SPECTRO™ BATTERY RAPID-TESTER

DESCRIPTION

Why do Starter Batteries Fail?

Mechanical	A mechanical defect is commonly diagnosed by physical inspection and a voltmeter. Batteries in trucks often fail due to shock and vibration. Plates short and cases crack. Replace the battery.
Heat-fail	Heat promotes corrosion that raises the internal resistance and slows cranking. The resulting drop in CCA can be measured with most automotive battery testers. A heat-fail battery does not die suddenly but gets gradually weaker and should be replaced.
Capacity-fade	Battery capacity drops unnoticed until the vehicle won’t start for lack of energy. Capacity and CCA readings don’t correlate; CCA can remain high while the capacity drops low gone. Start-stop, comfort-heating, and electric doors hasten capacity fade. A capacity of 40% estimates a remaining battery life of 6–12 months. Replace battery if lower.

Definition of a Starter Battery

SoC:	State-of-charge symbolizes the liquid levels as shown on the right.
CCA:	Cold Cranking Amp governs cranking simulated by a few- flowing tap.
Capacity:	Energy storage capability in RC (Reserve capacity) or Ah. Loss is shown as rock buildup.

Capacity is the Leading Health Indicator

To study failure modes, a luxury car maker in Europe tested 175 starter batteries. Mechanical and heat-fail batteries were eliminated before the test. Figure 6 demonstrates the aging trend.

Most batteries pass through the Capacity Line on the left of the green field following the arrow. Very few batteries fail by dropping through the CCA Line.

Figure 3: Capacity and CCA of 175 aging AGM starter batteries.

Most batteries pass through the Capacity Line; few fail because of low CCA. The test batteries were trunk mounted and driven in a moderate climate. Test Method: Capacity and CCA were tested according to DIN and IEC standards by an independent lab in Germany.

Evaluating a starter battery on CCA alone passes a faulty battery as good, only to fail on the road on low capacity. Meanwhile, good batteries are replaced in error based on a CCA threshold of 60–65%. CCA alone cannot predict the end of battery life reliably. CCA tends to stay high while the capacity drops predictably. The Figure 7 observes capacity and CCA of 20 aging batteries.

Figure 4: Comparing CCA and capacity of 20 aging batteries.

CCA of all batteries stays above 65% while the capacity of some batteries falls below 40%. Test Method: CCA was taken with Spectro CA-12; capacity was measured with an Agilent load bank by applying full discharges according to BCI standards.

Test Snapshot

This failure analysis was taken in Europe. Tropical countries have different ratios.

Ratio	Cause	Diagnostics
48%	Capacity-fade	Active mass is worn out.
23%	Low charge	City driving with ancillaries on.
15%	No fault found	EIS adds depth to estimations.
12%	Low CCA	Higher % in worm climates.
1.5%	Mechanical	Shock and vibration.
0.5%	Manufacturing defect	Most faults are user-induced.

Testing is Simple

To test a starter battery, select between flooded or AGM and then enter CCA and capacity ratings in reserve capacity (RC) or ampere hours (Ah). The battery should have a minimal state-of-charge of 50%. The non-invasive test takes 15 seconds; the pass/fail threshold using a generic matrix is set to 40% or other setting specified. (Numeric capacity reading is available with a battery-specific matrix.)

Why EIS?

Long test times and manual evaluation restricted this technology to laboratory use in the past. Multi-model electro-chemical impedance spectroscopy (Spectro™) scans the battery with multiple frequencies and performs complex modeling to obtain capacity and CCA data. Cadex holds a patent on this technology. Battery testers based on AC conductance only see R1 of the Randle’s model in Figure 8; Spectro™ provides capacity by modelling R2 and C with matrices serving as lookup tables.

Figure 5: Randle’s model. R1 reflects resistance (CCA); R2 and C evaluate capacity.

Scientists predict that the future of battery testing lays in EIS. Machine learning promises to expand the test range with high actuary. Cadex realizes the importance of battery diagnostics involving capacity and has been pioneering in EIS technologies since 2004. An analogy of advancement is the x-ray machine invented in 1895. While the X-ray only shows the outlines of a bone; the CAT scan also reveals soft tissues. Spectro™ with EIS provides this added information in a battery to enable accurate state-of-life predictions.

Integrated Solutions

Cloud Connectivity

Cadex Cloud API - Spectro Modular retrieves and uploads data and shows result on the host - Data is stored in secure database hosted on AWS - REST provides automated access - Transport Security – HTTPS Cloud Connectivity - Central storage for battery model data that - AI examines aging effects and predicts Remaining Useful Life (RUL) - Data input and retrieval via REST API.

Pattern Recognition

An EIS scan with the Spectro Modular allows comparing Nyquist plots against a “golden sample” from a known good battery. Deviation in Migration, Charge Transfer and Diffusion reveals unique battery characteristics.

Applications Research Labs: Evaluates cathode and anode materials; compares additives. Manufacturing: Checks batch consistency. Quality Control: Verifies incoming batteries. Environmental: Analyzes performance by temperatures, SoC and storage. Stress Test: Observes capacity loss with abusive conditions; tracks aging. Longevity: Checks cycling-induced wear. Structural Integrity: Detects dendrites, lithium plating and mechanical anomalies. Second Life: Verifies batteries for reuse. Note: The Nyquist plot also examines liquids.

Battery Matrix

Modern battery rapid-testing shares similarities with face recognition in which a camera takes a multi-dimensional image to identify features and characteristics with artificial intelligence (AI) and machine learning. Similarly, battery testing with EIS captures the “landscape” of a battery that leads to state-of-health (SoH) assessments with AI and machine learning. The battery landscape is expressed in a matrix serving as reference tables.

Figure 1. Modern battery testing resembles face recognition.

Creating a matrix involves scanning batteries of diverse SoH and measuring the capacity with charge/discharge cycles. The Data Acquisition Unit (DAU) automates the service.  DAU units are be made available by Cadex on request.
Figure 2. The Nyquist plot reflects battery SoH.

	Creating a matrix involves scanning batteries of diverse SoH and measuring the capacity with charge/discharge cycles. The Data Acquisition Unit (DAU) automates the service.  DAU units are be made available by Cadex on request.
Figure 3. Data Acquisition Unit (DAU) tests and scans batteries.

SPECS

SYSTEM SPECIFICATIONS

Model	Feature	SPECTRO CA-12	SPECTRO MODULAR
Desription	Battery Service Tool designed for Automotive Battery State of Health (SoH) assessment for Warranty and Aftermarket Service Programs. CCA tests alone do not predict end of battery life!	Handheld tester with full keyboard, integrated printer and display make it the in-house or compound workhorse for early battery failure detection @ dealers and workshops looking to make preventative maintenance part of their value addeded solution.	Compact module controlled by an external tablet or phone. Tests can be initiated by an Oem's global diagnostic warranty /after market program Tablet or phone and results relayed to the Cadex and Customer cloud.
Technology	Non-invasive battery diagnostic service tool based on multi-model electrochemical impedance spectroscopy (EIS) .
EIS Scan Freq.	EIS Frequency Scanning range	2048-20 Hz	2,048-16Hz
	EV Application (2023)		2,048-0.2/0.1Hz
Test Time		30 Seconds	<1Min.
	EV Application (2023)		<1-2Min.
Application	The Service Tool is designed for automotive battery warranty and aftermarket service  programs.	12V	12V
	EV Application (2023)		3 - 60V
Ordering Info	Part Number	11-500-013x	11-500-0200-00
Test Parameters:
Complete State Of Health Assessment ( SoH)	Includes: Cranking ability, Capacity (RC/Ah) &  High Resistance check	YES	YES
Capacity ( Ah/RC)	Classification; Pass/Fail assessment (Capacity entry by IEC and SAE norms)	YES	YES
	Capacity Test Range	27-105Ah/55-210RC	27-150Ah/55-300RC
CCA	In AMPS, Percent; Pass/Fail assessment	YES	YES
	CCA test Range:	CCA: 300-1200	CCA: 300-1250
High Resistance Test	Significantly reduces Charge & Re-Test decisions well below 50% SoC, especially Heat Failed batteries; possible structral integrity issues: welds, fractures	YES	YES
Battery Under Test Chemistry	12V Flooded, EFB and AGM starter batteries	YES	YES
	3–60V lithium-ion with model-specific battery characterization profiling (Available in 2023)	NO	YES
Min. SoC for Complete SoH test:	State-of-Charge ( SoC)  in percent (%) |Captures Soc Pass/Fail status	YES	YES
	Ability  to measure batteries at low SoC. Reduces “Charge & Re-Test” requirements	50% SoC	<50% SoC
Voltage Supported	Shown in 3-digit readout	12V	12V
Test Modes	Test Mode support for PDI, Dealer, Ports & aftermarket Service Drive/workshops	YES	YES
Charge & Re-Test decision	Dedicated Capacity ( Ah/RC Mins.) assessment further reduces battery “Charge & Re-Test” decisions	YES	YES
Surface Charge Detect	Promps that battery overcharged. Suggests discharging in order to complete SoH assessment.	YES	YES
Saved Test Results	Onboard	~150	~1000
	Cloud/Destop	Can export to Desktop/cloud	Aditional optional storage in cloud
Standalone Use	Integration with OEM & Aftermarket back end systems.	YES	YES
Integrated Solution( w/API Support)	Seamless integration with OEM Diagnostics or 3rd party Workshop/Fleet Software applications over API	NO	YES
	Wireless Connectivity with host devices (Tablet/Cell/Desktop) for OEM service/workshop maintenance systems	NO	YES
Test Messages	Good Battery	YES	YES
	Good battery – Recharge	YES	YES
	Replace Battery (Poor RC)	YES	YES
	Replace Battery ( Poor CCA)	YES	YES
	Replace Battery (Poor RC+CCA)	YES	YES
	Replace Battery (High Resistance Detected)	YES	YES
	Charge and Re-test	YES	YES
	Re-test after self-discharge (Surface Charge Detected)	YES	YES
Temperature Sensor	Degree Celsius and Degree Fahrenheit; selectable	YES	YES
Clamps	Field Replaceable, 4 point Kalvin	YES	YES
Printing capability	Standalone / via Host	YES (onboard)	NO ( via host )
Display	Screen	YES	NO ( via host )
Keypad		YES	NO ( via host )
Camera	For scanning	NO (barcode uploadable)	YES (via Host )
VIN Capture		YES	YES(Integrated Solution can import in real -time )
Barcode support	1D/2D	YES	YES (via Host )
Operating System		Embedded	Embedded
Rechargable Tester Battery	Li-ion battery cell(s)	YES ( 18650 cells)	YES (21700 cell)
	Number of tests between charge:	~150	~250
Connectivity/Ports		RS232, USB	B/G/N Wi-Fi Bluetooth
Cloud Support/Analytics	Connectivity to Cadex Cloud via  Cadex Link (ie.Web-App)	NO	Optional
	Cadex Link (Android & Windows Support)	NO	YES
Software upgrade	Via Serial Connection (RS232-USB to desktop/Wi-Fi)	YES	NO
	OTA (Over the Air ) Software updates or USC-C to Wifi	NO	YES
Physical Dimensions	D X W X H (mm/Inch/Kg/Lb )	D:172mm(6.77"") W:275mm (10.83"") H:117mm(4.61"") Wt: 1.58kg (3.5Lb)	D:182mm(7.16"") W:96mm (3.78"") H:47mm(1.85"") Wt: 430g (.94lb) Total. w/case: 1.46Kg/3.2lbs
Power	110–240VAC, 50–60Hz AC power supply	YES	YES
	USB-C	NO	YES
Environment	Temperature:  Humidity: 10–80%	0-40C	-10℃ to +45℃ (14°F to 113°F)
	Short-Term (up to 30 days) at –20℃ to +30℃ (–4° to 86°F) Humidity: non-condensing	YES	YES
	Long-Term (1-3 months +)  at –20℃ to +25℃ (–4° to 77°F) Humidity: non-condensing	YES	YES
Approval	Tested and approved to comply with:	UL3101, CSA 1010, EN61010 EMI/ EMC: FCC part 15 Class A, EN55011 Level A, EN61000-6-3:2001 for EMC	CSA/UL/CE standards. RoHS. REACH, RED,WEEE, ISTA 3A, IP52 and FCC Type A compliant
Warranty	Cadex warrants the device against defective materials and workmanship from the original purchase date	2 years	2 years
	The cable and clamp carries a  warranty peroid of:	1 year	1 year
	Internal battery Warranty	2 years	2 years
Patents	U.S. PATENTS:  6,778,913; 7,072,871; 10,302,709	YES	YES

* Specifications subject to change

Accessories

CA-12 A+ Battery Clamps Cable for Hyundai

CA-12 A+ Battery Clamps Cable for Hyundai Part Number: 17-797-0368-00 Product Description Weight: 1 kg Dimensions (packaged): 27 x 16 x 10 cm

CA-12 A+ Battery Clamps Cable for KIA

CA-12 A+ Battery Clamps Cable for KIA Part Number: 17-070-1016-00 Product Description Weight: 1 kg Dimensions (packaged): 27 x 16 x 10 cm

CA-12 A+ Battery Pack

CA-12 A+ Battery Pack Part Number: 92-470-0078-00 Product Description Weight: 1 kg Dimensions (packaged): 24 x 16 x 13 cm

CA-12 A+ AC Adapter Kit (NA power cord)

CA-12 A+ AC Adapter Kit (NA power cord) Part Number: 92-480-0003-00 Product Description Weight: 1 kg Dimensions (packaged): 24 x 16 x 13 cm

CA-12 A+ Calibration Shunt

CA-12 A+ Calibration Shunt Part Number: 17-797-0061 Product Description Weight: 0.5 kg Dimensions (packaged): 19 x 14 x 10 cm

CA-12 A+ Replacement Fuse

CA-12 A+ Replacement Fuse Part Number: 52-813-0701 Product Description Weight: tiny Dimensions (packaged): tiny

CA-12 A+ Thermal Paper Rolls (Pack of 10)

CA-12 A+ Thermal Paper Rolls (Pack of 10) Part Number: 89-000-0002 Product Description Weight: less than 1 kg Dimensions (Roll): 58mm x 28mm Dimensions (Pack L x W x H): 148mm x 28mm x 116mm

INQUIRY

The Spectro Modular is only available to Original Equipment Manufacturers (OEM) to seamlessly integrate into warranty and after-market programs. Product inquiries should be directed to the following Cadex Automotive office locations:

• America – Cadex HQ
  [email protected]

• Asia Pacific – Cadex Korea
  [email protected]

• Europe, Middle East, Africa – Cadex Europe
  [email protected]

Cadex is continuously advancing Spectro™ in the form of improved battery diagnostics, broader test ranges, new battery types, and the distribution of test results. We are interested in your application and would be pleased to discuss your requirements.