User Guide

Battery Tester

DataCan
Table of Contents
1 ABOUT THIS GUIDE ..........................................................................................................................3

1.1 W HO SHOULD USE IT .................................................................................................................3

1.2 DISCLAIMER...............................................................................................................................3

2 BATTERY TESTER INSTRUCTIONS ............................................................................................4

2.1 INSTRUCTIONS FOR USE.............................................................................................................4

2.2 LOW BATTERY VOLTAGE ............................................................................................................5
2.3 CONDITIONING BATTERIES .........................................................................................................5
2.4 MAINTENANCE ...........................................................................................................................6
2.5 BATTERY TESTER SPECIFICATIONS .............................................................................................7

3 LITHIUM BATTERY INFORMATION ..............................................................................................8

3.1 LITHIUM BATTERY SAFETY AND HANDLING GUIDELINES ...............................................................8

3.2 LITHIUM BATTERY DISCHARGE PATTERN .....................................................................................9
3.3 STORING LITHIUM BATTERIES .....................................................................................................9
3.4 SHIPPING ................................................................................................................................10
3.5 DISPOSAL ................................................................................................................................10

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1 About This Guide

1.1 Who Should Use It

This guide is intended for users of different degrees of knowledge and experience:

Operators: Gauge operators can learn how to test and condition lithium battery packs

Technicians: Technicians can learn how to interrogate and troubleshoot lithium battery packs.

This guide assumes that you have some lithium battery operation and safe use knowledge. For
more information, contact your local service representative.
www.datacan.ca
info@datacan.ca

1.2 Disclaimer
This document is intended as a supplement to formal training. DataCan is constantly working to
improve its products. We must therefore reserve the right to change designs, materials,
specifications and prices without notice. DataCan declines any liability that may arise out of the
potential inaccuracies in this guide.

The information contained in this document is for reference only. It should not be used in
place of appropriate Federal, State, or local regulations or other legal requirements.
DataCan is not responsible for updating its contents hereof, or for any incident that
occurs due to misuse or abuse of lithium cells and batteries.

We thank you for any feedback or comments that will help us to continue to improve our
products and service.

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2 Battery Tester Instructions

The DataCan Battery Tester has been specifically designed to test the voltage of battery packs
built for use with DataCan gauges.

This guide covers Battery Tester part number 100876.

Accessories available:
Rugged Zippered Carrying Case
Silicon Protection Holster
Various Connection Adapters

2.1 Instructions for Use

The DataCan Battery Tester is very easy to use with simple ON/OFF operation.
1. Power on the battery tester by holding ON/OFF button for about 2 seconds. With no
battery pack attached the unit should read 100 ohms.
2. Plug battery pack into connector.
3. The Battery Tester should automatically switch to a voltage reading. Observe the
display for a voltage read out. If the display indicates a value +0.2 V of the open circuit
voltage (OCV) indicated on the side of the battery pack, it is ok for use. If not, see the
next section.
4. To turn off the battery tester, hold ON/OFF button for about 2 seconds until the display
goes blank.

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 2.2 Low Battery Voltage
The most common reasons for low battery voltage are:
Depleted Energy
o This is when the battery no longer has any energy for use. The battery will
show a low voltage (<3V) or 0 V.
o When a battery is stored for an extended period in optimum storage
conditions, it will lose a few percent of its capacity each year. In non-ideal
storage conditions, loss of capacity will increase.
Passivation
o This condition occurs when an insulating layer forms inside the battery due to
lack of use. This can sometimes be seen with batteries that have been on the
shelf for an extended period of time (months or years). Passivation may
cause a voltage delay when a load is placed on the battery.
o To remove the passivation layer, the simplest solution is to connect the
battery to the battery tester for a period of time to condition the battery for
use. The current draw from the battery tester will break down the passivation
layer. Remove the battery when voltage returns to normal (>3V)

2.3 Conditioning Batteries

Under most operating conditions, depassivation of a lithium cell is unnecessary. However,
under some more severe conditions (such as high temperature storage) it may be beneficial
to depassivate a cell.

For the most effective depassivation, connect the battery to the battery tester. A
depassivation load should be applied until the cell voltage recovers to a normal level (>3.2
V). The duration will depend on the severity of the passivation.

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 2.4 Maintenance
Gently clean the unit with a damp cloth periodically.

Battery Replacement
If the meter starts up with a persistent resetting of the display or with the low batter icon on the
top of the screen, replace the battery. The Battery Tester uses one 3V coin cell IEC-CR2032.
1. Turn off the Battery Tester.
2. Disconnect any battery attached to the connector.
3. Remove rubber cover and loosen screw on the bottom of the case.
4. Lift the end of the case bottom nearest the wires until it snaps from the case top.
5. Replace the battery. Observe the polarity. (+) faces up towards the case bottom.
6. Replace the case bottom. Ensure the top near the LCD screen snaps into place.
Replace and tighten case screw.

Repair
There are no other serviceable parts in the Battery Tester beyond replacing the
battery outlined above. All items for repair should be returned to DataCan.

Warranty
This product carries a 1 year warranty that it will be free from defects in materials and workmanship from the date of purchase.
This warranty is limited to repair or replacement of the Battery Tester only at the discretion of DataCan. This warranty does not
cover fuses, disposable batteries, damage from accident, neglect, misuse, alteration, contamination, or abnormal conditions of
operation or handling. Resellers are not authorized to extend this or any other warranty on DataCan’s behalf. To obtain
service during the warranty period return the Battery Tester to DataCan. Return shipping is at the owner’s expense. Repaired
item will be shipped free of charge.

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 2.5 Battery Tester Specifications
Display and Update Rate: 4 digits, updates 5 times per second
Operating Temperature: 0°C - 40°C
Operating Relative Humidity: 80% RH max @30°C, 50%RH max @ 40°C
Storage Temperature: -20°C – 60°C, <80% RH with battery removed
Sensing: Averaging
Overload Protection: 450V
Low Battery: <2.4V
Power Supply: 3V button cell battery, PN IEC-CR2032
Power Consumption: 2mA
APO Power Consumption: 2 A
APO Timing: idle for 3 minutes
Dimensions/Weight: L113mm x W53mm x H10.2mm / approx. 80 g

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3 Lithium Battery Information

3.1 Lithium Battery Safety and Handling Guidelines

This guide is not a substitute for formal training on the safe use, handling, and disposal of lithium
batteries. This section is provided as a supplement to formal training.

While DataCan specifies lithium cells from reputable manufacturer’s and battery pack
assemblers, due to the nature of the product, certain hazards do exist.

Most primary lithium cells have a warning printed on their label that cautions against the
following conditions:
Short-circuit
Charging
Forced over discharge
Excessive heating or incineration
Crush, puncture or disassembly
Not guarding against these conditions may result in a hot cell or battery pack that could either
vent or explode. With lithium cells, the ensuing hazards associated with a hot cell, typically do
not occur the instant the cell is abused. Rather, the cell heats up over a period of time and
subsequently vents or explodes when its critical temperature is reached. The rate of heating is
proportional to the extent of the abusive condition. One condition that could lead to a sudden
explosion is severe structural deformation of the case or internal components due to excessive
mechanical abuse.

Special care should be taken when handling the lithium batteries in places like shipping and
receiving to prevent short circuits and mechanical damage.

Electrochem Batteries provides the following detailed information regarding primary lithium
batteries:
http://www.electrochempower.com/Support/SafetyHandling

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For further information on the handling, storage, disposal, and safety when using lithium primary
cells, please contact DataCan.

3.2 Lithium Battery Discharge Pattern

Lithium batteries are very good at holding their rated voltage for the life of the battery. Testing
the voltage of the cell does not give any indication as to how much capacity is remaining. It can
only ensure the battery is not “dead”.

Typical Discharge Pattern for Lithium Battery

5

3
Voltage

0
0 1 2 3 4 5 6 7
Capacity (Ah)

3.3 Storing Lithium Batteries

Storage of hazardous materials is generally regulated by Federal, State and local codes.
These codes may regulate the location and amount of material that may be stored in a
designated area. In addition these general guidelines should be followed:
Cells should be stored in their original containers.
Store the cells in a well-ventilated, dry area. The temperature should be as
cool as possible to maximize shelf life.
Store the cells in an isolated area, away from combustible materials. Store
depleted cells in an area separate from fresh cells.
Any lithium battery storage area should have immediate access to a class D
fire extinguisher and respirators.

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 Never stack heavy objects on top of boxes containing lithium batteries to
preclude crushing or puncturing the cell case. Such severe damage can lead to
internal short circuits resulting in a cell venting or explosion.
Do not allow excessive quantities of cells to accumulate in any storage area.

3.4 Shipping
DataCan battery packs are safe to transport when shipped according to International laws
regarding the transportation of lithium cells and batteries. Regulations do exist on the packaging,
labeling, and shipping papers for lithium cells and batteries. Our products have been tested for
compliance with the recommendations established by the United Nations regarding the transport
of dangerous goods.

Returns must be packaged and shipped in accordance with shipping regulations outlined by
various government bodies under UN3090 Class 9. DataCan’s packaging is fully certified. We
recommend customers use our packaging when returning product to our facility. The customer is
responsible for certifying their employees as shippers.

NOTE: Customers transporting packs / modules from offices to job sites are required to do so in
compliance with UN3091 Class 9 (batteries in tools) regulations.

3.5 Disposal
Lithium Batteries must be disposed of properly in accordance with local regulations. Companies
are available to take back your batteries for disposal and process them in accordance with
regulations. For recommendations on companies that dispose of your batteries, please contact
your local government representatives for information regarding packaging, and transportation
regulations. Pay particular attention to the MSDS disposal instructions.

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