AlfaBat Pro manual

V2.0
1. TABLE OF CONTENTS

1. Table of Contents .......................................................................................................................................................... 1

2. Introduction .................................................................................................................................................................... 3
2.1. Contents ................................................................................................................................................................. 3
2.2. Top panel of the AlfaBat ..................................................................................................................................... 4
2.3. Panel of the AlfaBat Pro ...................................................................................................................................... 5
3. Different Test Setups .................................................................................................................................................... 6
3.1. Capacity Test Setup ............................................................................................................................................. 6
3.2. Charger / Cycle Test Setup ................................................................................................................................ 7
3.3. 24V, 36V, 48V Charger Test Setup .................................................................................................................. 7
a. One AlfaBat ............................................................................................................................................................ 8
b. An equal amount of AlfaBats and batteries .................................................................................................... 8
3.4. 24V, 36V, 48V charger test with one AlfaBat ................................................................................................ 8
a. Charger test: .......................................................................................................................................................... 8
b. Cycle test: ............................................................................................................................................................... 8
3.5. 24V, 36V, 48V charger test with several AlfaBats....................................................................................... 10
3.6. Record Test Setup .............................................................................................................................................. 10
3.7. Only Adaptor ....................................................................................................................................................... 11
4. Stand Alone ................................................................................................................................................................... 13
4.1. Simple Capacity test ........................................................................................................................................... 13
4.2. How to perform a cycle test? .......................................................................................................................... 14
4.3. Start a Test ........................................................................................................................................................... 18
4.4. Test is running ..................................................................................................................................................... 19
4.5. Test stopped ........................................................................................................................................................ 20
4.6. How to end a Test? ............................................................................................................................................ 20
4.7. Read out results .................................................................................................................................................. 21
4.8. Meaning of results ............................................................................................................................................... 22
a. Capacity test ........................................................................................................................................................ 22
b. Charger test ......................................................................................................................................................... 23
c. Cycle test .............................................................................................................................................................. 23
d. Record test........................................................................................................................................................... 24
5. Interfacing With PC ..................................................................................................................................................... 25
5.1. Use Of Profiles .................................................................................................................................................... 26
a. Battery Voltage Auto Detection ..................................................................................................................... 27
b. Voltage (6V / 8V / 12V) ..................................................................................................................................... 27
c. User Preset Mode............................................................................................................................................... 27
d. Preset Mode (Discharge / Charge / Cycle / Record) ................................................................................. 27
e. Save Voltage ......................................................................................................................................................... 28
f. Save Current ........................................................................................................................................................ 28
g. Capacity Value ..................................................................................................................................................... 28
h. Capacity Unit ....................................................................................................................................................... 28
i. Peukert Factor ..................................................................................................................................................... 29
j. Peukert Calculation Test .................................................................................................................................. 29
k. Temperature ........................................................................................................................................................ 30
l. Temperature Unit (°C / °F).............................................................................................................................. 30
m. Max Charging Time / Recording Time ...................................................................................................... 30
n. Number Of Cycles In Cycle Mode ................................................................................................................. 31
o. Offset ..................................................................................................................................................................... 31
p. Bad Cell Timer .................................................................................................................................................... 31
q. Bad Cell Voltage High ........................................................................................................................................ 32
r. Bad Cell Voltage Low ........................................................................................................................................ 32
s. End Of Test Voltage ........................................................................................................................................... 32
t. Needs Charging Voltage.................................................................................................................................... 33
u. Pass / Fail Threshold........................................................................................................................................... 33
v. Max Discharge ..................................................................................................................................................... 34
w. Discharge Current .............................................................................................................................................. 34
x. Detect Start of Charge ...................................................................................................................................... 34
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 y. Detect End of Charge ........................................................................................................................................ 35
6. Trouble Shooting ......................................................................................................................................................... 36
6.1. Self-power down of the AlfaBat ...................................................................................................................... 36
6.2. No power up ....................................................................................................................................................... 36
6.3. Error: Over Temperature ................................................................................................................................ 37
6.4. Error: No Adaptor ............................................................................................................................................. 37
6.5. Error: Battery Low ............................................................................................................................................. 37
7. Technical specifications .............................................................................................................................................. 38
7.1. Technical specifications of the AlfaBat Pro................................................................................................... 38
8. Safety Instructions........................................................................................................................................................ 39
9. Clarification of symbols .............................................................................................................................................. 40
10. Maintenance .................................................................................................................................................................. 41
11. Warranty........................................................................................................................................................................ 42

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2. INTRODUCTION

Congratulations on your purchase of the unique battery and charger tester: ‘The AlfaBat Pro’.

The following topics will proof your professionalism when testing batteries and/or chargers:
- With the included BITS software, you can create professional, printed reports
- The AlfaBat is a highly accurate capacity tester
- Different battery technologies can be tested: flooded lead acid batteries, AGM, GEL, …
- Tests both 6V and 12V batteries
- Selectable capacity 0.8 – 400 Ah
- Three tests can be recorded in the internal memory
- Microprocessor controlled
- Reliable and qualitative
- 24V, 36V, … chargers can also be tested

2.1. CONTENTS

You should find following contents in the cardboard box:

- AlfaBat Pro
- USB stick with BITS software & manuals
- USB connection cable
- Getting started document
- Battery connection cable

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 2.2. TOP PANEL OF THE ALFABAT

Displays information about the test.

Enables you to set the most important parameters (battery capacity, kind of test battery, voltage,)

1. Display screen
2. Down button: decrease number, scroll in menu, etc.
3. Up button: increase number, scroll in menu, etc.
4. Enter/Power Up button: ON/OFF, Confirm a selection.

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 2.3. PANEL OF THE ALFABAT PRO

You can connect the following to the AlfaBat Pro:

- RS 232: interface with Computer or the external printer
- Charger: Charger – connector
- Battery: Battery – connector
- Power Supply: for connecting the power adaptor.

It is also possible to replace the fuse:

- This must be an UL-approved 50A MAXI-fuse.

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3. DIFFERENT TEST SETUPS

Use one of the following hardware setups:

- Capacity Test Setup
- Charger / Cycle Test Setup
- 24V, 36V, 48V Charger Test Setup Record Test Setup
- Printer Connection Only Adaptor

3.1. CAPACITY TEST SETUP

Use this test set-up if you want to perform a Capacity test on a battery or read out the results of a test.

You should connect the clamps properly to the battery (Check polarity! Red = positive, Black = negative).
The other side of this cable should be connected at the ‘battery – connector’ of the AlfaBat.

This set-up can also be used with an adaptor. This has the following advantage: there is no standby current,
thus the battery will not further discharge after the test is finished. A 6V battery with a bad cell can be better
detected because the battery can be discharged to a lower voltage.

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 3.2. CHARGER / CYCLE TEST SETUP

Use this test set-up if you want to perform a Charger-, or a Cycle test on a Battery.

You should connect the clamps properly to the battery (Check polarity! Red is positive, black is negative).
The other side of this cable should be connected at the ‘Battery – INPUT’ of the AlfaBat.

Connect the charger with the ‘Charger – INPUT’ of the AlfaBat (Check polarity! Red is positive, Blue is
negative). This must be a 6V or a 12V charger, corresponding to the battery.

This set-up only works with an adapter; otherwise the test will not start. Without an adaptor, the
consumption of the AlfaBat would disturb the measurements.

3.3. 24V, 36V, 48V CHARGER TEST SETUP

There are two possible ways to perform a ‘Charger Test’ on a battery:

- With one AlfaBat
- An equal amount of AlfaBats and batteries corresponding to the charger voltage.

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 a. One AlfaBat

- Charge current measuring

- Voltage measured on ONE battery
- Max one cycle!

b. An equal amount of AlfaBats and batteries

- Charge current measuring

- Voltage measuring of all batteries
- Multiple cycle test is possible

3.4. 24V, 36V, 48V CHARGER TEST WITH ONE ALFABAT

With only one AlfaBat you can do a charger test on a 24V, 36V, 48V battery.

a. Charger test:

These steps must be followed:

1. Discharge all batteries.
2. Use the connection schematic as showed below.
3. Upload or use the correct Profile in the AlfaBat.
4. Start the test on the discharged batteries.

b. Cycle test:

These steps must be followed:

1. Discharge all batteries, except the battery on which the AlfaBat is connected.
2. Use the connection schematic as showed below.
3. Upload or use a correct Profile in the AlfaBat.
4. Start a test on the batteries.
5. Push the UP-button directly after start-up, so "cycle first charge" will be skipped.
Only one cycle is possible!

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24V connection example

36V connection example

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 3.5. 24V, 36V, 48V CHARGER TEST WITH SEVERAL ALFABATS

With an equal amount of AlfaBats and batteries, you can do a charger test or a cycle test on a 24V, 36V, 48V
battery.

Upload the correct profile to the AlfaBats. Start a cycle or a charger test on the batteries at the same time.
Use the connection schematic as shown below.

36V Connection example

3.6. RECORD TEST SETUP

Use this test set-up if you want perform a Record test in an electrical Battery System.

A record test gives you the possibility to record voltage and/or current in an electrical battery system (record
current and/or voltage in time). This can be very useful if you want to know the energy balance (positive or
negative).

Example: Charger / Load system. If there is more consumption then charging, you can see the battery voltage
getting lower with the time.

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You should connect the clamps properly to the battery (Check polarity! Red is positive, Black is negative).
The other side of this cable should be connected at the ‘Battery – INPUT’ of the AlfaBat.

Connect the Load (Light, FAN, Heater, …) and/or the Charger with the ‘Charger –‘ input of the AlfaBat

This set-up only works with the adaptor; otherwise the test will not start. Without the adaptor, the
consumption of the AlfaBat would disturb the measurements.

3.7. ONLY ADAPTOR

Use this test setup if you want to read out the results on the computer or if you want to print-out the results
on a small printer.

After a test is completed, it is still possible to print-out the results. This is only possible if you enabled the
parameter 'Printer Output Enable' in the used profile during test. Follow the procedure 'read-out results'
(you can find this under topic 'Standalone') to print-out the results.

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4. STAND ALONE

The AlfaBat is made for use with a personal computer. However, measurements can be done without the
computer connected. Test results will be saved in the AlfaBats internal memory.

There are four modes where the AlfaBat could work with:
- Battery Capacity Test
- Charger Test
- Cycle Test
- Record

4.1. SIMPLE CAPACITY TEST

The device is standard delivered to start a capacity test in its easiest mode. If you are used to the AlfaBat,
you can use profiles to use all functions.

The next explanation should allow you to start a simple capacity test:

1. Connect the AlfaBat to the battery

Use following test setup: Capacity test setup
Note: charge the battery before starting a capacity test.

2. Switch on the device

Switch on the device with the ENTER - key. This button can be found on the top panel of the AlfaBat.

3. Enter the Capacity

Directly after power up of the AlfaBat, the user has the ability to choose the capacity in the 20-hour rating.
This is often the capacity indicated on the battery by the manufacturer. Remark: check if this value is not the
5-hour rating. The user can change this value with the UP - or DOWN - key. If you hold the key down a long
time, it gives you the possibility to speed up the change in value.

4. Confirm your selection

Confirm this capacity with the ENTER - key. The test will start. Dependent of the state and the capacity of
the battery, the test will take a few minutes to several hours.

5. Read out the results

After the battery is completely discharged, the result is shown on the display. Thirty minutes after test, the
device automatically shuts down. The results can still be read out: see topic read out results. For the meaning
of these results, we refer to following topic in the manual: Meaning of the results.

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 4.2. HOW TO PERFORM A CYCLE TEST?

The device is delivered as standard for performing a capacity test in the simplest way possible. To perform a
cycle test you must use profiles. You can read more about profiles in the Profiles section.

You can start a cycle test by following the simple procedure outlined below:

1. Connect to the battery

Use the following test setup: Charger/Cycle test setup.

NB. The device will not operate without an adapter (see the technical specifications). You must also connect
the AlfaBat to the computer via the serial cable. This is necessary in order to change the settings of the
AlfaBat.

2. Switch on the device

The device must be switched on with the ENTER key. This key is located on the upper panel of the AlfaBat.

3. Start BITS
The use of BITS is necessary in order to set the AlfaBat in the cycle mode.

4. Set BITS in the advanced mode

Set the program in the advanced mode. To do this, go to the ‘Options’ menu and select ‘Program Options’.

Tick the box ‘Enable advanced program options’.

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Then click OK. The program is now in the advanced mode.

6. Set the AlfaBat to the correct profile

Go to the ‘Device’ menu and select ‘Profiles’.

The profile window is displayed:

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At the top (A) there are three memory locations for profiles in the AlfaBat. A profile defines how the AlfaBat
has to perform a test. The AlfaBat is set as standard at memory location 1, i.e. for a capacity test. This can
easily be retrieved in ‘C’ (always use memory location 1).

In other words, to perform a cycle test you must always select ‘C’ and set the AlfaBat to start at memory
location 2 (always use memory location 2). After selecting this location, click OK. The AlfaBat is then set to
perform cycle tests.

Note: during this action, the device must be connected up and supplied with power. You can check this by
verifying that ‘Cycle test’ is displayed in the optional field after ‘Memory location 2’.

7. Switch off the device

Disconnect the device from the battery/adapter so that the device is switched off. The device is now set for
a cycle test.

8. Switch the device on again

The device must be switched on with the ENTER key. This key is located on the upper panel of the AlfaBat.

9. Enter the capacity

Immediately after the device is switched on, a command prompt appears on the display to enter the capacity
in 20h. This is the battery capacity as stated by the manufacturer. Note: the capacity may also be stated in
5h. This value can be changed with the ‘up’ or ‘down’ keys. Keeping the key depressed allows the value to be
changed quickly.
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10. Confirm your choice
Confirm your choice with the ENTER key.

The test will perform the following steps:

- Initial charge:
o The test will start by charging the battery. Depending upon the condition and capacity of the
battery, this test can take a few minutes to several hours.
- Cycle 1a (discharge cycle):
o The battery will undergo a capacity test. Depending upon the condition and capacity of the
battery, this phase can take a few minutes to several hours. The battery will be fully
discharged. The AlfaBat will automatically set the cutoff voltage.
- Cycle 1b (charge cycle):
o At the end of the discharge cycle the battery will be recharged. Depending upon the condition
and capacity of the battery, this phase can take a few minutes to several hours.
- Cycle 2a (discharge cycle):
o See cycle 1a.
- Cycle 2b (charge cycle):
o See cycle 1b.
- Cycle 3a (discharge cycle):
o See cycle 1a.
- Cycle 3b (charge cycle):
o See cycle 1b.

11. Readout of the test results

At the end of the test the result is shown on the display. Thirty minutes after the end of the test, the device
is automatically switched off. A readout can still be obtained after the device is switched off: see ‘Readout of
the test results’. For the meaning of the results, see under ‘Test results’ in the user guide.

It is recommended that you use the ‘Monitor test’ function for logging the results. This is because the AlfaBat
has a limited memory and is unable to store the full result. See the BITS user guide for more information.

The profile for a cycle test supplied with the device is set at three cycles with maximum discharge per cycle.
However, this can be adjusted by the user with user-configured profiles. See the BITS user guide for more
information (under ‘BITS reference’, subsection ‘Menu and toolbar’, subsection ‘Device menu’, under
‘Profiles’).

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 4.3. START A TEST

Use one of the different hardware set-ups: Capacity Test, Charger / Cycle Test, 24V, 36V, 48V Charger Test,
Record Test.

1. Power-up
Power-up the AlfaBat with the power-up button.

2. Initialize
First the AlfaBat will show the version number on the LCD - screen:
- AlfaBat Pro: ProV1.14

3. Choose Profile (If enabled in the profile)

The AlfaBat will ask which profile you want to load. Use the Up/Down keys to select the preferred Profile.
This option is by default disabled. This option can be enabled/disabled with the software: more information
in the BITS manual.

4. Enter the ambient temperature (If enabled in profile)

The AlfaBat will ask to enter ‘the ambient temperature’. Use the Up/Down keys to select the desired value.

5. Enter the Capacity Unit (If enabled in profile)

The AlfaBat will ask to enter ‘the Capacity Unit’. Use the Up/Down keys to select the desired value.
This is an important parameter, because a battery can deliver less or more energy dependent of the load
current.
Example: a battery has a capacity of 50Ah in 5h or 60Ah in 20h. The battery can deliver 10A during 5 hours
or 3A during 20 hours.
You have to be careful for choosing the correct battery capacity.

6. Enter the Capacity (If enabled in profile)

The AlfaBat will ask to enter ‘the Capacity’. Use the Up/Down keys to select the desired value.

7. Enter the battery voltage 6V, 8V, 10V or 12V (If enabled in profile)
The AlfaBat will ask to enter ‘the Battery voltage’. Use the Up/Down keys to select the desired value.

8. Enter Peukert value (If enabled in profile)

The AlfaBat will ask to enter ‘the Peukert value’. Use the Up/Down keys to select the desired value.

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9. Enter Timer value used during charging or recording (If enabled in profile)
The AlfaBat will ask to enter ‘the timer value’. Use the Up/Down keys to select the desired value.

10. Enter Max discharge (If enabled in profile)

The AlfaBat will ask to enter ‘the Max discharge value’. Use the Up/Down keys to select the desired value.

11. Enter Mode (If enabled in profile)

The AlfaBat will ask to enter ‘the Mode (discharge / charge / cycle / record)’. Use the Up/Down keys to select
the desired value.

12. Enter Number of cycles (If enabled in profile and mode cycle is selected)
The AlfaBat will ask to enter ‘the Number of cycles’. Use the Up/Down keys to select the desired value.

13. Test is running

4.4. TEST IS RUNNING

The AlfaBat will continuously show the test information. Each item will be on the LCD-screen for 3 seconds.
Item 1:
The LCD-screen shows the working mode:
- Mode Discharge
- Mode Charge
- Mode Record
- Cycle <number> Discharge
- Cycle <number> Charge

Item 2:
The LCD-screen shows the actual current in Amps:
- Current <value> in A

Item 3:
The LCD-screen shows the actual voltage in Volts:
- Voltage <value> in V

Item 4:
The LCD-screen shows the actual result (not available for ‘Record’ mode)
- Capacity <value> in %, for mode discharge and cycle discharge,
- Charge Factor <value>, for mode cycle charge,
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 - Capacity <value> in Ah, for mode charge and cycle 00 charge (initial charge).
After this item, the AlfaBat will restart with ‘Item 1’.

4.5. TEST STOPPED

Following results will appear on the LCD-screen, when a test is finished:

- Discharge Test:
o Passed + <value> in % (Battery is good)
o Failed + <value> in % (Battery is not good)
o Recharge + <value> in % (Battery needs charging before test)
o End user + <value> in % (User has ended the test)
o Capacity + <value> in % (Capacity)
o BadCell + <value> in % (BadCell detected)
o Disconnected + <value> in % (disconnected during test)
- Charge Test or Cycle 00 charge (Initial Charge):
o Capacity Ah + <value> in Ah
- Record Test:
o Record finished
- Cycle Discharge:
o Passed + <value> in % (Battery is good)
o Failed + <value> in % (Battery is not good)
o Recharge + <value> in % (Battery needs charging before test)
o End user + <value> in % (User has ended the test)
o Capacity + <value> in % (Capacity)
o Badc + <value> in % (BadCell detected)
o Disconnected + <value> in % (disconnected during test)
- Cycle Charge:
o Charge factor + <value>

Press enter again to switch off the device.

4.6. HOW TO END A TEST?

Step 1:
Push the ENTER-key when a test is running. The AlfaBat will show:
- Confirm Exit
In mode cycle, you can end ‘Cycle charge’ or ‘Cycle Discharge’ with the UP-key and start ‘Cycle Discharge’
or ‘Cycle Charge’. When the AlfaBat is in his last cycle, the AlfaBat will show the last result.

Item 2:
- With the ENTER-key, you can stop the test.
- With the DOWN-key, you can keep the test running.

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Item 3:
If you chose to end the test, the LCD-screen will now display the results:
- Discharge test
o "End user + <value> in %"
- Charge Test or Cycle 00 charge (Initial Charge):
o "Capacity Ah + <value> in Ah"
- Record Test:
o "Record finished"
- Cycle Discharge:
o "End user + <value> in %"
- Cycle Charge:
o "Charge factor + <value>"

Step 4:
Push the ENTER-key to shut-down the AlfaBat.

4.7. READ OUT RESULTS

Use one of the different hardware set-ups: Battery Test Setup; Charge / Cycle Test Setup; 24V, 36V, 48V
Charger Test Setup; Only Adapter; Record Test Setup.

Step 1:
Power-up the AlfaBat. Hold ENTER-key during power-up.

Step 2:
While initialize is busy, you need to hold the ENTER-key.
First the AlfaBat will show the firmware version on the LCD - screen:
- AlfaBat V1.14
- AlfaBat ProV1.14

Step 3:
Then, the AlfaBat will ask from which Test Result you want to see the results. Use the Up/Down keys to
select the preferred Test.
There are three memory locations where results are saved. The AlfaBat will ask to show the data about the
last test.
Important: If current and voltage is enabled in the profile, the two last results are from the same test!

Step 4: The result will appear on the LCD-screen

Depending on the kind of test, the AlfaBat will show:
- Discharge Test:
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 o Passed + <value> in % (Battery is good)
o Failed + <value> in % (Battery is not good)
o Recharge + <value> in % (Battery needs charging before test)
o End user + <value> in % (User has ended the test)
o Capacity + <value> in % (Capacity)
o BadCell + <value> in % (BadCell detected)
o Disconnected + <value> in % (disconnected during test)
- Charge Test or Cycle 00 charge (Initial Charge):
o Capacity Ah + <value> in Ah
- Record Test:
o Record finished
- Cycle Discharge:
o Passed + <value> in % (Battery is good)
o Failed + <value> in % (Battery is not good)
o Recharge + <value> in % (Battery needs charging before test)
o End user + <value> in % (User has ended the test)
o Capacity + <value> in % (Capacity)
o Badc + <value> in % (BadCell detected)
o Disconnected + <value> in % (disconnected during test)
- Cycle Charge:
o Charge factor + <value>

Step 5:
Push the ENTER-key to shut-down the AlfaBat.

4.8. MEANING OF RESULTS

a. Capacity test

Passed (%)
After the end of a capacity test, the AlfaBat shows "Passed" if the battery delivered more capacity then set
with the parameter Pass / Fail. By default, this parameter is set to 60%.

Failed (%)
After the end of a capacity test, the AlfaBat shows "Failed" if the battery delivered less capacity then set with
the parameter Pass / Fail. By default, this parameter is set to 60%.

BadCell (%)
A lead acid battery consists of different cells of 2V (for example: a 12V battery consists of 6 cells of 2V),
which are serial connected. Due to production error, age, ...
a cell can get broken. Without load it looks like the cell is ok, but with a load on the battery the voltage
drops after a time with 2V. This kind of events points to a Bad Cell.
The AlfaBat has an algorithm for detection of a Bad Cell. BadCell is shown on the display after the ending of
a capacity if a Bad Cell in a battery is detected (only before 25% capacity reached).

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Recharge (%)
A capacity test is automatically ended if the voltage drops under a certain level before 2% capacity is reached.
This parameter is to avoid testing of a discharged battery. If you're sure the battery is fully charged, then the
battery is defective.

Capacity (%)
This information is shown on the display after the ending of a capacity test if a preselected capacity is reached.
This value can be adjusted with parameter Max Discharge.

ShutDown (%)
This information is shown on the display after read out of the results when the device is disconnected during
test. The results of this test cannot be used to classify the battery as bad.

End User (%)

It is also possible to end a capacity test. If a user does so, the message above is indicated on the AlfaBat. The
results of this test cannot be used to classify the battery as bad.

b. Charger test

Capacity (Ah)
After the ending of a charger test, the capacity, which the charger has delivered, is shown on the display in
ampere-hour.

c. Cycle test

Cycle Initial Charge (Ah)

Before the start of the first cycle, the battery will be charged initially. This is needed for starting the first cycle
with a fully charged battery. This is shown on the display with 'Mode000 Charge'

Cycle Discharge (%)

A cycle starts always with a capacity test. The results of these tests are the same as a normal capacity test.
This is shown on the display with 'Mode001 Discharg'.

Cycle Charge (Charge Factor)

A cycle ends always with charging. During these tests the AlfaBat measures how many energy is charged into
the battery. The charge factor must be between 1.10 and 1.25. When the charge factor is below 1.10, the
battery will get undercharged with capacity loss in time. When higher then 1.25, the battery will age much
faster. Remark: for systems with acid circulation systems the charge factor can be between 1.05 and 1.10.
This mode is shown on the display with 'Mode001 Charge'.

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Note
Not every charger is suitable to perform a cycle test on a battery. Here's a list of possible problems:
- The charger goes in stop after the first charge and must be restarted with the ON/OFF button before
the charger can charge again.
- The charger is not able to charge 100% discharged batteries many cycles. This has declining capacity
as result after a few cycles. If the charger is not suitable for charging 100% discharged batteries, you
can't classify the battery as bad if capacity is declining. It is also not possible to classify the charger as
bad, because the charger could be designed for charging batteries, which are discharged for max 80%.

d. Record test

Record finished
This message is shown on the display after the ending of a record test. The results can be transferred to the
computer. During a record test, only data is recorded (no calculations).

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5. INTERFACING WITH PC

The AlfaBat can be used without a personal computer. However, if you want to use all functions of the device,
you need a computer.

The software gives you following extra possibilities:

- Editing profiles (gives the possibility to use all functions of the AlfaBat) Monitor tests (Online
information about the test)
- Read out results (transfer data to the computer)
- Uploading firmware (Placing new firmware in the device)
- Set clock (synchronize clock of the AlfaBat with the clock of the computer)
For more information: see BITS-manual.

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 5.1. USE OF PROFILES

The AlfaBat works with profiles. This is a predefined table with customized settings, which makes it very easy
to use the AlfaBat.
For example: You only want to test 12V batteries with a capacity of 24Ah/20h. With a profile it is possible
to connect the battery and start the test immediately, without setting different parameters.
The table shows the optimal profile for the example described above:
Parameter Min Max Default Value
01: Battery voltage auto detection ( 0 = Manual / 1 = Auto ) 0 1 1 1
02: Preselect battery voltage ( 00 = 6V / 01 = 8V / 11 = 12V ) 0 11 11 11
03: Use Preset mode ( 0 = Automatic / 1 = Manual ) 0 1 1 0
04: Preset Mode ( 00 = discharge, 01 = charger test, 10 = 0 11 0 0
cycle,11 = record )
05: Record Voltage ( 0 = OFF, 1 = ON ) 0 1 1 1
06: Record Current ( 0 = OFF, 1 = ON ) 0 1 1 1
07: Printer output enable ( 0 = OFF, 1 = ON ) 0 1 0 0
08: Preset Capacity ( 0 = Manual, 0.8 - 100 Ah ) 0.8 100 20 24
09: Capacity Unit ( 0 = Manual, 5 = C5, 10 = C10, 20 = C20 ) 5 20 0 20
10: Peukert Factor ( 0 = Manual, 1.10, 1.12, 1.14, .., 1.36 ) 1.1 1.36 1.2 1.2
11: Peukert calculation test ( 0 = OFF / 1 = ON ) 0 1 0 0
12: Temperature ( 0 = Automatic, 1..127 ) 0 127 0 20
13: Temperature Unit ( 0 = °C, 1 = °F ) 0 1 0 0
14: Maximum Charging Time / Recording Time (0 = Manual, 0 99 12 12
1..99hour )
15: Number of cycle in cycle mode ( 0 = Manual ) 0 99 3 3
16: Offset (1/impedance) 0 255 24 24
17: Bad Cell Timer in minutes ( 0 = Auto, 1..30 ) 0 30 0 0
18: Bad Cell Voltage High level ( 0 = Auto, 1.50V .. 2.55V ) 1.5 2.55 0 0
19: Bad Cell Voltage Low level ( 0 = Auto, 1.50V .. 2.55V ) 1.5 2.55 0 0
20: End of discharge voltage in Volt / element ( 0 = Auto, 1.51 2.55 0 0
1.51 ..2.55 )
21: Needs charging voltage in Volt / element ( 0 = Auto, 1.51 .. 1.51 2.55 0 0
2.55 )
22: Pass / Fail Threshold in % ( 0 .. 100 ) 0 100 60 60
23: Maximum discharge ( 0 = OFF / 1 .. 150 ) 0 150 0 0
24: Discharge current ( 0 = AUTO, 5 = 5A, 10 = 10A) 0 10 0 0
25: Detect start of charge ( 0 = OFF / 1 = ON ) 0 1 1 1
26: Detect end of charge ( 0 = OFF / 1 = ON ) 0 1 1 1

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 a. Battery Voltage Auto Detection

Automatic
When set to automatic, the tester measures the battery voltage: 6V, 8V or 12V. Important: The auto
detection will fail on a very deep discharged 12V-battery.

Manual
Before a test will start, you can make a selection between a 6V, 8V or a 12V-battery.

b. Voltage (6V / 8V / 12V)

This parameter is disabled, if the "Battery Voltage Auto Detection"-parameter is enabled.

6V
The tester will ask to test a 6V-battery. It is possible to choose another value on the device.
8V
The tester will ask to test a 8V-battery. It is possible to choose another value on the device.
12V
The tester will ask to test a 12V-battery. It is possible to choose another value on the device.

c. User Preset Mode

The AlfaBat can work in the following different modes: Discharge, Charge, Cycle and Record.

Automatic
The AlfaBat will use the mode which is set with parameter ‘Mode (Discharge / Charge / Cycle / Record)’,
without asking the user to choose the working mode.

Manual
The AlfaBat will ask to use the mode which is set with parameter ‘Mode’. The user can scroll between
different modes with UP / DOWN keys.

d. Preset Mode (Discharge / Charge / Cycle / Record)

Discharge
Selecting this mode will do a capacity test.

Charge
Selecting this mode will do a charger test.

Cycle
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Selecting this mode will do a battery / charger test as many times as set with the parameter ‘Cycle number’.

Record
This mode does not make measurements; it only records data (voltage and/or current).

e. Save Voltage

Enabled
During a test, a voltage curve will be saved in the AlfaBats internal memory.

Disabled
During a test, no voltage curve will be saved in the AlfaBats internal memory.
Note: If both (Save Voltage and Save Current) are disabled, no information about a test at all will be saved in
the internal memory (no percentage, charge factor, ...).

f. Save Current

Enabled
During a test, a current curve will be saved in the AlfaBats internal memory.

Disabled
During a test, no current curve will be saved in the AlfaBats internal memory.
Note: If both (Save Voltage and Save Current) are disabled, no information about a test at all will be saved in
the internal memory (no percentage, charge factor, ...).

g. Capacity Value

Manual
When using this mode, the user will be asked to use the last used value of the capacity.

Set value
The user can set a value in the profile from 0.8Ah to 100Ah (AlfaBat) / 400Ah (AlfaBat Pro). 'Zero' will set
this option to Manual.

h. Capacity Unit

The Capacity of a battery can be given in 5h, 10h, 20h, …

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For example: A battery with a capacity of 60Ah in 20h can have a capacity of 50Ah in 5h.
 The battery with this specification can supply 3A during 20h or supply 10A during 5h.
The relation between the value in 20h, 5h, … depends on the battery technology and is described with the
Peukert Factor.

Manual
When using this mode, the user will be asked to use the last used value (5h to 20h) of the unit of the capacity.

Set value
The user can set a value in the profile from 5h to 20h. 'Zero' will set this option to Manual.

i. Peukert Factor

The amount of energy you can take out of a battery depends of the discharge current.
For example: A 60Ah/20h (and 50Ah/5h) battery can supply 3A during 20h. When this battery has no losses,
this battery can supply 12A during 5h. Because there are no loss-less systems in the real world, this value will
be lower in 5h.
In this example it will be 10A during 5h (the Peukert factor for this battery is 1.15).
The relation between the available capacities at different discharge rates can be expressed by a single constant,
known as the Peukert value. Each battery type has its own Peukert value. The Peukert capacity of a battery
is the net available capacity at a discharge rate of 1 Amp.
Note: If you don’t know the Peukert factor of a battery, you can always calculate it with the AlfaBat. The
AlfaBat must then set in the profile with the parameter: Peukert Calculation Test.

Manual
When using this mode, the user will be asked to use the last used value (1.10 to 1.36) of the Peukert value.

Set value
The user can set a value in the profile from 1.10 to 1.36. Zero will set this option to Manual.

j. Peukert Calculation Test

Sometimes it is hard to find any information about the Peukert Factor of a battery. With this setting, you can
automatically perform a Peukert calculation on a battery. This calculation is only possible if you use the
'Monitor test' function with the BITS-software
This test can only be performed with a cycle test of minimum two cycles. However, the more even cycles
you perform the more accurate the Peukert value will be.
You also need to set the discharge current at its maximum.
Important: use a new healthy battery; otherwise the results will not be representative for the type of
battery of which you would like to know the Peukert factor.
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Note: This parameter must be disabled in normal use.

k. Temperature

The ambient temperature is a necessary parameter to correct the measurement of the battery capacity.

Automatic
When using this mode, the user will be asked to use the measured value (0°C to 30°C / 32°F to 86°F). When
the measured value is higher than 30°C/86°F, the last used temperature will be shown on the display.

Set value
The user can set a value in the profile from 1 to 127 (°C or °F, depends of parameter: Temperature Unit).
Zero will set this option to Manual.

l. Temperature Unit (°C / °F)

Degrees Celsius (0)

The temperature can be chosen on the device in degrees Celsius.

Degrees Fahrenheit (1)

The temperature can be chosen on the device in degrees Fahrenheit.
Note: Any value you chose between 1°F to 32°F, will be converted to 32°F.

m. Max Charging Time / Recording Time

The timer has two functions for a charger test:

- During a charger test data recording will start when a current change over C/200 is detected
(C=nominal battery capacity). The test will stop if there is no current change within the set time. It
is possible to disable this function with parameter 'Detect Start of Charge'.
- Data recording will stop when:
o the charging current is below C/200 for 10 minutes. It is possible to disable this function with
parameter 'Detect end of Charge'.
o the max charge timer value (when data recording is started) has expired.
This timer is also required to set the time of a record test.

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Manual
When using this mode, the user will be asked to use the last used value of the Max Charging Time or
Recording Time.

Set value
The user can set a value in the profile from 1 to 99 hours. 'Zero' will set this option to Manual.

n. Number of Cycles in Cycle Mode

This parameter will set the number of cycles when you want to perform a Cycle Test on a Battery and a
Charger.
Important: 255 will perform a cycle test without end (only an error or a user can stop the test). This can
be very useful for testing the long term quality of a Battery (this test can take a very long time: months!).

Manual
Before a Cycle Test will start, the user will be asked to use the last used value (1 to 255) of the number of
cycles.

Set value
The user can set a value in the profile from 1 to 255. Zero will set this option to Manual.

o. Offset

What
The value placed in the profile is the ‘1/impedance’ – setting. It is a parameter that describes the losses over
cables and connectors.

Why?
Because of the voltage drop over the cables and connections, the AlfaBat measures a wrong Battery-voltage.
With this parameter the losses can be corrected and give an improvement of the accuracy.
Important: Changing this value can disturb the correct working of the AlfaBat. Normally you should leave
this parameter at its default setting.

p. Bad Cell Timer

This is a necessary part of the BadCell - detection algorithm. This value depends of the capacity and the
discharge current.

Note: It is best to use the automatic calculation.

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Automatic
Setting this parameter to ‘zero’, gives an automatic calculation of the correct value.

Set value
The user can set a value in the profile from 1 to 128 seconds or from 1 to 128 minutes.

q. Bad Cell Voltage High

This is a necessary part of the BadCell - detection algorithm.

Note: It is best to use the automatic calculation.

Automatic
When using this setting, the AlfaBat will use the same value as the 'end of test voltage'-parameter.

Set value
The user can set a value in the profile from 1.50V/Cell to 2.55V/Cell.

r. Bad Cell Voltage Low

This is a necessary part of the BADC - detection algorithm.

Note: It’s best to use the automatic calculation.

Automatic
Setting this parameter to ‘zero’, gives an automatic calculation of the correct value.

Set value
The user can set a value in the profile from 1.50V/Cell to 2.55V/Cell.

s. End of Test Voltage

This is the value where the battery is discharged for 100%. This value depends on the load current and the
battery capacity.
Note: It’s best to use the automatic calculation.

Automatic
Setting this parameter to ‘zero’, gives an automatic calculation of the correct value.
The curve below shows how the AlfaBat calculates the 'End of Test Voltage' with the load factor. The load
factor is the relation between the load current and I5 (= C5 / 5h).
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Set value
The user can set a value in the profile from 1.51V/Cell to 2.55V/Cell.

t. Needs Charging Voltage

A battery that is not charged will go fast below this voltage when a capacity test is started. This parameter
depends of the load current and the battery capacity.
Note: It is best to use the automatic calculation.

Automatic
Setting this parameter to ‘zero’, gives an automatic calculation of the correct value.

Set value
The user can set a value in the profile from 1.51V/Cell to 2.55V/Cell.

u. Pass / Fail Threshold

This parameter describes if the battery is good or bad.

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Example: Parameter is set to 60%. After the AlfaBat has finished a test, the display will show:
- ‘Passed’ if the capacity is above 60%,
- 'Failed' if the result is below 60%.
Note: Normally a Battery with less than 60% is worn out.

v. Max Discharge

This parameter gives the possibility to discharge a battery between 1 and 150%.
- Example 1: This parameter can be very useful for testing the quality of a charger with a discharged
battery for 80%.
- Example 2: The security sector: the battery can only be discharged for 60%, others there will be a
safety problem.

Disabled:
Setting this parameter to ‘zero’ will disable this function.

Manual:
Any value between 1 and 150% sets this value to manual mode. The user can change this value between 1
and 150%.

w. Discharge Current

With this parameter, you can set the battery discharge current.
Note: 10A on a 0.8Ah/20h battery is very high and not good for the battery.

Automatic
Setting this parameter to ‘zero’, gives an automatic calculation of the discharge current. This calculation
happens as described in the following table:
Capacity Discharge current
0.8 .. 9.9Ah 5A
10 .. 49Ah 15A
50 .. 400Ah 30A

Set Value
AlfaBat Pro: any value between 3.0A to 30.0A with steps from 0.2A can be used.

x. Detect Start of Charge

Enabled (ON)

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During a charger test, the recording of data will start when a current change from C/200 is detected
(C=nominal battery capacity).

Disabled (OFF)
The recording of data, independent of the charge current, starts directly.

y. Detect End of Charge

Enabled (ON)
During a charger test data recording will end when a current change over C/200 is detected (C=nominal
battery capacity) or when there is an overflow of the max time.

Disabled (OFF)
The Charger test will be ended when there is an overflow of the max time.

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6. TROUBLE SHOOTING

In this part of the manual we want to give some solutions for technical problems.

Use first of all this list:

1. Think: no connection faults (polarity, wrong port, ...)
2. Check in the manual if you can find your fault
3. Contact your dealer

6.1. SELF-POWER DOWN OF THE ALFABAT

After a few seconds:

When a device is powered-up, there is a detection of the battery-voltage. When this voltage is higher than
15V, the AlfaBat will be powered off.

After 30 minutes (before or after a test):

When a device is powered-up, the test must start within 30 minutes. After a test is finished the device will
automatically shut down after 30 minutes.

Within 30 minutes (before or after a test):

When a device is powered-up and the voltage is to low, the device will automatically shut down. This is to
avoid deep discharging of the battery.

6.2. NO POWER UP

- Fuse blown
- Inverse polarity
- Check connections

Replace the fuse of the AlfaBat:

 Type: MINI Blade Fuse 15A 32V AC/DC (Littelfuse)
 Contact your dealer for replacement of this fuse.

Replace the fuse of the AlfaBat Pro:

 Type: MAXI Blade Fuse 50A 32V AC/DC (Littelfuse)
 This fuse can be found on the front of the device. This fuse can be removed by pulling the fuse
forwards. After this, it is easy to place the new one.
 This fuse can be bought from your dealer

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 6.3. ERROR: OVER TEMPERATURE

When a test is running there is a continuous detection of the internal temperature. When it arises above
75 °C / 167°F it will automatically stop the test.
Check if the ambient temperature is not above 40°C / 104°F, ventilation holes are not covered with towels,
etc.

6.4. ERROR: NO ADAPTOR

When a Charger, Cycle, Record test is running there is a continuous detection of the absence of the external
adaptor. When it is disconnected, the test automatically stops.
This is necessary for correct measurements.

Solutions:
 Connect adapter
 Check if the adaptor is connected correctly
 Compare specifications with specifications needed for the AlfaBat

6.5. ERROR: BATTERY LOW

When a test is running there is a continuous detection of the Battery Voltage. When it gets lower than 3.8V,
the test automatically stops.

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7. TECHNICAL SPECIFICATIONS

7.1. TECHNICAL SPECIFICATIONS OF THE ALFABAT PRO

Absolute Maximum Ratings

- Battery voltage: 0-30V
- Charger voltage: 0-30V
- Charger current: 50A
- Ambient temperature: 0-40°C
- Accuracy: 1% (4%) *
However, the max rating for the voltage is 30V, it is not possible to perform a test under these conditions.

Normal use:
- Discharge current: 30A Max
- Charging current: 50A Max
- Power dissipation: 360W Max
- Standby current: 0.06A Max
The AlfaBat Pro is designed for testing 6V, 8V or 12V lead-acid batteries (0.8Ah - 400Ah).

DC - Adaptor:
- Adapter current: 0.75ADC
- Voltage: 9VDC
- Regulation: Not needed
- DC-plug: 2.1/5.5 DC-plug
The inside of this DC-plug should be positive.
The AlfaBat is designed to be used with adapter FW7400/09. This adaptor must be connected to the main
supply (100-240VAC / 50-60Hz).
The functionality of the unit is only guarantied if this adaptor is used.

Communication Cable:
This must be a mini USB cable.

* The accuracy for a capacity test is 1% for a 30A discharge current and 4% for a 5A discharge current. This
accuracy is only reachable if all parameters (temperature, Peukert factor, ...) are correctly selected. This
accuracy is exclusive possible deviations in the Peukert model.

** This appliance complies to the Low Voltage Directive for electrical safety and this according to IEC 61010.
This appliance complies to the EMC directive 61326.
This under condition that the battery-charger fulfills the requirements for safety (IEC 60335-2-39) and EMC
and is CE-marked or additionally certified by an independent Certification Body.

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8. SAFETY INSTRUCTIONS

- Connect only chargers directly to the Charger-port, which are suitable for charging 6V, 8V or 12V-
batteries.
- Only test 6V, 8V or 12V rechargeable lead-acid batteries. Test of non-rechargeable batteries can
cause explosion or damage to the battery / device with possible injuries as result.
- Do not block airflow in and out of the machine. A minimum clearance of 10 cm (4") around the unit
is required.
- Do not expose to rain or moisture. The unit is designed for indoor use and is not waterproof: keep
it away from areas of high humidity to avoid damage.
- Disconnect all terminals before cleaning the machine.
- Connect only equipment, which is suitable for use with the AlfaBat or AlfaBat Pro. Check this first in
the technical specifications.
- The user may not make changes or adaptations to the device unless with agreement of the
manufacturer. If the user makes changes or adaptations to the device without agreement of the
manufacturer, the responsibility of the manufacturer expires and it is prohibited for the user to use
the device.
- The user is not allowed to open the device. Repair of the device is only allowed through an authorized
technician.

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9. CLARIFICATION OF SYMBOLS

Read the safety and installation instructions before use.

This appliance complies to the Low Voltage Directive for electrical safety and this according
to IEC 61010. This appliance complies to the EMC directive 61326.
This under condition that the battery-charger fulfils the requirements for safety (IEC 60335-
2-39) and EMC and is CE-marked or additionally certified by an independent Certification
Body.

Tested to comply with the FCC standards.

The surface of the AlfaBat can reach temperatures higher than 70°C. Be careful when touching
the device during or after operation.

EXT Connect the FW7400/09 power supply here (technical specifications).

DC symbol.

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10. MAINTENANCE

Cleaning:
 Disconnect all terminals before cleaning the machine.
 The AlfaBat and AlfaBat Pro are not waterproof. Do not immerse the device.
 Use a soft and dry towel to clean the device.

Fuse replacement
 Type: MAXI Blade Fuse 50A 32V AC/DC (Littelfuse)
 This fuse can be found on the front of the device. This fuse can be removed by pulling the fuse
forwards. After this, it is easy to place the new one.
 This fuse can be bought from your dealer.

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11. WARRANTY

Leclanché warrants that the AlfaBat will be free from defects in materials and workmanship for a period of
one (1) year from the date of shipment. If the product proves defective during the warranty period, Leclanché,
at its option, will:
1. Repair the product.
2. Replace the product with a comparable product.

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