Battery Capacity Analyzer with record storage 603B User Manual
Safety Summary The following safety precautions apply to both operating and maintenance personnel and must be followed during all phases of operation, service, and repair of this instrument. WARNING Before applying power to this instrument: ● Read and understand the safety and operational information in this manual. ● Apply all the listed safety precautions. ● Verify that the voltage selector at the line power cord input is set to the correct line voltage.
WARNING Do not use this instrument in an electrical environment with a higher category rating than what is specified in this manual for this instrument. WARNING You must ensure that each accessory you use with this instrument has a category rating equal to or higher than the instrument’s category rating to maintain the instrument’s category rating. Failure to do so will lower the category rating of the measuring system.
Do not operate instrument if damaged WARNING If the instrument is damaged, appears to be damaged, or if any liquid, chemical, or other material gets on or inside the instrument, remove the instrument’s power cord, remove the instrument from service, label it as not to be operated, and return the instrument to B&K Precision for repair. Notify B&K Precision of the nature of any contamination of the instrument.
Table of contents 1 GENERAL OPERATING INSTRUCTIONS.................................................................................................6 2 BUTTON DESCRIPTIONS.........................................................................................................................8 3 QUICK TEST MODE – SOC.......................................................................................................................9 4 MAIN MENU.........................................................
1 General Operating Instructions This section describes general operating instructions that apply to all of the testing modes. Before connecting the 603B to any battery or circuit read and follow the information provided in the safety section. Verify the voltage and current is within the safe operating range of the 603B. Refer to the Specifications section. The 603B is powered by the battery or charger circuit under test.
4. Insert the 3-pin connector into the mating connector using a slight left right rotation the 3-pin connector slips in to place. The outer ring can now be rotated until the groves align and the ring move slightly forward. Continue to gently push the connector forward while twisting the outer ring. The outer ring should easily turn clockwise ¼ turn locking the two mating connectors together. Gently pull on the shell of the connector to make sure the cable is locked into place.
2 Button Descriptions This section provides an overview of each button and its description, refer to Table 1. Some buttons will have different functions additional detail is provide in the section where the button is used.
3 Quick Test Mode – SOC The Quick Test mode is used to find degraded or damaged batteries quickly. The test can be configured and results viewed in a few minutes. The only information required is the battery ampere hour (Ah). This is usually found directly on the battery or the battery manufacturer’s data sheet. The ampere hour setting used during the test is saved in memory.
7. The back light will turn off indicating the test has started. To cancel the test, press the button. 8. The back light will illuminate after approximately 6 seconds and the results will be displayed. BATTERY QUICK TEST VO : 12. 77 SOC : 90 VL : 12. 28 IR : 24m RS : N/A Result screen Tip: After completing the test, the cables can me moved to a new battery of the same type. 1.
3.1 Quick Test Mode - Pass/Fail The Pass/fail option compares a batteries’ internal resistance to a known good nominal value and determines if the battery under test is PASS or FAIL. The Nominal Internal Resistance or “NIR” value is optional. If the NIR is set to the default of value of N/A the 603B will display RS: N/A. The NIR entered is compared to the battery under test measured IR. If the battery under test is less than or equal to 160% of the NIR value the 603B will display “RS: PASS” in the field.
3.2 Quick Test Mode - Charger Circuit Test Similar to the other Quick Test modes the Charger Circuit test is a tool to help evaluate the performance of the charger circuit under an open and loaded condition. Both the open voltage OCV and LCV values are displayed. The load applied is based on the Ah value entered and is calculated to place a light load that should be will within the nominal range of the charger circuit.
5. Press the button to begin the test. The back light will turn off indicating the test has started. After approximately 2 seconds the back light will illuminate and the results will be displayed. CHARGER QUICK TEST OCV : 13. 61 Ah : 007 LCV : 13.59 Press TEST or CANCEL Both “OCV:” and “LCV:” will be measured and displayed. If the LCV voltage is significantly below the OCV: the voltage charger circuit could have a problem. Contact the control panel (charger), manufacturer for more information.
4 Main Menu The Main menu provides access to Record Mode, additional test tools and system configuration. 1. Connect the 603B and verify the displayed voltage is in range. VO = 12.78 Volts Quick press [TEST] or Main press [ENTER] Power on menu 2. To access the Main menu level by pressing the button View Edit Records Add New Record Load Test System Mani menu The Main menu has four options available. Each of these options is explained below in more detail. 4.
To view a specific record in the database. 4. Press the button to move the cursor over to the Record number field. 5. Press the to increment or decrement through the existing records. If the record exists the record will be displayed on the screen. If the record exists but is empty you will only see the field labels with no data in the field. The 603B will step through all the records in memory and start over. 6.
4.3 Database Record Format The 603B can store up to 50 records in the internal memory. Existing records can be selected, viewed and edited. A new 603B will have only one record number 001 in memory. This record will have no data in the fields also called a blank or empty record. You can use the View/Edit Records to add information in the User editable fields. Each record contains 31 fields refer to table 2 for more details.
4.3.1 System type field Knowing the system type is helpful for sorting and evaluating the batteries’ life cycle. The system type options are identified with a letter and described in table 3. This field is not a required and can be left blank.
4.3.3 Numeric type fields If the field has numeric digits it can be changed by 1. Pressing the arrow buttons. 2. Press and hold is also supported to increment and decrement the values quickly. 3. Press the button to save the changes in the database or the button to exit without saving. 4.4 Add New Record The new blank record can be added to the database if the database is not full. 1.
2. The Load Test will open with the cursor located in the Load Current, LC: field. Press the to increase the current to lower the value. 3. Press the right arrow key to move to the Load Time field LT: the cursor will move to this increase or decrease the LT time. 4. Press the button to start. The display back light will be turned off during the test. Press the Cancel button to stop the test. LC : 10.0A LT: 5.0sec VO : -- . --V VC: -- . --V Arrow Keys to Set TEST Key to Test 5.
4.6.1 Setting date The date needs to be set when the 603B is new or has been factory restored. The date is recorded in the database after each test when using Record Mode. To set or change the date 1. Use the buttons to move the pointer to the “Date:” row. 2. Press the button to advance the cursor to the year field, Month or day field with each press. 3. Use the buttons to increment or decrement the values in the field. 4.
2. Use the buttons to move the pointer to “Delete Records” and press the button. Del . One Record Del . Records Del . All Records Delete record options A new menu will show with three rows of delete options. The pointer will be located on the first row “Del. One Record”. 3. Press the button to select this option. Press ENTER to Del . Record Number : 001 Delete record screen A new screen will be displayed with the cursor located in the Record Number: field. 4.
The display will show a cursor located in the “from” field. 4. Use the to increment the number to the first record to be deleted. 5. Press the button to move to the cursor to the last record number field. 6. Use the to increment the number to the last record in the range to be deleted. 7. Verify the range of records is correct as all the records in this range will be deleted. 8. Press the button.
A new screen for entering the password will be displayed. The password is 13579. The cursor will be located at the first digit of the password. 5. Use the buttons to increment this digit to 1 6. Press the button to move to the next digit and increment this digit to 3. 7. Proceed in complete all for digits until 13579 is showing in this field. 8. Press the button to proceed. A confirmation screen will be presented providing the option to proceed or cancel.
1. 2. 3. 4. Power on the 603B. Press the button to select the Main Menu. Use the buttons to move the pointer to the row “System” and press the button. Use the buttons to move the pointer to the row “SOC Profile Settings” and press the button. SOC 100 90 80 Pro f ile SOC1 = 26 . 214V = 26 . 214V = 26 . 214V Selecting a profile The pointer will be located at the row “Setting 12 V SOC #1” by default.
4. Use the buttons to move the pointer to row “SOC Selection” and press the button. Quick 12V SOC = D Quick 6V SOC = d Record 12V SOC = D Record 6V SOC = d SOC select 5. Use the buttons to move the pointer to select a row for the test mode and voltage desired and press the button to move the cursor in the field and enable editing. 6. Use the buttons to step through the options.
Weighting is an estimating method used to provide a more useful representation of the batteries’ State of Charge (SOC). The user must provide the nominal internal resistance (NIR) value for this feature to function. NIR can be entered in the Quick test mode for using during the Quick test or added to the record for use in Record Mode. When SOC Weighting is turned off the 603B calculates the SOC using the same method as a volt meter and an SOC chart.
Starting Fan Process Fan Off after 5 min or CANCEL to Leave 2. Press the button to stop the end the Fan test early and return. Tip: In hot environments with repeated load testing the outside case of the 603B may become uncomfortable hot. This Fan Start feature can be used to help cool the 603B. Load testing should be delayed until the 5 minute timer shuts off the fan. If the case is still hot repeat the Fan Start process. 4.
Adjust VO: 12.79 VL: 12.31 IR: 24m TMP: SOC: 90 TMP: 25 RS: N A Temperature adjustment 5. Keep the default temperature value or use the to adjust the temperature to record a more accurate battery environment. This information is not used in the 603B calculations this is only stored in the database record for future analysis by the user. Tip: Use a none contact thermometer to measure the battery temperature for more accurate database record. 6.
2. Disconnect the 603B from the battery. The 603B will remember the record in use and return to this record when power is restored ready to test the charge circuit. 3. Connect the 603B cables and verify the positive and negative leads are correct and the Reverse Polarity LED is not illuminated. Use the Tab type adapters if required. Tab adapter CHARGER TEST OCV : 12. 71 LCV : REC: 001 Press TEST or CANCEL Charger screen 4. Verify the OCV: voltage in the expected range. 5.
5 Firmware Update Procedures 5.1 Firmware Update Instructions The following section describes the steps to complete a firmware update. The steps include: 1. Downloading and installing the firmware application software called “Bootloader”. 2. Connecting the 603B to the computer. 3. Updating the firmware. 4. Restoring the calibration data. Downloading the Software The Bootloader has been tested on Microsoft Windows 7 and 10. Download the application 603B_Bootloader v1.07 from the bkprecison.com website.
Unplug the 603B from the USB port and observe which COM port disappears. Plug the 603B back in, open the COM selection and select this COM port from the list. In this example the operating system assigned COM4 your system my assign a different COM. 1. 2. Under the heading Firmware File, click on the Open File button. Select the text file FW 1.xx.txt where xx is the correct firmware revision. 3. The path to the firmware selected should now show at the top of window. 4. Click the Open File button.
The green progress bar will advanced as the memory is updated and log messages will be displayed. The existing calibration data will be read from the 603B. The log will display “Read Calibration Data OK”. This file will be automatically saved on the host computer with a file name containing “…….Calibration Data.txt”. This file will be used in the Restoring Calibration steps. The bootloader window will display Finish when the update is compete.
5.2 Restoring the Calibration Data The calibration data now needs to be restored. This step is recommended even if you plan to complete the calibration process after the firmware update. 1. Under the section “Calibration File”, click the Open File button. 2. Find the file “…….Calibration Data.txt” create in the previous steps verify the date and time the file was created and select it. The file path should now show in the Calibration File window. 3. Click the upgrade button to start the process. 4.
6 Calibration Procedures The calibration section describes the process and equipment needed to calibrate the 603B. The calibration process is made up of several sections. All sections should be competed in full. Read the enter calibration section before attempting. 6.1 Equipment An adjustable DC power supply is required to complete the calibration.
6.2 Voltage Calibration This section describes how to calibrate the voltage. The label is easy to confuse as V_Min_1 is similar to V_Med_1 carefully match the values in the tables to the label on the 603B at each step. From table XXX find the voltage for V_Min_1 of 5.40 V and set the power supply to this voltage. 603B Row Label Voltage Setting V Min 1 5.40 V V Med 1 8.00 V V Max 1 18.00 V Press V Min V Med V Max ENTER to 1 = 1114 1 = 1627 1 = 3607 Set ADC ADC ADC Voltage screen 1 of 2 9.
6.3 Current Calibration 15. From the 3 part calibration screen move the point to the row “Current Calibration”. Voltage Calibration Current Calibration Load Calibration 16. 17. 18. 19. 20. Press the button to select current calibration. Set the voltage on the power supply to 12.000 volts. Set the current on the power supply to 12.000 amps. Set the power supply to Meter mode so the current can be monitored. Verify the pointer is located on the first row, “I_Min...
I Med 4 = 01462 mA I Max 4 = 02896 mA Current Calibration 4 of 4 screens 6.4 Load Calibration This is a similar process to Current calibration with only 3 calibration points. The button is used to trigger the 603B placing a load on the power supply. Monitor the maximum current used as displayed on the power supply current meter. Write the maximum value down. Enter this 4 digit value in the row. Repeat until all three calibration points are adjusted. Note that the value in the 603B is in mA.
7 Specifications Range 603B Open voltage Displayed Quick Test Mode Record Mode VO Voltage open VL Voltage loaded IR Internal resistance SOC State of charge percentage RS Resistance status, pass/fail user configured VO Voltage open VL Voltage loaded IR Internal resistance SOC State of charge percentage SOT SOC table used for test Tmp User provided temperature RS Resistance status, pass/fail user configured Data 24 Volts 5.5 V to 6.8 V 5.5 V to 8.
8 Service Information Warranty Service: Please go to the support and service section on our website at www.bkprecision.com to obtain a RMA #. Return the product in the original packaging with proof of purchase to the address below. Clearly state on the RMA the performance problem and return any leads, probes, connectors and accessories that you are using with the device. Non-Warranty Service: Please go to the support and service section on our website at www.bkprecision.com to obtain a RMA #.
9 Limited One-Year Warranty B&K Precision Corp. warrants to the original purchaser that its products and the component parts thereof, will be free from defects in workmanship and materials for a period of one year from date of purchase. B&K Precision Corp. will, without charge, repair or replace, at its option, defective product or component parts. Returned product must be accompanied by proof of the purchase date in the form of a sales receipt.
10 CE Declaration of Conformity This instrument meets the requirements of 2006/95/EC Low Voltage Directive and 2004/108/EC Electromagnetic Compatibility Directive with the following standards. Low Voltage Directive - EN61010-1 : 2001 EMC Directive - EN61326-1 : 2013 - CISPR11 - EN61000-4-2 : 2009 - EN61000-4-3 : 2006 + A2 : 2010 - EN61000-4-8 : 2010 Reference to our most updated CE info: http://www.bkprecision.com/support/downloads/ce-declarations.
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