000 Series Battery Analyzer Battery or touch any part of
its internal components if you are not grounded.

To replace the Cadex analyzer backup battery

1. Remove all batteries and adapters, turn off the analyzer and unplug
the power cord and serial and parallel port cords. Wait one minute
before continuing.

Do not attempt to open the C7000 Series Battery Analyzer while it is plugged
into an electrical outlet or any peripheral device.

Severe electrical shock and/or damage to the analyzer could result!

2. Use the Phillips screwdriver to remove the three screws along the top
of the back panel.

Figure 13: C7400 and C7400ER: Remove the back screws

Figure 14: C7200: Remove the bottom screws

116 Cadex Electronics Inc.

 3. Remove the top cover by sliding it back slightly and then lifting.

Figure 15: Cadex 7400 with cover removed. The backup battery on the C7400ER
is in a similar location

Cadex C7000 Series Battery Analyzers 117

 Figure 16: Cadex C7200 with cover removed

4. The battery is located towards the back of the analyzer (see

Figure 15). Carefully remove the existing battery:

a) Move the upper clip of the battery holder out of the way.

b) Using your fingers or insulated pliers or tweezers, gently pull the

old battery out of the holder. Be very careful not to damage the
battery.

Caution!

Do not use pliers or tweezers with bare metal tips. They will short the battery.

118 Cadex Electronics Inc.

 5. Insert the new battery in the holder, with the positive terminal facing
into the clip and away from the fan until the clip slips in place.

6. Replace the cover and the three screws on the back panel. Ensure
that no interior wires or cables are caught or pinched between the
cover and the unit.

7. Plug in the power cord and serial cable.

8. Turn on the machine. All settings, including custom programs, will

have returned to factory defaults, so you will have to reprogram any
customized settings or programs.

Replacing the Station Fuses

Each station on the C7000 Series Battery Analyzer has a protection fuse (marked
F1 to F4) located beside the adapter socket on the main board.

DO NOT ATTEMPT TO REPLACE THESE FUSES BY YOURSELF. ONLY

A CADEX SERVICE CENTER IS AUTHORIZED TO REPLACE THESE
FUSES.

Station Fuse

Cadex C7000 Series Battery Analyzers 119

 Upgrading the Firmware

From time to time, Cadex offers firmware upgrades for the Cadex analyzer.
These can usually be downloaded to your computer from our Internet site
(www.cadex.com) and then copied to your Cadex analyzer using the Cadex
Firmware Utility software, available from Cadex Electronics Inc. (the Firmware Utility
software comes with BatteryShopTM).

The current version of the firmware is always displayed in the lower left-hand
corner of the Cadex analyzer startup screen, followed by the current version of
the Cadex Firmware Utility software, as shown here:

You can also display this screen without restarting the unit.

To verify firmware version (display start-up screen)

1. From the global display, press FN and then press 7.

2. Press ESC to return to the global display.

Resetting the System

You can reset the system to the factory defaults.

The parameters that are reset to their default values include these settings:

• OhmTest, Runtime, Self-Discharge, Life-Cycle and custom programs.

• Battery startup settings.
• Key sound and alert sound.
• Parallel port device.

120 Cadex Electronics Inc.

 • Voltage display.
• Service counter (number of batteries serviced).

The setting for the serial port device changes to BATTERYSHOP.

To reset parameters to the factory default and restart the analyzer

1. From the global display, press ALT, and then press 0.

2. Press ENTER to confirm or ESC to cancel.

Note This function also serves as a general system reboot.

Cleaning the Analyzer

Caution! Before cleaning, turn off the power and unplug the AC power
cord.

Clean the analyzer only with a damp cloth moistened with mild soap and water
and allow to thoroughly dry. Do not allow any liquids to enter the analyzer
case under any circumstances.

Cadex C7000 Series Battery Analyzers 121

 Chapter 12 System Calibration

There are two kinds of calibration that should be performed on the Cadex
analyzer on a regular basis: voltage calibration; and adapter, or station,
calibration.

Calibrating Voltage

Voltage calibration should be performed at least yearly. To calibrate the voltage,

you need a calibration kit, which consists of calibration adapters and an instruction
sheet (see Appendix D - Parts and Accessories, page 162) for ordering and
part-number information.

To calibrate the voltage

1. Remove all battery adapters.

2. From the global display, press MENU.

3. Press  or  to scroll to SYSTEM SETUP and then press ENTER.

4. Press  or  to scroll to CALIBRATE VOLTAGE and then press ENTER.

5. Firmly insert the two voltage calibration adapters, one into each
station.

6. Wait for the prompt, then remove the calibration adapters.

7. Press MENU to return to the global display.

122 Cadex Electronics Inc.

 8. Press FN, and then press 7. The “#” sign appears in the upper right
corner of the startup screen, indicating successful completion of
voltage calibration.

Servicing the Voltage Calibration Adapters

Return the voltage calibration adapters to the factory every three years for
authorized calibration. Contact Cadex for a Return Authorization number.

Calibrating Adapters

Battery adapters should be calibrated once a year or whenever they are moved
from one analyzer to another. Station calibration corrects variations in tolerances
due to aging of the components in the adapter and compensates for voltage loss
from cables and electrical contacts.

Failure to calibrate battery adapters can cause inaccurate capacity readings,

especially on low voltage batteries or single cells operating at high charge or
discharge currents. OhmTest and QuickTestTM results can also be affected, in
some cases dramatically.

Use an electrical short with a 10 AWG wire or a copper plate for this procedure.

To calibrate an adapter

1. Make sure that there is no battery inserted into the adapter.

2. From the global display, press FN and then press 8.

Or

a) From the global display, press MENU.

b) Press  or  to scroll to SYSTEM SETUP and then press ENTER.

c) Press  or  to scroll to CALIBRATE STATION and then press

ENTER.

Cadex C7000 Series Battery Analyzers 123

 3. Press the station key for the station that contains the adapter you
want to calibrate.

Use a short length of heavy gauge wire (AWG 10) or a copper plate
to short the positive and negative terminals on the battery adapter
together. If you are calibrating a Smart Cable Adapter, clip the leads
together.

Do NOT short the temperature sensor on the adapter.

Do NOT short the contacts on a battery.

4. Press ENTER to start calibrating. Calibration takes about 20 seconds.

5. Remove the adapter when prompted.

Adapter Calibration Values

Adapters are calibrated at the factory and the calibration value is permanently
stored in adapter memory. After calibration, the new calibration value and factory
calibration value are compared.

If the difference between the calibration values is less than 50mΩ, the new value
is displayed on the screen and replaces the factory calibration value.

If the difference is more than 50mΩ, the calibration value and the original factory
calibration value is displayed; select Yes or No to accept or discard the new value.

If the new calibration is over 400mΩ, the new value is rejected.

Use an electrical short with a 10 AWG wire or a copper plate when

calibrating to keep calibration values within 50mΩ.

Calibration Values for QuickTestTM

If you are planning to use QuickTestTM, check the calibration result with the
following table. These values cannot be used to determine if an adapter is faulty
or not. It only indicates if the adapter has an acceptable range for QuickTestTM.
124 Cadex Electronics Inc.
 These ranges are only for new adapters. Older adapters may have higher
values.

All values were determined using a 1” wide copper plate for shorting. For the
blade contacts, the values were collected using a 10AWG wire with banana plugs.

Contact Type Typical Calibration Resistance

Flat blade shaped contacts (typical C7200 & C7400 < 220mΩ
for laptop battery adapters) C7400ER < 250mΩ
All other contacts (including C7200, C7400 and C7400ER < 250mΩ
removable Pogo contacts)
Smart Cable (07-110-0115) C7400 < 270mΩ
C7400ER < 330mΩ
Flex Arm (07-110-0180) C7200, C7400 and C7400ER < 380mΩ

Note: The Smart Cable (07-110-0115) and FlexArm (P/N 07-110-0180) are not
recommended for QuickTestTM

Cadex C7000 Series Battery Analyzers 125

 Chapter 13 Solving Problems and Getting Help

Troubleshooting

The common problems and solutions listed below will answer most of your
questions. The detailed alphabetical list of display messages in Appendix A -
Messages and Warnings on page 132 can help to sort out problems not listed
here.

If you need personalized help, contact the Technical Support department at 1 800
565-5228.

Problem Possible Reasons or Solutions

Analyzer does not power up. Make sure that the power cord is firmly
inserted in the back connector.
Check the power supply
Check the input fuse, (see Replacing the
Primary (Input) Fuse, page 114).
Analyzer prompts for the Turn OFF the ‘Ask for Battery ID’ setting in
Battery ID Battery Startup under the Option Controls,
(see To set user input, page 78).
Battery continually cycles Battery Cells may be soft or in poor
without ending on QuickTest condition. Verify battery condition using the
Auto program. Battery may be unable to be
QuickTestTM.

126 Cadex Electronics Inc.

 Problem Possible Reasons or Solutions
Battery disconnected during If the battery is hot, the thermal fuse may
service and is not recognized by have temporarily opened the battery. Lower
the analyzer the charge rate and allow the battery to cool
before servicing again.
Protection circuits in the battery may not be
able to handle the rapid pulses of the
OhmTest. Turn off the automatic OhmTest,
(see To turn Automatic OhmTest on or
off, page 79)
Battery has completed service Contact Cadex for a firmware upgrade.
but there is no LED
Battery is getting hot It is normal for batteries to heat up during
charge. However, they should be just warm
to the touch. If they are getting too hot,
reduce the Charge rate or Trickle Charge
Rate in the Extended C-code and/or
activate the adapter temperature sensing.
Battery passes on analyzer but Run OhmTest. If the resistance is high, the
fails in the field. battery may not be able to hold a charge.
Run Self-Discharge. If self-discharge is
more than 30%, the battery may not be able
to hold a charge.
Battery service does not start or Ensure that the adapter is firmly inserted
is not recognized when inserted into the analyzer.
in the analyzer.
Verify that the battery is correctly and firmly
inserted into the adapter. Ensure that the
contacts on the battery connect with the
contacts on the adapter.
If the battery has a switch, turn it on.
Press ENTER after selecting the C-code and
the service program.
Verify that the selected C-code is correct for
the battery.
Battery voltage is too low for battery to be
recognized by the unit. Run Boost, (see To
run the Boost program, page 36).

Cadex C7000 Series Battery Analyzers 127

 Problem Possible Reasons or Solutions
Cannot program an 18V (or The C7200 and C7400 can support a
higher voltage) battery. maximum of 14.4V. The C7200 and C7400
cannot be modified to accommodate
batteries higher than 14.4V. Batteries higher
than 14.4V require the C7400ER.
Capacity readings between Verify that the C-codes are the same
stations are inconsistent. between stations.
Calibrate the stations, (see To calibrate an
adapter, page 123).
Clicking noise is heard from the The noise is caused by pulse charges in the
analyzer when batteries are analyzer circuits. This noise is normal.
being charged.
Code 150 appears when Li-ion For Li-ion batteries, adapters must have
batteries are serviced. temperature-sensing capability. A custom-
Temperature Sensing in the C- designed adapter is strongly recommended.
code cannot be Disabled.
Connection between battery The battery may be intrinsically safe.
and the analyzer is intermittent. Change the charge method in the extended
C-code to DC Charge; lower the charge and
discharge rates; reduce the end-of-
discharge setting to 0.92 V/cell. Ensure that
the adapter is correct. Verify if the battery
contacts or adapter terminals are damaged.
Capacity of the analyzer is Check that all the C-codes match. Calibrate
different from the older model the adapter. Set the ‘Charge Optimization’
C7000 analyzer. to ‘Charge’, (see Optimizing Charge Time
or Capacity, page 80)
Dates are changing or negative Replace the backup battery, (see
dates are appearing. Replacing the Backup Battery, page 115)
Display is frozen and there are Contact Cadex.
clicking sounds
Fan changes speed. This is normal.
LED is flashing irregularly Contact Cadex.
NULL CODE appears on the C-code is blank. Program a C-code, (see
display Create or Edit a C-code, page 59).

128 Cadex Electronics Inc.

 Problem Possible Reasons or Solutions
Password is not accepted even Replace the backup battery, (see
though no password is stored in Replacing the Backup Battery, page 115).
the analyzer.
Program did not resume after a Default power-off time out is 1 hour. Users
power failure. can increase the default time to 2; 12; 24;
48 or 72 hours.
Note: if using BatteryShopTM, servicing data
will not be saved.
If the power fails during the information
save, the program will not continue when
power resumes.
Replace the backup battery, (see
Replacing the Backup Battery, page 115).
QuickTest, Q-Learn and Learn Older battery adapters have a 4-kilobit
does not appear on the display capacity. All new battery adapters
manufactured by Cadex, however, have a
16-kilobit capacity. (All 16K adapters are
identified with a label at the back.) You
must have 16K adapters to use the
QuickTestTM, Q-Learn and Learn
programs.
Reports or labels are not Check the serial port setup for the serial
printing. printer (see Connecting Devices to the
Serial Port, page 71).
Check that the serial port is enabled for
correct print device (see Connecting
Devices to the Serial Port, page 71).
Check that the serial cable is correctly
configured (see Typical Serial Cable Pin
Configurations, page 73).
Resistance readings are Calibrate the station, (see Calibrating
consistently high. Adapters, page 123).
The battery or adapter contacts may be
damaged.
The battery is faulty.

Cadex C7000 Series Battery Analyzers 129

 Problem Possible Reasons or Solutions
Service starts without asking for Turn ON the ‘Ask for Battery C-code’ setting
the C-code in Battery Startup under the Option
Controls, (see To set user input, page 78).
Single cell gives inconsistent Calibrate the station, (see To calibrate an
results. adapter, page 123).
Set the charge method in the extended C-
code to DC Charge (for low terminal
voltage).
Single cells are discharging or charging too
quickly. Lower the discharge and charge
rates to 0.2 C.
Temperature is not displayed on Turn on the temperature sensing in the C-
the detailed station screen code, (see Temperature Sensing, page
during service 50).
Analyzer does not respond to Incomplete boot or power failure during in
input and there is continuous boot up. Remove the adapters, restart the
beeping analyzer.

Manual Updates and Other References

The Cadex website is an additional resource for information about Cadex

products. Visit www.cadex.com For:

• Product specifications and technical information

• Articles
• FAQ
• Battery adapter catalog
• User manual and firmware version updates

For more information about rechargeable batteries, Batteries in a Portable World

(second edition) is an authoritative and popular reference book. Written by Isidor
Buchmann, Cadex President and founder, Batteries in a Portable World can be
ordered by visiting the Cadex website or by calling Cadex Electronics Inc.

130 Cadex Electronics Inc.

Technical Support

If you have a technical problem that cannot be solved with this manual or the
Cadex Web site, contact our Technical Support department by phone, fax, e-mail,
or mail. Provide the following information:

• Serial number of the analyzer and firmware version (press FN and then 7 to
display the version number)
• Display message and/or code
• LED lights that are on or flashing
• What you were doing when the problem occurred? Exactly what happened?
• Move the adapter and/or battery between stations to isolate if it is a battery or
adapter issue.

For questions related to batteries or adapters, also provide the following:

• Battery model number

• Adapter number
• C-code being used (including parameter settings)
• Display message and/or code

You can reach Cadex Technical Support by phone from 8:00 am to 4:30 pm,
Pacific Time (GMT -8:00), Monday through Friday.

• Telephone: +1 604 231-7777 ext. 315

• Toll Free: +1 800 565-5228 (US and Canada only)
• Fax: +1 604 231-7755
• E-mail: service@cadex.com
• Mail: Cadex Electronics Inc.
22000 Fraserwood Way, Richmond, BC, Canada V6W 1J6
Attn: Product Support

Cadex C7000 Series Battery Analyzers 131

Appendix A
Messages and Warnings

This appendix describes all the messages and warnings that can appear on the
display.

The global message is the first to appear, often with the warning code number.

To view the detailed warning message, press the appropriate station key, in this
case 2 , and then press . A display similar to this one appears:

Messages and warnings are listed in this appendix by code number and by
detailed message. The listing by detailed message also lists the usual reasons for
the appearance of individual messages as well as possible solutions to the
problems they indicate.

Cadex C7000 Series Battery Analyzer 132

Non-Coded Messages
Global Message Description
Battery Service Reset the Service Counter, (see To set the
Limit Reached battery service counter, page 69)
BatteryShopTM Analyzer is waiting for input from
Mode Wait BatteryShopTM software. If the unit is not
connected to BatteryShopTM, disable the
Serial Port, (see Connecting to
BatteryShopTM or a Printer, page 70)
Calibration Error The short between terminals may have
disconnected during calibration. Redo the
calibration.
C-code Locked C-code is locked and cannot be edited. Use
an unlocked C-code. Delete and re-enter the
C-code to remove the locked C-code.
Internal Error LCD memory is full. Press the Esc key to
clear the buffer and restart the analyzer.
Services may resume.
N/A Not Applicable. QuickTestTM or OhmTest has
not yet been completed.
N/R Not readable. QuickTestTM could not
determine the SoH for the battery. In most
cases, the resistance may not be within
acceptable limits.
NULL CODE See Code 211 (NULL C-CODE IN ADAPTER) in
the next section.
Unable to Print Printer port is disabled.
Serial Port and Parallel Port may be sharing
the same printer setting. Set the serial or
parallel port to another device or set it to
Disabled, (see Connecting to BatteryShopTM
or a Printer, page 70)

Cadex C7000 Series Battery Analyzers 133

 By Code

In this table, messages and warnings are listed in order of code number (see By
Detailed Message, page 137).
Code Global Message Detailed Message
0 OFFLINE STATION OFF LINE
1 NO ADAPT NO ADAPTER
2 CHARGE CHARGING
3 TRKL CHRG TRICKLE CHARGE
4 RECOND. RECONDITIONING
5 READY READY
6 DCHG WAIT DISCHARGE WAIT
7 DISCHARGE DISCHARGING
8 INSERT INSERT THE BATTERY
9 CHG WAIT CHARGE WAIT
10 EMPTY NO BATTERY
11 START START BATTERY PROCESS
12 COLD WAIT BATTERY TOO COLD
13 HOT WAIT BATTERY TOO HOT
14 OVERHEAT BATTERY OVER TEMP
15 FINISHED PROCESS COMPLETE
16 WARN 16 PROGRAM HAS FAILED
17 REMOVED BATTERY REMOVED
18 INTERRUPT PROCESS SUSPENDED
19 RESTING RESTING
20 INSERTED BATTERY INSERTED
21 RESTING RESTING
22 CAL WAIT SETTING UP CALIBRATION
23 CALIBRATE STATION CALIBRATING
25 RESUME PROCESSING RESUMING
26 REMOVED BATTERY REMOVED
27 OHMTEST RESISTANCE TEST
28 OHMTEST RESISTANCE TEST
29 CALIBRATE STATION CALIBRATING
30 END CYCLE CHARGE CYCLE COMPLETE
31 END CYCLE DCHG CYCLE COMPLETE
32 RESUMED CYCLE RESUMED
33 END CYCLE USER PROGRAMMED TIMEOUT
34 BATSHOP BATSHOP MODE WAIT
35 FINISHED PROGRAM COMPLETE or QuickTest
Completed for BatteryShop

134 Cadex Electronics Inc.

 Code Global Message Detailed Message
36 FINISHED PROGRAM COMPLETE or Q-Learn
completed for BatteryShop
112 ALERT 112 CELL MISMATCH
113 ALERT 113 PLATEAU TIMEOUT
115 FAIL 115 TARGET CAPACITY NOT MET in service
116 FAIL 116 TARGET CAPACITY NOT MET after service
118 ALERT 118 CHRGE CURRENT REDUCED
120 FAIL 120 OVER VOLTAGE
121 REVERSED BATTERY REVERSED
122 SHORTED BATTERY SHORTED
123 LOW VOLT LOW VOLTAGE TIMEOUT1
124 LOW VOLT LOW VOLTAGE TIMEOUT2
125 LOW VOLT NO SLOPE TIMEOUT ZONE1
126 LOW VOLT LOW VOLTAGE AT NEG. SLOPE
127 LOW VOLT LOW VOLTAGE TIMEOUT3
128 SOFT UNABLE TO CLAMP CHARGE VOLTAGE
129 FAIL 129 INTERMITTENT BATTERY
130 ALERT 130 CURRENT RISE AT FULL CHARGE
135 FAIL 135 HIGH CELL RESISTANCE
136 FAIL 136 HIGH CELL RESISTANCE
142 TIMEOUT DISCHARGE TIMEOUT
144 TIMEOUT CHARGE TIMEOUT
146 TIMEOUT RECONDITION TIMEOUT
150 FAIL 150 THERMISTOR FAILURE
152 TEMP RISE RAPID HEAT RISE
154 HOT BATT CHG COMPLETE TEMP. RISE
156 TEMP RISE HOT BATTERY, LOW VOLTAGE
158 HOT BATT HEAT TERMINATION
159 FAIL 159 HOT BATTERY ON TRICKLE CHARGE
160 FAIL 160 BAD FUSE OR DRIVER
162 FAIL 162 DISCHARGE CURRENT LOW
164 FAIL 164 CHARGE CURRENT LOW
170 FAIL 170 CALIBRATION FAULT
171 FAULT SMART ADAPTER FAULT
172 FAULT SMART BATTERY FAULT
175 LOW SOC BATTERY UNDERCHARGED
176 HIGH SOC BATTERY OVERCHARGED
177 ALERT 177 BATTERY UNDERCHARGED
178 ALERT178 BATTERY OVERCHARGED
179 FAIL 179 UNABLE TO LEARN MATRIX
188 INTERRUPT SERVICE INTERRUPTED
192 READY CELL MISMATCH CORRECTED
195 READY CAP. IMPROVED TO TARGET

Cadex C7000 Series Battery Analyzers 135

 Code Global Message Detailed Message
200 POWER ON POWER ON
201 ADAPT IN ADAPTER INSERTED
202 ADAPT OUT ADAPTER REMOVED
203 (none) PASSWORD ENTERED
204 (none) INVALID PASSWORD ENTERED
205 (none) SECURITY ENABLED
206 (none) ADAPTER SETUP UPDATED
207 SYST-TEMP SYSTEM TEMP. HIGH: COOLING
208 FAIL 208 ADAPTER NOT SETUP
209 INV ADAPT ADAPTER DATA INVALID
210 BAD ADAPT BAD ADAPTER
211 NULL CODE NULL C-CODE IN ADAPTER
250 (none) (none – battery being processed)

136 Cadex Electronics Inc.

By Detailed Message
Detailed Message CODE Reasons Solutions
ADAPTER DATA 209 Invalid value in selected C- Delete and re-enter the
INVALID code. C-code, reset the
extended C-code to
The C-code is not
default values.
compatible with the
firmware. Contact Cadex to
upgrade firmware.
There may be a defect with
the adapter memory

ADAPTER 201 Adapter is detected on a If the message persists,

INSERTED station. This message Press Esc.
appears momentarily.
ADAPTER NOT 208 Adapter is not programmed Delete and re-enter the
SET UP with a C-code, or the C- C-code. Contact Cadex to
code is invalid. upgrade firmware.
ADAPTER 202 Adapter is removed from a If message persists,
REMOVED station. press ESC.
ADAPTER SETUP 206 Cadex BatteryShop has If message persists,
UPDATED updated c-code in the press ESC.
battery adapter.
BAD ADAPTER 210 The analyzer does not Remove and re-insert the
recognize adapter. adapter.
Delete and reenter the C-
code.
Clean the adapter
contacts.
Contact Cadex to
upgrade firmware.
If message persists,
replace adapter.

Cadex C7000 Series Battery Analyzers 137

 Detailed Message CODE Reasons Solutions
BAD FUSE OR 160 The analyzer is not able to Clean the battery and
DRIVER supply current to the battery adapter contacts.
through its current drivers.
Verify that mAh rating of
Very low values of current
the battery matches the
(about 0 mA) are displayed
C-code.
on the analyzer and after 10
seconds processing stops. Lower the Charge rate
and the Trickle Charge
rate in the C-code.
Use I/S settings (see
Intrinsically Safe
Batteries, page 57) if the
battery is intrinsically
safe.
The battery may be
faulty. Try a different
battery in the same
station.
Single Cell NiCd or NiMH
batteries may produce
this error on the
C7400ER. Service single
cells on the C7200 or
C7400.
Check the fuses on the
analyzer. If all fails,
contact Cadex for service.
BATSHOP MODE 34 Battery is detected on an If service has been
WAIT analyzer connected to started and this message
Cadex BatteryShop™. remains, verify the C-
Waiting for user to start code in Cadex
battery service in Cadex BatteryShopTM to ensure
BatteryShop. that settings are correct
for the battery.
BATTERY 20 The Cadex 7200 detects a If message persists,
INSERTED battery in an adapter. press ESC.

138 Cadex Electronics Inc.

 Detailed Message CODE Reasons Solutions
BATTERY OVER 14 Battery has overheated Reduce the Charge rate
TEMP during charge. Station goes in the C-code.
to Resting 00:00 (code 19)
If using a non-OEM
until the battery cools.
battery, the battery
thermistor may be
incorrect for the adapter.
Contact Cadex to
upgrade the adapter for
your particular battery.
BATTERY 178 Current program Discharge the battery for
OVERCHARGED completed; battery SoC 10 minutes and then
(State of Charge) is too charge again.
high.
Verify that correct
contacts are used.
Battery may have a high
internal resistance. Verify
with OhmTest and
discard the battery.
HOT BATTERY 159 Battery temperature has Verify that the mAh rating
ON TRICKLE exceeded its maximum of the battery matches
CHARGE setting after service has the C-code mAh setting.
ended and battery was on
Reduce the Charge rate
trickle charge. The trickle
in the C-code. Reduce
charge stops.
the trickle-charge rate or
the maximum standby
voltage in the extended
C-code.
Lower the room
temperature.
BATTERY 17 Battery was removed when This message appears
REMOVED the program completed. briefly when the battery is
removed. If message
persists, press ESC.
BATTERY 26 A five-second delay after If message persists,
REMOVED the battery is removed press ESC.
when the program
completed.

Cadex C7000 Series Battery Analyzers 139

 Detailed Message CODE Reasons Solutions
BATTERY 121 Battery voltage too low Battery may be
REVERSED (less than 0.30V/cell) on connected backwards in
insertion. the adapter. Ensure that
battery leads are firmly
connected to the battery.
Apply a Boost.
BATTERY 122 Battery is not accepting Ensure battery leads are
SHORTED charge in the initial charge firmly connected to the
cycle (the voltage remains battery.
low).
Battery may be fully
discharged. Recharge
battery in its original
charger before placing it
in the analyzer, or run
Boost, (see Boost,
page 36).
Battery may have shorted
cells - if unable to charge
in the original charger,
discard battery.
BATTERY 176 Battery SoC (State of If OhmTest is running, the
OVERCHARGED Charge) is too high for program is aborted.
QuickTest or OhmTest Discharge the battery
before running OhmTest
The battery is discharged
again.
for five minutes, after which
QuickTest restarts. Turn off the automatic
Discharge is repeated up to OhmTest. If error
5 times until SoC is below continues, battery cannot
90%. be run on QuickTest or
OhmTest.

140 Cadex Electronics Inc.

 Detailed Message CODE Reasons Solutions
BATTERY 175 Battery SoC (State of If OhmTest is running, the
UNDERCHARGED Charge) is too low for program is aborted.
QuickTest or OhmTest Partially charge the
battery before running
The battery is charged for
OhmTest again.
five minutes, after which
QuickTest restarts. Charge
is repeated up to 5 times
until SoC is above 20%.

BATTERY TOO 12 Battery temperature is too Allow the battery to warm

COLD cold when inserted. The up.
battery is trickle charged
If the battery is non-OEM,
until temperature rises
the thermistor may not
above 5°C
match that on the
adapter.
BATTERY TOO 13 Battery temperature is too Allow the battery to cool
HOT hot when inserted. The or use the analyzer in a
battery automatically starts cooler room.
processing when
If the battery is non-OEM,
temperature drops 5°C
the thermistor may not
below maximum value set
match that on the
in the C-code Temperature
adapter.
Sensing.
BATTERY 177 Current program Run the Charge program
UNDERCHARGED completed; battery SoC on the battery.
(State of Charge) low.
CALIBRATION 170 Current cannot pass A minimum AWG 10
FAULT through shorted terminal (2.5 mm) wire is
during calibration. recommended to short
contacts/leads.
The wires may have
disconnected during the
calibration process.
Repeat calibration
procedure.

Cadex C7000 Series Battery Analyzers 141

 Detailed Message CODE Reasons Solutions
CAP. IMPROVED 195 Target capacity is achieved See code 115, Target
TO TARGET or exceeded after an initial capacity not met.
warning
C-CODE NOT 214 C-code is not suitable or is The C-code may have
USABLE out of range for the been created on an
analyzer. “Extended Range” (ER)
analyzer or an analyzer
with more recent firmware
version.
Verify required battery
parameters and edit or
re-enter the C-code.
Update the firmware on
your analyzer to the most
recent version if
necessary (see
Upgrading the
Firmware, page 120).
CELL MISMATCH 112 For NiCd or NiMH batteries Wait until processing is
only. Cells are reaching full complete because the
charge at different times so Auto and Prime programs
the negative slope is not will attempt to correct this
well defined. The program warning through several
proceeds to the next cycle. more charge and
discharge cycles. If
corrected, code 192 (Cell
mismatch corrected)
appears.
Reduce the negative
slope in extended C-code
to 8mV/cell.
Battery is old or has been
in storage. Operating time
may be reduced. Either
monitor battery use or
discard the battery.
If the battery is new, use
the Prime program.

142 Cadex Electronics Inc.

 Detailed Message CODE Reasons Solutions
CELL MISMATCH 192 Cell mismatch (code 112) is Use the battery as
CORRECTED corrected through several normal.
charge/discharge cycles.
HOT 158 Midway during charge the See code 154, Charge
BATTERY/HEAT temperature went above complete temp rise.
TERMINATION the maximum set in the C- Reduce charge rate if
code. Program resumed problem persists (see
when battery cooled by page 47).
5°C. A WAIT code may
appear for the battery to
cool before the next
process begins.
CHARGE 164 Current driver cannot See code 160, Bad fuses
CURRENT LOW provide the requested or driver.
charge current
CHARGE CYCLE 30 Charge cycle completed. Program is going to the
COMPLETE next step.
CHARGE 144 Charge time has exceeded Verify that the mAh rating
TIMEOUT the expected value for the of the battery matches
battery. the C-code mAh setting.
Analyzer may not have
detected the end of
charge conditions.
Reduce the negative
slope to 8mV/cell for
NiCd and NiMH. Raise
the End of Charge
settings for Li-ion or SLA.
CHARGE WAIT 9 Station is on hold until This is normal if large
sufficient power is batteries are being
available. serviced. Service
resumes automatically
when sufficient power is
available to the station.
CHARGING 2 Battery is being charged
normally.

Cadex C7000 Series Battery Analyzers 143

 Detailed Message CODE Reasons Solutions
RAPID HEAT RISE 154 Midway during charge the Wait until processing is
temperature rose too complete. Lower the
rapidly (more than 2°C in 2 charge rate in the
minutes). Program stops extended C-code.
until battery is cooled by Observe battery
5°C and then resumes. A performance. The battery
WAIT code may appear for may be old.
the battery to cool before
the next process begins.
CURRENT RISE 130 Generally for SLA and Li Raise the End of Charge
AT FULL CHARGE only. Battery current settings.
suddenly increased as the
If the SLA battery is a
end-of-charge condition
Hawker cell, use the
was achieved.
Hawker C-code settings
(see page 58). Allow the
station to complete
service.
CYCLE RESUMED 32 Power resumed or the
battery is re-inserted into
the adapter.
DCHG CYCLE 31 Discharge cycle completed. Program is going to the
COMPLETE next step.
DISCHARGE 162 The analyzer cannot (See code 160, Bad fuses
CURRENT LOW discharge the battery. Very or driver).
low values of current (<
50mA) are displayed on the
analyzer before this code
appears
DISCHARGE 142 Battery capacity has Verify that the mAh rating
TIMEOUT exceeded 250% of the of the battery matches
rated capacity. the C-code mAh setting.
Raise the discharge rate
in the extended C-code.
DISCHARGE WAIT 6 Station is on hold until Wait until other stations
sufficient power is have completed battery
available. service.

144 Cadex Electronics Inc.

 Detailed Message CODE Reasons Solutions
DISCHARGING 7 Battery is being discharged Program will continue
normally. when cycle has
completed.
HIGH CELL 135 Battery resistance has Program is complete (see
RESISTANCE exceeded the OhmTest To edit the OhmTest
setpoint threshold Setpoint, page 34).
HIGH CELL 136 The battery resistance has Program is complete (see
RESISTANCE exceeded the OhmTest To edit the OhmTest
setpoint threshold – this Setpoint, page 34).
message is for
BatteryShopTM
HOT BATTERY, 156 Battery temperature went to Reduce the Charge rate
LOW VOLTAGE its maximum setting in the in the C-code. Allow
initial charge cycle. Service battery to cool before
terminates. servicing the battery
again.
The internal cells may
have shorted or the
battery is old. Either
monitor battery use or
discard.
INSERT THE 8 Insert battery in the battery
BATTERY adapter.

Cadex C7000 Series Battery Analyzers 145

 Detailed Message CODE Reasons Solutions
INTERMITTENT 129 Battery connection opened Check and clean the
BATTERY five times in one minute. battery contacts. Verify
that correct contacts are
used. Verify that the
battery is properly
inserted. Verify that the
C-code is correct for the
battery.
Reduce the charge rate in
extended C-code.
Increase end-of-
discharge voltage.
For intrinsically safe
batteries, use I/S settings
(see (Intrinsically Safe
Batteries, page 57).
INTERNAL (NONE) Display Buffer is full Machine will reset in a
ERROR few minutes a resume
service. If message
persists, press the Esc
key for a few minutes, the
machine will reboot and
resume service.
This may occur if
QuickTestTM (a processing
intensive program) is
used. Start QuickTestTM in
each station after 10
seconds.

146 Cadex Electronics Inc.

 Detailed Message CODE Reasons Solutions
INVALID 204 (Code 204) An incorrect Enter the correct
PASSWORD password has been password.
ENTERED entered.
If message persists or if
no password should be
required, replace backup
battery (see Replacing
the Backup Battery,
page 115).
If correct password is
unknown, contact Cadex
with unit serial number.
LOW VOLTAGE 126 A negative slope was Reduce the charge rate in
AT NEG. SLOPE detected when the battery the Extended C-code. If
voltage was low. I.e. The battery is a high capacity
battery acted as if it was NiCd, reduce the charge
fully charged even though it rate to 0.5C.
was empty.
Prime the battery.
The battery’s high
impedance may be
causing this failure so use
the Intrinsically Safe C-
code.
If all fails, discard the
battery.
RAPID HEAT RISE 152 On initial charge, the Use ExtPrime program if
battery temperature is rising the battery has been in
too rapidly (2°C in 1 minute) storage
For safety, charging is
Reduce the charge rate in
terminated.
the extended C-code.
The battery may be old or
have shorted cells.
Discard the battery.
LOW VOLTAGE 123 Battery voltage remains low See code 122, Battery
(TIMEOUT 1) (less than 0.80V/cell) after shorted.
approximately one minute
into the charge cycle

Cadex C7000 Series Battery Analyzers 147

 Detailed Message CODE Reasons Solutions
LOW VOLTAGE 124 Battery voltage remains low See code 122, Battery
(TIMEOUT 2) (less than 0.80V/cell) after shorted.
approximately ten minutes
into the charge cycle
LOW VOLTAGE 127 Charge terminated. Correct Verify C-code settings
(TIMEOUT 3) voltage could not be and battery rating.
obtained in allotted time Replace battery if low
due to high battery capacity voltage remains.
for set charge current,
incorrect voltage setting, or
shorted cells.
N/A mΩ (No OhmTest has not been Battery readings are
code) performed, so no resistance above the readable
reading is available. values for the analyzer.
NO ADAPTER 1 No battery adapter is Check contacts. Clean
inserted, or the inserted with a lint-free cotton
adapter is not detected. swab dipped in 100%
isopropyl alcohol.
NO BATTERY 10 No battery is inserted, or Check contacts. Turn on
the inserted battery is not battery switch if
detected. applicable. Check for
correct battery for the
adapter and adapter
contacts. Clean all
contacts. Run Boost, (see
Boost, page 36).
NO NEGATIVE 125 A plateau was detected Increase the charge rate
SLOPE ON when the battery voltage in the C-code. If the
TIMEOUT 1 was low. I.e. The battery battery was in storage,
acted as if it was fully use Ext. Prime. If all fails,
charged even though it discard the battery.
isn’t.
NULL C-CODE IN 211 An empty C-code is Select a programmed C-
ADAPTER selected. code or program the
selected empty C-code.

148 Cadex Electronics Inc.

 Detailed Message CODE Reasons Solutions
OVER VOLTAGE 120 Battery voltage is too high. Verify the C-code voltage
setting, (see Battery
Voltage (Volts), page
45).
If the battery is new,
charge it for a few
minutes in the original
charger.
Li-ion safety circuits may
be activated. Discharge
the battery in its original
equipment for a few
minutes. For SLA
batteries, check the
electrolyte.
If all fails, discard the
battery.
PASSWORD 203 System password has been Password is required for
ENTERED entered and activated. some actions, depending
on security level selected,
(see Security, page 75).
PLATEAU 113 Battery was fully charged The end-of-charge setting
TIMEOUT before full-charge in the C-code may have
conditions were met. For to be increased. Battery
SLA and Li batteries only. may be old and operating
time less than
manufacturer’s
specifications.
POWER ON 200 Power is detected inside
the analyzer.
PROCESS 15, 35, Current battery-service
COMPLETE 36 program is complete.
PROCESS 18 Battery is removed during Re-insert battery within 5
SUSPENDED service. seconds to resume
service. If message
persists, see Code 188
for further information.

Cadex C7000 Series Battery Analyzers 149

 Detailed Message CODE Reasons Solutions
SERVICE 188 Battery is removed during If the battery was not
INTERRUPTED service for more than five removed the battery
seconds. Program protection circuit or
terminated. thermistor may have
activated disconnecting
the terminals. The
analyzer then thinks that
the battery has been
removed.
If the battery is hot,
reduce heating by
lowering the Charge and
Discharge. For Li-ion
batteries, reduce the Max
Charge voltage or the
Max Standby Voltage.
PROCESS 25 (Code 25) Battery service is This message appears
RESUMING continuing after a power after the initial startup
interruption. screen and remains until
the analyzer determines
the point at which battery
service was interrupted
and resumes the current
program from that point.
CUSTOM 16 (Code 16) The custom See the detailed display
PROGRAM HAS program has produced an for the exact nature of
FAILED – error. The Next statement is battery failure.
DISPLAY WILL not processed. The
If Code 16 is displayed,
SHOW REASON program has been
then there is a bug in the
FOR FAILURE terminated.
custom program - verify
the custom program
statements.
READY 5 Service has completed and Faults or warnings (if any)
battery is ready. Final were corrected. Remove
capacity or state of health is battery and use as
displayed. normal.

150 Cadex Electronics Inc.

 Detailed Message CODE Reasons Solutions
RECONDITION 146 Recondition time has Verify the mAh settings
TIMEOUT exceeded the expected on the C-code.
value for the battery.
Raise the recondition
Program goes to the next
discharge rate, (see
cycle.
Recondition Discharge
Rate, page 49).
The battery may be
intrinsically safe,
preventing deep
discharge. Use I/S
settings for the battery,
(see Intrinsically Safe
Batteries, page 57)
If battery is new or has
been in storage, use the
Prime program.
Cells may be
mismatched, run the
Prime program.
Monitor the battery use.
RECONDITIONING 4 Battery is being The program will proceed
reconditioned. to the next step when
recondition has
completed.
RESISTANCE 27 A manually selected or Program completes in
TEST programmed resistance test 5 seconds.
for the battery is in
progress.
RESISTANCE 28 An automatic resistance Program completes in 5
TEST test in a factory program seconds and will continue
(Prime, QuickTestTM or to the next step of the
Auto) is in progress. program.
RESTING 19 Station is in a rest period, The program will proceed
as specified in the custom to the next step when
program. resting period is
complete.

Cadex C7000 Series Battery Analyzers 151

 Detailed Message CODE Reasons Solutions
RESTING 21 Station is in an automatic This message appears
rest period specified in the for NiMH batteries only.
charge program for NiMH The program will proceed
batteries when temperature to the next step when
sensing in the C-code is not resting is complete.
enabled.
SECURITY 205 System security has been Password required for
ENABLED activated. some actions, depending
on security level selected.
SETTING UP 22 Station is preparing for a If message persists,
CALIBRATION calibration process. remove the adapter.
Turn off the analyzer.
SMART ADAPTER 171 The analyzer has old Contact Cadex to obtain
FAULT firmware incompatible with a firmware upgrade.
the adapter.
SMART BATTERY 172 The analyzer has old Contact Cadex to obtain
FAULT firmware incompatible with a firmware upgrade.
the adapter.
UNABLE TO 128 Battery voltage is too high: Battery may be a high
CLAMP CHARGE NiCd and NiMH - more than capacity type battery.
VOLTAGE 1.8V/cell Reduce the charge rate.
SLA – more than Battery may be
2.75V/cell. overcharged. Discharge
the battery for 10
Li-ion – more than 4.5V/cell
minutes, then charge
Processing has ended. again.
Battery is new. Use the
Prime program to prepare
the battery for use.
Raise End of Charge
(SLA and Li-ion) to
0.10C.
Check that correct
contacts are used.

152 Cadex Electronics Inc.

 Detailed Message CODE Reasons Solutions
CHARGE 118 Battery voltage exceeds Wait until processing is
CURRENT maximum limit (1.8V/cell for complete. If voltage rises
REDUCED NiMH and NiMH, 2.75V/cell again, code 128 (Soft
for SLA). Analyzer will battery) appears and the
attempt to complete service program ends.
by reducing current rate to
Reduce the charge rate in
half.
the extended C-code.
If the battery is new or
has been in storage, use
the Prime program.
START BATTERY 11 Battery service has started. If message persists,
PROCESS press Esc.
STATION 23, 29 Station is being calibrated. This process takes 10 –
CALIBRATING 20 seconds, wait until it
completes
STATION OFF 0 Station is not reading the Remove the adapter and
LINE adapter. restart the analyzer.
Make sure all your
analyzers have the same
firmware version number.
Delete the C-code that
was selected for the
battery.
Reset the system, (see
Resetting the System,
page 120).
SYSTEM TEMP. 207 Service on all stations are Service will resume in a
HIGH: COOLING temporarily suspended due few minutes, after the
to high temperature inside board has cooled down. If
the analyzer. it reoccurs continually,
move the analyzer to a
cooler room.
The firmware chip in the
analyzer may be loose.
Contact Cadex for
instructions to reinsert
firmware.

Cadex C7000 Series Battery Analyzers 153

 Detailed Message CODE Reasons Solutions
TARGET 115 Battery capacity is below Wait until service is
CAPACITY NOT the target capacity. The complete. The Auto and
MET analyzer attempts to Prime programs will try to
improve the capacity by correct this warning. If
reconditioning the battery. corrected, Code 195
appears. If not corrected,
Code 116 appears. See
Code 195 and 116 for
further information.
TARGET 116 Final capacity of the battery Confirm that the battery
CAPACITY NOT is below the target capacity. rating matches the C-
MET Attempts to improve battery code mAh setting.
capacity did not succeed in
Battery is old and has
bringing capacity above
less operating time than
target.
manufacturer’s
specification.
THERMISTOR 150 The battery temperature Clean the contacts on the
FAILURE reading is invalid. battery.
Thermistors on non-OEM
batteries may not be the
same as that used on
OEM batteries. Contact
Cadex to upgrade the
adapter for your particular
battery. If the battery is
NiCd or NiMH, turn off the
temperature sensing.
If the battery is known to
be good or the adapter
has two contacts (in
these adapters, the
negative contact is a
thermistor), the battery
thermistor is defective,
contact Cadex.

154 Cadex Electronics Inc.

 Detailed Message CODE Reasons Solutions
TRICKLE 3 The program is running a
CHARGE trickle charge.
The reconditioning process
is complete, and the battery
is being recharged.
UNABLE TO 179 A matrix cannot be created Use another battery to
LEARN MATRIX because: battery capacity is run Q-Learn or Learn.
less than 50%, the
OhmTest reading does not
produce a result or the
battery cannot handle
1.00C charge or discharge
rate required by Learn
USER 33 The time programmed in a The program goes to the
PROGRAMMED custom program has next step.
TIMEOUT completed.

Cadex C7000 Series Battery Analyzers 155

 Appendix B
Charge Algorithms

The C7000 series battery analyzer uses two different algorithms to charge a battery: a
constant current (CC) method for NiCd and NIMH batteries and a constant
current/constant voltage (CC/CV) method for Li-ion and SLA batteries.

NiCd and NIMH batteries

The C7x00 analyzer uses a Constant Current algorithm to charge NiCd and NiMH
batteries. A current and voltage plot is shown for a typical NiCd battery serviced on the
analyzer using default values. This plot is similar to a NiMH battery.

156 Cadex Electronics Inc.

A battery that is fully discharged is about 1.00V/cell. During charge, the analyzer applies a
constant current. As the battery gets charged, the voltage rises. Charge is terminated
depending on how the NiCd and NiMH Optimization have been set (see Setting the
Optimization, page 81).

If NiCd and NiMH Optimization have been set to Capacity, the battery is terminated when
a negative slope (a gradual voltage drop indicating that the battery is fully charged) is
encountered. If there is a voltage plateau or temperature rise more than dT/dt, the current
is reduced by half and the charge continues till the battery reaches full charge. For NiMH
batteries, the current is often reduced by half twice.

If NiCd and NiMH Optimization have been set to Time (this is the default setting), the
temperature will be monitored and charge will terminate when the battery reaches either
the negative slope, dT/dt or maximum battery temperature.

This table summarizes the charge methods:

NiCd and NiMH dT/dt Negative Slope Max Temperature

Optimization (dV/dt)

Capacity Current is reduced Charge is complete Current is reduced

Time Charge is completed Charge is completed Charge is completed

Cadex C7000 Series Battery Analyzers 157

 SLA and Li-ion batteries

The C7x00 analyzer uses a Constant Current/Constant Voltage Charge algorithm to

charge SLA and Li-ion batteries. A current and voltage plot is shown for a typical Li-ion
battery serviced on the analyzer with default C-Code settings. This plot is similar for the
SLA battery.

There are three stages during the charge:

Stage 1: the battery is charged at a constant current (this current is the ‘Charge Rate’ in
the Extended C-Code) until the battery reaches the Maximum Charge Voltage (set in the
Extended C-Code) is reached.

Stage 2: When the battery reaches Maximum Battery Voltage, the analyzer switches to
constant voltage. During this stage, current is reduced to maintain Maximum Charge
Voltage until the End of Charge current (set in the C-Code) is reached.

158 Cadex Electronics Inc.

If SLA and Li Optimization are set to Capacity (see Saving Program and Target
Capacity Settings, page 80), the charge time is extended for approximately 20 minutes
after End of Charge has been reached. This additional charging period may add 4% to 6%
capacity; however, you may find that the increase in capacity is not worth the additional
time.

If SLA and Li Optimization are been set to Time (this is the recommended setting), charge
will terminate as soon as End of Charge has been reached.

In both cases of Optimization settings, exceeding dT/dt will fail a battery.

Stage 3: After the charge has completed, the battery is maintained at a constant voltage
level (this is voltage is the Maximum Standby Voltage set in the C-Code).

This table summarizes the charge methods:

SLA and Li dT/dt End of Charge Max Temperature

Optimization

Capacity Fail 152 or Approximately extra Charge continues after

Fail 158 ~20 minutes charge temperature drops 5ºC
time added below max threshold

Time Fail 152 or Charge completes as Charge continues after

Fail 158 soon as end of Charge temperature drops 5ºC
is reached. below max threshold

Cadex C7000 Series Battery Analyzers 159

 Appendix C
Specifications

Hardware
Battery Analyzers C7200 C7400 C7400ER
Part Numbers 07-720-0000 07-740-0000 07-740-1000
Independent 2 4 4
stations
Battery voltage 1.2-15V 1.2-15V Li-ion and SLA 1.2-36V
NiCd and NiMH: 1.2 – 28.8V
Charge/discharge 100mA-4A 100mA-4A 100mA-4A*
current
Accuracy +/- 1% at max rated voltage, +/- 2% at 4000mA
Services batteries up to 24Ah. If set above 4A*, the current
automatically scales down.
Maximum charge 40W per station; 55W per station; 75W per station; 170W total
power 40W total 80W total
Maximum 35W per station; 35W per station; 50W per station; 200W total
discharge power 70W total 140W total
Power On high load demands, the current scales down; large batteries may
management go on waiting queue
Line voltages 100-240VAC, 50- 100-240VAC, 50- 100-120/200-240VAC,50-
60Hz; 1.5A max 60Hz, 1.75A max 60Hz; 4A max
Chemistries Lithium-ion, nickel-metal-hydride, nickel-cadmium; lead-acid
Charge method Automatic full charge detection, safe termination under all conditions.
Temperature controlled.
Lithium-ion and lead-acid: constant voltage with current limit. Nickel-
based: constant current with Reverse Load adjustable from 5-12%.
Customized charge methods possible.

160 Cadex Electronics Inc.

Discharge method Constant discharge current to end-of-discharge voltage threshold
Battery Adapters Custom and universal SnapLock™ adapters. Each adapter holds up
to 10 C-codes to service different battery types. Re-programmable
with menu function. Temperature controlled.
Security
Level 0 Open, no programming restrictions (default)
Level 1 Password protected (low); allows C-code selection and display
options
Level 2 Password protected (high); most programming choices are locked
Display 80-character LCD, backlit; each station also features RUN, READY,
FAIL signal lights
Data Ports RS-232 interfaces to PC and label printer, parallel printer port and
USB (future release) on C7400 and C7400ER only. BatteryShop™
supports special printers.
Throughput
QuickTest™ 30-40 batteries/hr 60-80 batteries/hr
Full service Fleet of 80 batteries typical Fleet of 160 batteries typical
Throughput on full service is based on recommended monthly
maintenance. Each analyzer services two battery batches every 24h
(day and night run), 20 days per month.
Physical
Length 12.1”; 312mm 14.4”; 360mm 15.4"; 398mm
Width 9,4”; 240mm 11.0”; 280mm 11.0"; 280mm
Height 3.5”; 90mm 3.8”; 100mm 4.2"; 107mm
Weight 7.1lb.; 3.2 kg 10.05lb.; 4.54kg 12.1lb; 5.5kg
Environmental Operating temperature 41°F to 95 °F; 5°C to 35°C
Storage temperatures –40°F to 167°F; -40°F to 75°C
Firmware Upgradeable with BatteryShopTM, flash memory. Lifetime upgrade
subscription available.
Approvals Tested and approved by ITS and TUV to comply with
CSA/UL/CE/PSE standards. (PSE not available on C7400ER)
Warranty Cadex warrants the analyzer against defective materials and
workmanship for a period of three (3) years from the original
purchase date.
* A 6A charge/discharge current can be used with specialized / customer adapters.

Cadex C7000 Series Battery Analyzers 161

 Appendix D
Parts and Accessories

Part Cadex Part Number (P/N)

Cadex Battery adapters Visit www.cadex.com for the latest list of
battery adapters available.
Smart Cable (universal battery adapter) 07-110-0115
DYMO SE300 Label printer 00-004-3013
DYMO Battery labels, 1500/roll 00-004-3031
Battery labels for dot-matrix printers (Epson 88-110-0010
FX-850-compatible) 1.625" x 0.438", 5000/pack
SP-2 serial/parallel converter cable 04-880-0031
Voltage-calibration kit (with instructions and 92-770-0210
calibration adapters)
Power cord, 6' 68-723-1804
Cadex User’s manual 89-307-1013
C7200 & C7400 Primary Fuse T2.0A 250 V 52-546-0200
C7400ER Primary Fuse T5.0A 250V 52-546-0500
Lithium coin cell backup battery 45-206-0001
Cadex BatteryShop (battery-management Contact Cadex Electronics Inc. or your
software for Windows) authorized Cadex dealer for more
information about Cadex software products.
Book: Batteries in a Portable World, 2nd edition Contact Cadex Electronics Inc. or visit our
Web site (www.cadex.com).

162 Cadex Electronics Inc.

Index

adapters, battery, 14, 162 replacing, 115, 119

16 kilobit, 25, 38, 40, 129 bar code labels, 87
calibrating, 123 basic programs, 22. See also programs
copying, 63 Auto, 22, 23
inserting, 15, 17 Charge, 22, 24
removing, 16 Prime, 23, 25
setup report, 85 Quicktest, 23, 25
Smart Cable, 15, 43, 47, 124 batteries
adapters, custom. See adapters, battery basic service, 17
adapters, voltage calibration displaying number serviced, 70
servicing, 123 Gell SLA, 58
advanced programs. See also programs Hawker SLA, 47, 58, 144
Boost, 28, 36 inserting, 16, 18
custom, 28, 41 intrinsically safe, 47, 57, 128, 151
Discharge Only, 27, 31 removing, 16
editing, 29, 34, 35 service programs, 22
Extended Prime, 27, 32 service time, 42
Learn, 28, 38, 40 servicing, 17
Life Cycle Test, 27, 30 smart, 6, 32, 52
OhmTest, 27, 33 voltage, 45
RunTime, 28, 34 Batteries in a Portable World, 130, 162
Self-Discharge Test, 27, 29 battery adapters, 14, 162
Auto program, 22, 23 16 kilobit, 25, 38, 40, 129
automatic OhmTest, 79, 140, 141 calibrating, 123
Auto-Print, 88 copying, 63
backup battery, 162 inserting, 15, 17

Cadex C7000 Series Battery Analyzer 163

 removing, 16 target, 6, 45, 81, 111, 142, 154
setup report, 85 C-Code parameters, basic, 44
Smart Cable, 15, 43, 47, 124 battery capacity, 46
battery capacity, 46 battery rating, 46
battery chemistries, 45 battery voltage, 45
battery configuration, 43 chemistry, 45
battery labels, 86, 162 mAh, 46
battery rating, 46 program, 44
battery service counter, 69 target capacity, 45
disabling, 69 type, 45
restarting, 69 volts, 45
setting, 69 C-Code parameters, extended, 47
battery service report, 85, 87 capacity offset, 49
battery startup setting, 78 charge rate, 47
battery, backup, 162 C-Rate, 47
replacing, 115, 119 discharge rate, 48
Boost. See Boost program end of charge, 54
Boost program, 28, 36, 140, 148 end of discharge, 51
editing, 37 negative slope, 51
running, 36 recondition discharge rate, 49
Buchmann, Isidor, 130 temperature sensing, 50
Cadex Batteryshop, 41, 85, 120, 137, trickle-charge rate, 49
138, 162 C-Codes, 15, 43
connecting to, 72 copying, 63
Cadex Firmware Utility, 120 creating, 59
calibrating deleting, 62
battery adapters, 123 displaying, 19, 59
stations, 123 editing, 59, 61
voltage, 122 managing, 58
calibration, 122 naming, 46
calibration adapters resetting extended parameters, 62
servicing, 123 selecting, 19, 58
calibration kit, 162 setting active, 58
capacity setup name, 46
battery, 46 changing
offset, 49 password, 77

164 Cadex Electronics Inc.

 target capacity, 59 data log, 95
charge setting up, 99
end of, 54 default settings
optimizing, 80 extended C-Codes, 57, 58
rate, 47 deleting
trickle, 6, 49 C-Codes, 62
Charge program, 22, 24 detailed display, 11
chemistry, battery, 45 devices
cleaning analyzer, 121 output, 70, 74
clearing event log, 94 discharge
components, 8, 9 end of, 51
computer, connecting to, 70, 72 rate, 48
confidence grade, 26, 97 recondition, 49
configurations, serial cable pin, 73, 74 self, 6
connecting Discharge Only program, 27, 31
to Cadex Batteryshop, 72 editing, 32
to computer, 70, 72 display, 132
to label printer, 70, 72, 74 detailed, 11
to printer, 70, 74 global, 10
copying lights (LEDs), 12
battery adapters, 63 displaying
C-Codes, 63 C-Codes, 19, 59
Quicktest matrices, 63 event log, 94
counter, battery service. See battery firmware version, 120
service counter number of batteries serviced, 70
C-Rate (C), 47 done phase, 109
creating editing
C-Codes, 59 Boost program, 37
custom programs, 109 C-Codes, 59, 61
custom adapters. See battery adapters custom programs, 109
custom programs, 28, 41, 104 Discharge Only program, 32
creating, 109 Life Cycle Test program, 31
editing, 109 OhmTest program, 34
phases, 105, 107, 109 RunTime program, 35
cycle 1, 105 Self-Discharge Test program, 29
cycle 2, 105 target capacity, 59

Cadex C7000 Series Battery Analyzers 165

 ELSE statements, 108 connecting to, 70, 72, 74
end of charge, 54 labels
end of discharge, 51 bar code, 87
event log, 92 battery, 86, 162
clearing, 94 printing, 89
displaying, 94 Learn program, 28, 38, 40
events, 92 LEDs, 12
printing, 94 Life Cycle Test program, 27, 30, 120
extended C-Codes editing, 31
default settings, 57, 58 lights (LEDs), 12
Extended Prime program, 27, 32 log
FALSE statements, 108 data. See data log
firmware event. See event log
displaying version, 120 managing
upgrading, 120 C-Codes, 58
function (Fn) keys, 8, 62, 63, 64, 70, matrix, Quicktest, 58
120, 123 copying, 63
fuse menu, 13
primary (input), 162 messages, 96, 132
replacing, 114 modifying. See also editing
Gell SLA batteries, 58 name, C-Code, 46
global display, 10 negative slope, 51
Hawker SLA batteries, 47, 58, 144 NULL code, 18, 136
IF statements, 107 offset, capacity, 49
input fuse, 162 OhmTest program, 27, 33, 120, 123,
replacing, 114 140, 141
inserting editing, 34
batteries, 16, 18 OhmTest, automatic, 79, 140, 141
battery adapters, 15, 17 optimizing charge, 80
internal resistance. See resistance output devices, 70, 74
intrinsically safe batteries, 47, 57, 128, parallel port settings, 74
151 parameters, basic C-Code. See C-Code
keys, 8, 9 parameters, basic
function (Fn), 8, 62, 63, 64, 70, 120, parameters, extended C-Code. See
123 C-Code parameters, extended
label printer, 71 parts, 8, 9

166 Cadex Electronics Inc.

passwords Self-Discharge Test, 27, 29, 120
changing, 77 service time, 42
required at security levels, 75 QuickLearn, 38, 40
phases, custom programs Quicktest matrices, 58
cycle 1, 105 copying, 63
cycle 2, 105 Quicktest program, 23, 25, 97, 123, 140,
done, 109 141
test, 107 rate
primary (input) fuse, 162 charge, 47
replacing, 114 discharge, 48
Prime program, 23, 25, 151 recondition discharge, 49
printer, 74 trickle charge, 49
connecting to, 70, 74 rating, battery, 46
label, 71 rebooting system, 120
printing recondition discharge rate, 49
event log, 94 removing
reports and labels, 89 batteries, 16
programs, 44 battery adapters, 16
Auto, 22, 23 security, 76
basic, 22 replacing
battery service, 22 backup battery, 115, 119
Boost, 28, 36, 140, 148 primary (input) fuse, 114
Charge, 22, 24 reports
custom, 28, 41, 104 adapter setup, 85
creating, 109 battery service, 85, 87
editing, 109 printing, 89
phases, 105, 107, 109 system setup, 85
Discharge Only, 27, 31 resetting extended C-Code parameters,
editing specialty, 29, 34, 35 62
Extended Prime, 27, 32 resetting system, 120
Learn, 28, 38, 40 resistance
Life Cycle Test, 27, 30, 120 defined, 6
OhmTest, 27, 33, 120, 123, 140, 141 running
Prime, 23, 25, 151 Boost program, 36
Quicktest, 23, 25, 97, 123, 140, 141 RunTime program, 28, 34, 120
RunTime, 28, 34, 120 editing, 35

Cadex C7000 Series Battery Analyzers 167

 safety system. See system settings
precautions, 36 setup name, C-Code, 46
security, 75 slope, negative, 51
levels, 75 smart batteries, 6, 32, 52
passwords, 75 Smart Cable Adapters, 14, 15, 43, 47,
removing, 76 124
setting level, 76 SOC. See State of Charge
selecting SOH. See State of Health
automatic OhmTest, 79 sounds, 66, 67
C-Codes, 19, 58 SP-2 serial/parallel converter, 162
charge optimization, 80 specialty programs. See advanced
correct voltage, 45 programs
self-discharge, 6 State of Charge, 6, 26, 139, 140, 141
Self-Discharge Test program, 27, 29, State of Health, 6, 26, 97
120 statements
editing, 29 ELSE, 108
serial cable pin configurations, 73, 74 FALSE, 108
serial device settings, 72 IF, 107
serial port settings, 71, 100 THEN, 108
serial/parallel converter, SP-2, 162 TRUE, 108
service counter. See battery service stations, calibrating, 123
counter system
services. See also programs rebooting, 120
servicing resetting, 120
batteries, 17 system security. See security
voltage calibration adapters, 123 system settings, 65
setting automatic OhmTest, 79
active C-Code, 58 battery startup, 78
password, 77 calibration, 122
security level, 76 charge optimization, 80
sound control, 66 sounds, 66, 67
settings voltage, 68
default extended C-Codes, 57, 58 system setup report, 85
parallel port, 74 target capacity, 6, 45, 81, 111, 142, 154
serial device, 72 changing, 59
serial port, 71, 100 technical support, 131

168 Cadex Electronics Inc.

temperature sensing, 50 TRUE statements, 108
terminal, 99 upgrading firmware, 120
test in custom program, 107 user interface, 10
tests version, firmware, 120
automatic OhmTest, 79, 140, 141 viewing. See displaying
Life Cycle, 27, 30, 120 voltage
OhmTest, 27, 33, 120, 123, 140, 141 battery, 45
Quicktest, 23, 25, 123, 140, 141 calibrating, 122
RunTime, 28, 34 calibration adapters
Self-Discharge, 27, 29, 120 servicing, 123
THEN statements, 108 calibration kit, 162
trickle charge, 6 display setting, 68
rate, 49 selecting correct, 45
troubleshooting, 126 warnings, 96, 132

Cadex C7000 Series Battery Analyzers 169