C8000 Battery Testing System

By all imagination, the Cadex C8000 may well be the most complete battery testing system available.

The Cadex C8000 stands in a class by itself in flexibility and affordable price. Test SMBus batteries, monitor cell balance and capture load signatures to observe batteries with a unique load protocol. Add a thermal chamber, an external load bank, a safety circuit and alarm to form a command center and you begin realizing the unique qualities of this fine battery testing system.
  • 4 independent digital drivers for maximum flexibility
  • 1.2V – 36V, 10A charge and discharge per channel
  • 100W per channel on charge; 80W on discharge
Part Number: 11-308-0000

Features

Digital technology widens the test range, provides ultimate stability and gets more power into a compact housing than is possible with analog devices. Each channel can be programmed with up to 10A charge and discharge current each. Power handling is 100W per channel on charge and 80W on discharge, or 400W on charge and 320W on discharge on all four channels.

The Cadex C8000 is more than a programmable power supply and load bank; the instrument has intelligence to assist in safe battery testing. Protected charge and discharge algorithms with redundant safety features identify a faulty battery and safely terminate the service should an anomaly occur. The system can be overridden for destructive tests.

Separate Battery and I/O Ports

Each channel features a Battery Port and I/O Port for individual programming. The system includes:
  • Positive/negative input; 4-wire Kelvin
  • Analog thermistor input
  • 4 differential analog voltage inputs
  • 2 analog outputs
  • 4 input/output control for switching
  • SMBus, clock, data for smart packs
C8000 Ports

LABORATORY SYSTEM

Use the C8000 as command center to control these accessories:
  • Thermal chamber *
  • Digital load bank
  • Heating element
  • Pressure gauge
  • Cell monitoring
  • Safety circuit
  • Alarms **
* See Specifications for listing
** With PC-BatteryLab™ and Custom programs
Building a Laboratory System

Monitoring individual cells

Four differential (floating) analog inputs enable voltage check of up to 5 cells; 4 direct and one by voltage extraction. Monitoring Individual Cells

Load Capture

With the Load Capture Unit, the Cadex C8000 takes load signatures and plays them back as a simulated load protocol to check battery runtime in the lab. Check the battery runtime with different load demands and battery types. The C8000 goes to 10A; an external load bank brings this up to 240A. Building a Laboratory System

external load bank

For higher load currents on discharge, you can connect the C8000 to a designated external load bank, enabling loads of up to 2,400 watts and 48 volts. (Supported on one channel only).

See Specifications for listing
C8000 with External Load Bank

Dual Power Port Cable

The Dual Power Port Cable ties two channels together to double the current from 10A to up to 20A. Applicable on discharge only. C8000 Dual Power Port Cable

Smart Battery testing

The Cadex C8000 reads register settings of SMBus batteries to verify function and identify anomalies.
  • Assists in the design of smart batteries
  • Checks cell voltages to verify proper function
  • Reads Full Charge Capacity (FCC)
Smart Battery Testing

Load TEST

The Cadex C8000 allows testing batteries under GSM, CDMA or other discharge protocols. Programming is in 50μs intervals and the minimum setting is 500μs.

Runtime discharges a battery under three load conditions. You can set time duration and load levels. The cycle repeats itself until the capacity drops to the target setting. PC-BatteryLab™ provides charts and stores the results.
Load Test

LIFECYCLE TEST

The program verifies battery endurance by counting the cycles until the capacity drops to the target capacity. This helps select a battery and do incoming inspections to ensure consistent quality. The program is fully automated; PC-BatteryLab™ displays and stores the test. Lifecycle Test

Service Programs


The automated programs are grouped into Basic, Advanced, Rapid-test and Custom programs.

basic Programs

Charge Applies fast charge; trickle when applicable.
Auto Exercises batteries with charge-discharge-charge. Applies recondition on nickel-based batteries to reverse memory if user-set target capacity cannot be reached.
Prime Prepares batteries with discharge-charge-discharge by repeated cycling until maximum capacity is reached. The first reading is the spare capacity before charge.
Extended Prime 16-hour trickle charge prior to Prime. Prepares difficult to charge batteries
Boost Activates batteries that became deactivated due to low discharge.

Advanced Programs

Load Test Tests batteries under simulated GSM, CDMA and other discharge protocols, 50μs steps; minimum setting 500μs.
Runtime Allows three different discharge levels; programmable in hours and minutes.
Lifecycle Cycles battery until the performance drops the target capacity.
Self-Discharge Measures self-discharge. Identifies stresses leading to compromised safety.
Discharge Only Prepares battery for storage. Also checks charger function.
Load Capture Simulates real life conditions with pre-recorded load. Requires PC-BatteryLab™ and Load Capture Unit to record load signature.

RAPID TESTS

OhmTest™  Measure battery resistance with DC pulses 13 seconds; based on IEC61436.
Impedance  Measures battery resistance with 1000Hz signal. Channel 1 only.
Note: Readings of a reactive device differ with DC and AC test methods.

Custom Programs

These programs allow user-defined settings of charge, discharge, recondition, wait and repeat. You can set conditional gates that proceed on a different course if certain criteria are met. Custom works with PC-BatteryLab™ and has a limit of 100 user-defined programs.
One of the critical applications of the custom program is preparing a battery for shipping. You may also want to prepare a battery for storage.

Note: Supervision recommended in the absence of automated terminations.

Accessories


C8000 Power Port Cables and Auxiliary Cables

Four Power Port Cable and four Auxiliary Cables are included as standard accessories. The Power Port Cable alone can be used for basic tests; the Auxiliary Cable manages sensing voltages and data.

Part Number: 17-670-0059

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C8000 Power and Auxiliary Port Cables

RigidArm™ Universal Adapter

The RigidArm™ simplifies connecting small (e.g. cellular phone) batteries. Spring-loaded arms meet the battery contacts from the top down and lockable mechanism allows quick and repetitive testing. The retractable floor holds the battery in vertical or horizontal position.

Part Number: 07-110-0192

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RigidArm Adapter

Dual Power Port Cables (DPPC)

Allows parallel connection of channels 1 and 2, or 3 and 4. Doubles current from 10A to 20A. Applies only to discharge. One Dual Power Port Cables is included as standard accessory.

Part Number: 17-070-1008

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C8000 Dual Power Port Cable

LOAD CAPTURE UNIT (LCU)

Captures load signatures of up to 100A; digitizes the information and replays the recorded load protocol in the C8000 for simulated battery testing.

Part Number: 11-308-0011

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Load Control Unit

Adapter Unit

The Adapter Unit provides access to SnapLock™ Battery Adapters Accommodates two batteries.
  • Over 3,200 SnapLock™ battery adapters
  • Provides quick and dependable interface
  • Allows the sharing with other Cadex systems
Part Number: 07-510-0000

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C8000 Optional Adapter Unit

Software


No test instrument is complete without good software. PC- BatteryLab™ provides a simple yet powerful interface to control and monitor batteries by shifting the operation from the C8000 to the PC.

BatteryLab™ Software

  • Operates up to eight C8000 testers; 32 batteries
  • Operation shifts from the C8000 to the PC
  • Allows custom program and load capture
  • Readings and graphics displayed in real time
  • Manage and print results

BatteryLab Software

Specs

Standard Components
Each Standard System includes
  • C8000 Test Unit
  • PC-BatteryLab Software (CD-ROM)
  • 4 Power Port Cables
  • 4 Auxiliary Cables
  • 1 Dual Power Port Cable
  • 1 Ethernet Cable
  • 3AC Power Cords (N. America, Europe, UK type)
  • Rack Mounting Bracket Set for 19” 3U Rack
  • 1 QuickStart Guide

Systems and Ports

Input Power 100–240VAC; 50–60Hz; maximum 8A
Channels 4 independent channels, each includes one Battery Port  and one I/O Port
Battery Ports
4 ports in front each including:
  • Battery Positive (+)
  • Battery Negative (–)
  • Sense Positive (+)
  • Sense Negative (–)
  • Thermistor Input
  • Thermistor Ground
Active Data Ports
on back Panel
  • Ethernet 10/100 MB for connection to PC
  • Designated Serial Port for external load
  • Designated Serial Port for environmental chamber
Power Port Cable 4 items, 1.8m (6’) with alligator type clips
Auxiliary Cable 4 items, 1.8m (6’)
Dual Port Power Cable 1 item, 1.8m (6’); connects to channels 1+2 or 3+4; doubles current to 20A
Battery Adapter Unit
(2 bays, optional)
Connects to C8000 to support SnapLock™ battery adapters.
List of SnapLock™ Battery Adapters

Battery and Service

Battery chemistries
  • Lead Acid
  • Ni-based: NiMH, NiCd
  • Li-based: Li-ion, Li-Phosphate
Battery voltage range Nominal 1.2V–36V nominal (max 45V) supports serial connection of:
  • Up to 10 Li-ion cells (3.6V/cell)
  • Up to 18 Lead Acid cells (2.0V/cell)
  • Up to 30 Nickel-based cells (1.2V/cell) – Note: 45V maximum total
Maximum Charge Power 100W per channel; 400W total; power management when exceeding temperature
Maximum Discharge Power 80W per channel; 320W total
160W per channel pair using Dual Power Port cable
Note: External Load may be used to increase discharge up to 2400W
Maximum Charge/Discharge Current 30mA to 10A set in 1mA increments
20A maximum discharge rate using Dual Power Port cable
External Load may be used to increase discharge up to 240A
Output Frequency Square 2kHz (500 microseconds)
Accuracy Voltage 0.1%; current 0.25% full scale
Power Management Current automatically scaled down with message if power limits are exceeded
Charge Methods Lead Acid: Constant voltage with current limit, saturation charge, float charge
Nickel-based: Constant current; negative slope or plateau timer, trickle charge
Li-ion: Constant voltage with current limit, saturation charge, no trickle charge
Discharge Methods Constant current to set discharge voltage threshold
Constant power to set discharge voltage threshold
Basic Programs Charge: Applies fast charge with termination
Auto: Charge-discharge-charge; applies Recondition on nickel-based batteries if user-set target capacity is not met
Prime: Discharge-charge-charge. Reads spare capacity, prepares batteries by cycling until maximum capacity is reached.
Extended Prime: 16h trickle charge prior to Prime. Prepares difficult batteries.
Boost: Activates seemingly dead batteries.
Advanced Programs Load Test: Tests batteries under simulated GSM, CDMA and other discharge protocols, 50μs steps; minimum setting 500μs.
Runtime: Allows three discharge levels, programmable in hours and minutes.
Lifecycle: Cycles battery until set target capacity is reached.
Self-Discharge: Measures self-discharge.
Discharge Only: Prepares battery for shipment and storage.
Load Capture: Captures load signature for replay; requires PC-BatteryLab, LCU
SMBus: Battery info, fuel gauge calibrate, SMB charge,  SMB discharge, FCC
Rapid Test Programs OhmTest™: Measure battery resistance with DC pulses (IEC61436), 13 seconds
Impedance: Measures battery resistance with 1000Hz signal. (Channel 1 only)
Note: Readings of a reactive device differ with DC and AC test methods.
Custom Programs
(requires BatteryLab)
Allows 100 user-defined programs of charge, discharge, waits, repeats, etc.
Note: Supervision recommended in the absence of automated terminations.

Data Acquisition

System Sample Rate 500 microseconds (once per second)
Termination Data Capture Rate 2–200 microseconds (last 500 samples)
Capture/Display Rate 1–0 seconds (non-termination)
Load Capture Minimum sample rate increment 500 microseconds; number of samples 10–500

Certification, Warranty, Physical

Safety CSA, UL, CE
Environmental RoHS, WEEE
Warranty Standard: 2 year limited warranty (materials & workmanship)
Extended Warranty (Optional): Additional 2 years (total of 4 years)
Calibration Recommended factory calibration every 1 year; contact Cadex
Upgrades Firmware upgrades enabled by PC-BatteryLab™ software
Dimensions
Weight
Mounting Option
Display
480mm x 380mm x 140mm (18.9” x 15.0” x 5.5”)
15.5 kg (34 lb)
Desktop or 19” (483mm) 3U Rack-mount (brackets included)
5.7” (145mm) QVGA 320x240 graphics with backlight

External Test Equipment Control

Environmental Chambers Thermotron 2800/3800/8800
Test Equity Watlow 4
External Digital Loads
B&K Precision Programmable
DC Electronic Loads 8500
8510 (0.1V–120V/120A/600W)
8514 (0.1V–120V/240A/1200W)
8518 (0.1V–60V/240A/1200W)
8520 (0.1V–120V/120A/2400W)
Load Capture Cadex Load Capture Unit (LCU)
Security Password protection

PC-BatteryLab™

System Requirements
PC with the following available:
Windows O/S, Ethernet connection, 1.2 GHz processor, 512 MB RAM
10 GB storage memory
License capacity: Up to 8 C8000 test systems;
Up to 32 individual batteries
Specifications subject to change

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