September 2013 167-000502EN-A EXP-1002 Expandable Electrical Diagnostic Platform For testing 6- and 12-volt automotive and 12-volt and 24-volt charging systems. INSTRUCTION MANUAL Midtronics Inc. EXP-1002 7000 Monroe Street Willowbrook, IL 60527 2 www.midtronics.com EXP-1002 Contents Chapter 1: Introduction & Overview 5 Personal Precautions Accessories* External Connections Connecting The Battery Test Cable Connecting An Accessory Cable Data Card Conventions Used in This Manual Display And Keypad Data Entry Methods Menu Icons Option Buttons Scrolling Lists Scroll Boxes Alphanumeric Entry Menu Maps Main Menu Utility Menu DMM Menu Info Menu Test Preparation Inspecting the Battery Testing Out-of-Vehicle Testing In-Vehicle Connecting The Test Cable Connecting an Accessory Cable Setting User Preferences Initial Power-up 5 Chapter 2: Battery Test Additional Test Requirements Surface Noise/Unstable Battery Deep Scan Test Battery Test Results Chapter 3: System Test Battery Test Additional Test Requirements Battery Test Results Starter System Test Starter System Test Results Charging System Test Charging System Test Results Chapter 4: Cable Drop Test Performing A Test Cable Drop Test Results Chapter 6: DMM (Digital Multimeter) 5 6 6 6 6 6 7 8 8 8 8 8 8 9 9 9 10 10 11 11 11 11 11 11 11 11 14 15 15 16 16 17 17 24 24 24 24 24 24 24 24 25 25 25 25 25 25 25 26 26 26 26 26 26 27 27 27 27 27 27 27 Chapter 9: Maintenance & Troubleshooting Testing Clamp Continuity Performing A Continuity Test Internal Batteries Battery Power Indicator Replacing The Tester Batteries Troubleshooting The Display Does Not Turn On The STATUS LED Flashes Data Will Not Print 19 19 19 20 20 20 Chapter 7: Info Clock Mode Time Format Date Shop Display Contrast Level Backlight Time Coupon Edit Coupon Temp Language Format Update Admin Options Clear Test Totals Reset Defaults 14 Selecting Test Parameters Printing Test Results Clearing Test Results 21 21 21 21 22 22 22 22 22 Chapter 8: Utility 13 13 13 13 20 DC Volts AC Volts Scope DC Amp AC Amp Temp Ohm Meter Diode Volts/Amp Print/View View Cable Test View Inventory Test Totals Transfer Version Internal Batteries 12 Chapter 5: Inventory Test Appendix: Templates 3 Midtronics Inc. 28 28 28 28 28 28 29 29 29 29 30 Header And Coupon Templates www.midtronics.com 21 7000 Monroe Street 30 Willowbrook, IL 60527 Midtronics Inc. EXP-1002 7000 Monroe Street Willowbrook, IL 60527 4 www.midtronics.com EXP-1002 Chapter 1: Introduction & Overview Chapter 1: Introduction & Overview Personal Precautions Inspect the battery for damage and check the electrolyte level. If the electrolyte level is too low, replenish it and fully charge the battery. Always use the necessary safety precautions when working with batteries to prevent severe injury or death. Follow all manufacturers’ instructions and BCI (Battery Council International) safety recommendations, which include the following precautions: Battery acid is highly corrosive. If acid enters your eyes, immediately flush them thoroughly with cold running water for at least 15 minutes and seek medical attention. If battery acid gets on your skin or clothing, wash immediately with a mixture of water and baking soda. Always wear proper safety glasses or face shield when working with or around batteries. Keep hair, hands, and clothing as well as the analyzer cords and cables away from moving engine parts. Remove any jewelry or watches before you start servicing the battery. Use caution when working with metallic tools to prevent sparks or short circuits. Never lean over a battery when testing, charging, or jump starting. Risk of explosive gases. Never smoke or allow a spark or flame in the vicinity of a battery. Batteries can produce a highly explosive mix of hydrogen gas and oxygen, even when the battery is not in operation. Always work in a well-ventilated area. Wash hands after handling. REQUIRED BY CALIFORNIA PROP. 65: Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the state of California to cause cancer and birth defects or other reproductive harm. Accessories* Soft Carrying Case (Std.) Hard Carrying Case (incl. w/Amp Kit) Printer Paper (Std.) Stud Adapters (Std.) DMM Probe Kit (incl. w/Amp Kit) 10’ Battery Test Cable (Std.) A087 IR Printer (incl. w/Amp Kit) A028 DMM Cable (incl. w/Amp Kit) A018 Amp Clamp (incl. w/Amp Kit) * - AMP Kit includes all shown accessories except item . www.midtronics.com 5 Midtronics Inc. 7000 Monroe Street Willowbrook, IL 60527 Chapter 1: Introduction & Overview EXP-1002 Connecting The Battery Test Cable External Connections Connect the battery test cable to the tester by first aligning the cable connector’s 6 pins with the holes on top of the tester. Firmly insert the connector and finger-tighten the locking ring. IMPORTANT: Do not turn the locking ring more than ¾ of a turn or you will damage the tester components. Connecting An Accessory Cable If you are using an accessory cable, plug it into the accessories port on top of the tester as you would a phone jack. To remove it, press the lever and pull out the cable connector. Data Card RJ45 connector (Accessories Port) with a release lever for accessory connections. 6-pin connector, with a locking ring, for the battery test leads. The analyzer ships with a plastic insert in the data card slot to protect it from dust and debris. To remove the plastic insert or a data card, push briefly on its edge to release it and pull it from the slot. When inserting a card, push it into the slot until it locks. The card is correctly inserted when it is not protruding from the slot. To protect the card slot and enable the analyzer to read and write to the card, leave the card in the slot. Temperature measurement sensor. Data transmitter, which transmits test results to an IR printer. Conventions Used in This Manual DB-9 connector for future accessories. Spring-loaded data card slot for test data storage and software upgrades. To help you learn how to use your Midtronics product, the manual uses these symbols and typographical conventions: Symbols And Typographical Conventions Convention ! Description The safety symbol indicates instructions for avoiding hazardous conditions and personal injury. The safety symbol with the words CAUTION, WARNING, or DANGER indicates instructions for avoiding hazardous conditions and personal injury. The wrench symbol indicates procedural notes and helpful information. Midtronics Inc. 7000 Monroe Street Willowbrook, IL 60527 6 These symbols indicate which arrow keys on the keypad to press for a given function. CAPITAL LETTERS The text for screen options are in regular capital letters. NEXT The text for soft keys are in Bold capital letters. www.midtronics.com EXP-1002 Chapter 1: Introduction & Overview Display And Keypad The analyzer keypad and display work together to help you quickly find and use the right tools at the right time. The display also keeps you on track with on-screen navigation aids, directions, and messages. The illustration below shows how the elements on the screen relate to the keypad. POWER Key Press the POWER button to turn the analyzer on and off. The analyzer also turns on automatically when you connect its test leads to a battery. Title Bar The title bar shows you the name of the current menu, test tool, utility, or function. Selection Area The selection area below the Title Bar contains selectable items or dialog boxes that display information or require a response. Menu Screen Arrows When displayed in menu screens, the menu screen arrows show you which ARROW key on the keypad to press to display other icons or screens. When displayed under a list of options, the menu screen arrows show you which keypad arrow to press to highlight a character or item in a list. Scroll Bar Another navigational aid is the scroll bar on the right side of the screen. The position of its scroll box shows you whether the screen is the top (or only screen), middle, or last in a series. Scroll Box Top or only screen Internal Batteries Status Indicator This indicator appears in the screen’s top left corner, lets you know the status and charge level of the analyzer’s six (6) 1.5-volt batteries. The X in the top left corner of the screen shows that the analyzer is powered by the battery you’re testing to conserve the analyzer’s internal batteries. Last screen Arrow ( ) Keys Press to move up to the next selectable item or row. When entering text, use to move to the previous character. Press to move down to the next selectable item or row. When entering text, use to move to the next available character. Use or to scroll to the letters A through Z and the numbers 0 through 9. When entering text, use to move one space to the right and to move one space to the left. Voltmeter When you first connect the analyzer to a battery it functions as a voltmeter. The voltage reading appears above the left soft key until you move to other menus or functions. Soft Keys Press the two soft keys linked to the bottom of the screen to perform the functions displayed above them. The functions change depending on the menu or test process. So it may be helpful to think of the words appearing above them as part of the keys. Some of the more common softkey functions are SELECT, BACK, and END. www.midtronics.com Middle screen Alphanumeric Keypad In some cases, you can use the Alphanumeric Keypad to enter numerical test parameters instead of scrolling to them with the keys. You can also use the Alphanumeric Keys to create and edit customer coupons. The keypad includes characters for punctuation. To add a space, press . To add a character or insert a space, press . 7 Midtronics Inc. 7000 Monroe Street Willowbrook, IL 60527 Chapter 1: Introduction & Overview EXP-1002 Option Buttons Some lists have option buttons before each item. To select an item, use or to move the dot to the button next to the item. To confirm your selection, press the appropriate soft key. Refer to the following table for the characters associated with each alphanumeric key. Key Character $ - () 1 a b c 2 d e f 3 g h i 4 j k l 5 m n o 6 p q r s t u v 8 w x y z 9 % , . # 0 Scrolling Lists Scrolling lists contain items that extend above and below the screen. The first number above the right soft key indicates the position in the list of the highlighted item. The second number above the right soft key indicates the number of items in the list. 7 Data Entry Methods To select an item, press or to highlight the item and press the appropriate soft key. To advance the highlight bar up or down four lines at a time, press or . To perform a particular test or function, the tester requires different types of information. This means that the methods you use to enter information will change depending on the type of information requested. The five types of entry methods are described below. Scroll Boxes Scroll boxes contain variables that are displayed by scrolling using arrow keys. To select, use or to scroll to the value, and press the appropriate soft key. In the illustration the left directional arrow indicates that you can press to clear all or part of the entry. Typically, the soft key below the right half of the screen confirms your choice, although the command above it may vary. (Examples: SELECT, NEXT, and SAVE.) In a similar fashion, the soft key below the left half of the screen cancels your choice or returns you to the previous screen, although the word above it may also vary. (Examples: BACK and END.) Alphanumeric Entry Some selections require you to alphanumeric characters. These “user-defined” selections have a blinking horizontal line (cursor) to the right of the last character. Menu Icons A menu icon is a graphical representation of a function you can select, such as the Battery test Icon in the Main Menu. To select an icon, use or to highlight it. Highlighting changes the icon to a white picture on a black background. To confirm your selection, press the appropriate soft key. Midtronics Inc. 7000 Monroe Street Willowbrook, IL 60527 Use or to highlight a line for editing. Press SELECT to edit the selected line. Display the character or number you want by rapidly pressing an ARROW key as many times as needed, or press and hold the ARROW key to rapidly scroll. To backspace, press . Use to add a space. When finished, press the appropriate soft key to save the text you entered. 8 www.midtronics.com EXP-1002 Chapter 1: Introduction & Overview Menu Maps Utility Menu This section will help you get to your destination while letting you know what test leads you may need when you arrive. The test leads are represented by symbols for their connectors. The Utilities Menu allows you customize your analyzer. Before testing, check the default values to see which options you may want to change. Menu Icon Main Menu The Main Menu is the starting point for all tools and utilities, which are depicted as icons. Some icons lead directly to the function they represent, while others are menu icons that lead to two or more functions. Description Settings to adjust date and time. Allows you to add a custom header to printed test results. Required test leads Settings to adjust the screen contrast and backlight time. Battery Test Menu Icon Amp Clamp Cable Drop If you created a coupon with the Edit Coupon utility, use Coupon to enable or disable the inclusion of a coupon on printed test results. Description Allows you to create and store up to three separate coupons to be printed on test results. Tests one battery using the battery information you select in a series of screens. Allows you to select degrees in C or F for temperature measurements. Tests the battery pack or individual batteries (and the starting and charging systems. Sets the language of the display and printouts. Tests both sides of a circuit simultaneously for voltage drop. Three preset tests and one userdefined. Formats the data card to receive data. Also erases all data on the card. Enables up to 100 batteries to be tested in succession without re-entering battery information each time. * Digital multimeter with eight test meters, a temperature sensor, and options for clamps and probes. * Includes a test counter, data transfer utility, the tester software version and serial number. * Nine utilities, many of which customize your user interface. www.midtronics.com Updates the analyzer software via files on a data card. Clear test totals, address header printing, restore defaults, and enable BMIS functionality. 9 Midtronics Inc. 7000 Monroe Street Willowbrook, IL 60527 Chapter 1: Introduction & Overview EXP-1002 DMM Menu Info Menu Use the DMM Menu to access the test meters, temperature sensor, and probe and clamp options, some of which require optional test leads. Menu Icon The Info Menu has seven utilities to help you manage your test data, and track the analyzer’s usage and history. Description Menu Icon Measures voltage within a range of 0 to 60 Vdc. * Description Allows you to view your stored test results and print them to an optional IR printer. Measures voltage within a range of 0 to 24 Vac. Displays the last Cable Drop Test result. Sends the result to an optional IR printer. Voltage trace with time and frequency measurements. View and print the results of the last test of new batteries in inventory. Tests the strength of the direct current flow through a circuit. Displays the total number of test in three categories: Lifetime of the analyzer, by User ID, and by decision. Tests the strength of the alternating current flow through a circuit. An optional IR software and hardware package allows you to transfer test data to a PC. Sensor that displays temperature in degrees F or C (units you can select in the Utilities Menu.) Displays the software version, total tests from first use, and the serial number. Tests a circuit for continuity and resistance measured in ohms (Ω). Displays the power status of the tester’s internal batteries. Tests a diode for forward voltage drop. Measures two signals simultaneously: DC voltage and amperage. Midtronics Inc. 7000 Monroe Street Willowbrook, IL 60527 10 www.midtronics.com EXP-1002 Chapter 1: Introduction & Overview Test Preparation Connecting The Test Cable Inspecting the Battery Before starting the test visually inspect the battery for: •• Cracked, buckled, or leaking case. If you see any of these defects, replace the battery. •• Corroded, loose, or damaged cables and connections. Repair or replace them as needed. •• Corrosion on the battery terminals, and dirt or acid on the case top. Clean the case and terminals using a wire brush and a mixture of water and baking soda. •• Low electrolyte level. If the electrolyte level is too low, add distilled water to fill up to ½ above the top of the plates and fully charge the battery. Do not overfill. •• Corroded or loose battery tray and hold-down fixture. Tighten or replace as needed. Do not connect the tester to a voltage source greater than 30 Vdc. Connect the battery test cable to the tester by first aligning the cable connector’s 6 pins with the holes on top of the tester. Firmly insert the connector and tighten the locking ring. Connect the clamps to the tester: the red clamp to the positive (+) terminal and the black clamp to the negative (–) terminal. If you connect the clamps in the wrong polarity (positive to negative or negative to positive), the tester displays CLAMPS REVERSED! Reconnect the clamps. To make sure both sides of the clamps are gripping the terminals, rock the each clamp back and forth. A poor connection will prevent testing, and the tester will display the message CHECK CONNECTION. If the message reappears after you have correctly reconnected the clamps, clean the terminals and reconnect. Testing Out-of-Vehicle The preferred battery test location is in the vehicle. However, if you plan to test out of the vehicle: •• Always disconnect the negative cable from the battery first and reconnect it last. •• Always use a carry tool or strap to lift and transport the battery. Connecting an Accessory Cable If you are using an accessory cable, plug it as you would a phone jack into the accessories port on top of the tester. It locks automatically into the port. To remove it after testing, press the lever and pull the connector out. Setting User Preferences Before starting your test you may want to customize the use of your analyzer by setting preferences in the Utility Menu. The menu has settings for the display’s date and time, the contrast and backlight time, a utility to customize printouts for the optional IR printer, among others. The Utility Menu is described in Chapter 9. Failure to properly install lead terminal adapters, or using adapters that are dirty or worn, may cause false test results. When testing side-post or Group 31 batteries, always use lead terminal adapters provided with the tester—do not test at the battery’s steel bolts. To avoid damage, never use a wrench to tighten the adapters more than ¼ turn. NOTE: To conserve the analyzer’s internal batteries, the tester will turn off after 30 seconds of inactivity. Testing In-Vehicle The preferred test position is at the battery posts. If you must test at a remote-post location, it should have both a positive and negative post. Otherwise, you must remove the battery and perform an out-of-vehicle test. Initial Power-up The first selection screen enables you to set the language for the display and printed test results. This option can disable. See “Options” in Utility Menu. At the start of the test, make sure all vehicle accessory loads are off, the key is not in the ignition, and the doors are closed. The Main Menu is then displayed on the screen. www.midtronics.com 11 Midtronics Inc. 7000 Monroe Street Willowbrook, IL 60527 Chapter 2: Battery Test EXP-1002 Chapter 2: Battery Test The Battery Test function tests one battery in or out of the vehicle and guides you through selecting battery the test parameters and interpreting the results. 6. Use or to select the battery RATING UNITS and press NEXT to continue or press the corresponding number key. This information is usually printed on the battery label. Use the BACK key to return to the Main Menu at the start of the test or to the previous screen as you progress. 1 1. In the Main Menu, select the Battery Test icon. 3 2. Use or to select the LOCATION and press NEXT to continue or press the corresponding number key. 1 2 3. 4 5 OUT OF VEHICLE 6 IN VEHICLE 7 Use or to select the POST TYPE and press NEXT to continue or press the corresponding number key. 1 2 3 4. 2 8 Rating TOP SIDE 2 3 4 5 6 AUTOMOTIVE (default) GROUP 31 COMMERCIAL 4D/8D LAWN & GARDEN If you select MOTORCYCLE as the battery type, the analyzer asks for the battery part number. Scroll to the part number (128 available). To increase your scrolling speed, hold the or key, or use or to move up or down four part numbers at a time. 5. Use or to select the BATTERY TYPE and press NEXT to continue or press the corresponding number key. 1 2 3 4 7. REGULAR FLOODED CA MCA JIS DIN SAE IEC EN Description Range Cold Cranking Amps (specified 100 to by SAE): The amount of current a 3000 battery can provide at 0 ºF (–17.8 ºC). CA Cranking Amps: The amount of current a battery can provide at 32°F (0 ºC). 100 to 3000 MCA Marine Cranking Amps: The amount of current a battery can provide at 32°F (0 ºC). 100 to 3000 JIS Japanese Industrial Standard: 26A17 to (shown on a battery as a 245H52 combination of numbers and letters. (72 numbers) DIN Deutsche Industrie-Norm 100 to 1000 SAE European labeling of CCA 100 to 3000 IEC International Electrotechnical Commission 100 to 1000 EN Europa-Norm 100 to 1700 MARINE BATTERY MOTORCYCLE CCA CCA JUMP START POST Use or to select the APPLICATION and press NEXT to continue. 1 Press or to select the BATTERY RATING or use the numeric keys and press NEXT to continue. a) If CCA, use the keypad or scroll to the rating and press SELECT. The entry range is 100 to 3000, except for DIN and IEC, which have a range of 100 to 1000. AGM AGM/SPIRAL GEL 500 CCA b) If JIS, scroll to the JIS number. 26A17 26A19 26B17 28A19 Midtronics Inc. 7000 Monroe Street Willowbrook, IL 60527 12 www.midtronics.com EXP-1002 8. Chapter 2: Battery Test Battery Test Results If prompted, measure the ambient battery temperature by aiming the temperature sensor on the top of the tester at the battery case and press NEXT to continue the test. After the test the tester will display one of five battery decisions with the complete results in a series of screens. Use or to scroll through each result. To send the results to an IR printer, press PRINT. To return to the Main Menu, press END, or to continue testing if you’ve selected the system text, press NEXT. You’ll have the opportunity to print all the results at the end of the System Test. Battery Case (Top) Sensor Measured Voltage Measured Capacity Temperature (If required) Battery Decision Additional Test Requirements Rating Units For a more decisive result the tester may require additional information. The following messages and instructions may appear before the analyzer displays the results of your test. Surface Noise/Unstable Battery The battery will hold a surface charge if the engine has been running or after the battery has been charged. The analyzer may prompt you to remove the surface charge before it begins testing. 1. Follow the tester’s instructions indicating when to turn the headlights on and off. 2. The analyzer will resume testing after it detects that the surface charge is removed. State Of Health Decision Deep Scan Test In some cases the tester may need to further analyze the battery to determine whether the battery should be replaced or it has a significant chance to be recovered. It will then conduct a Deep Scan Test of the battery for a few seconds. After the Deep Scan Test the tester will either display the results or give you the option to perform the 5-Minute Discharged Battery Test. Although this test takes several minutes, it gives a more precise result for difficult-to-diagnose batteries. GOOD BATTERY Return the battery to service. GOOD–RECHARGE Fully charge the battery and return it to service. CHARGE & RETEST * Fully charge the battery and retest. Failure to fully charge the battery before retesting may cause false readings. If CHARGE & RETEST appears again after you fully charge the battery, replace the battery. REPLACE BATTERY ** Replace the battery and retest. A REPLACE BATTERY result may also mean a poor connection between the battery cables and the battery. After disconnecting the battery cables, retest the battery using the out-of-vehicle test before replacing it. BAD CELL–REPLACE ** Replace the battery and retest. * For a more decisive result, the analyzer may ask if you are testing the battery before or after charging. If the vehicle has just been driven, select BEFORE CHARGE. Press NEXT to continue. www.midtronics.com Recommended Action If the result is CHARGE & RETEST, the tester will calculate and display the time needed to charge the battery at 10, 20, and 40 A. ** When testing at the jump start posts, the tester may need to verify the result. It will give you the option of retesting at the battery posts 13 Midtronics Inc. 7000 Monroe Street Willowbrook, IL 60527 Chapter 3: System Test EXP-1002 Chapter 3: System Test The System Test evaluates the battery, starting and charging systems. The System Test includes Battery Test to eliminate it as the cause of starting or charging problems. 6. Use or to select the battery RATING UNITS and press NEXT to continue or press the corresponding number key. This information is usually printed on the battery label. 1 The BACK key returns you to the Main Menu at the start of the test and to the previous screen as you progress. 2 3 Battery Test 4 The System Test includes a test of the battery to eliminate it as the cause of starting or charging problems. 5 1. In the Main Menu, select the System Test icon. 7 2. Use or to select the AMP CLAMP availability and press NEXT to continue, or press the corresponding number key. 8 6 Rating If you select the Amp Clamp, follow the on-screen instructions for zeroing out clamp and placing it around the negative battery cable before proceeding. 3. Use or to select the POST TYPE and press NEXT to continue or press the corresponding number key. 1 2 3 4. TOP JUMP START 2 3 4 5 6 AUTOMOTIVE (default) MARINE BATTERY MOTORCYCLE GROUP 31 COMMERCIAL 4D/8D LAWN & GARDEN 7. If you select MOTORCYCLE as the battery type, the analyzer asks for the battery part number. Scroll to the part number (128 available). To increase your scrolling speed, hold the or key, or use or to move up or down four part numbers at a time. 5. 2 3 4 CA MCA JIS DIN SAE IEC EN Description Range Cold Cranking Amps (specified 100 to by SAE): The amount of current a 3000 battery can provide at 0 ºF (–17.8 ºC). CA Cranking Amps: The amount of current a battery can provide at 32°F (0 ºC). 100 to 3000 MCA Marine Cranking Amps: The amount of current a battery can provide at 32°F (0 ºC). 100 to 3000 JIS Japanese Industrial Standard: 26A17 to (shown on a battery as a 245H52 combination of numbers and letters. (72 numbers) DIN Deutsche Industrie-Norm 100 to 1000 SAE European labeling of CCA 100 to 3000 IEC International Electrotechnical Commission 100 to 1000 EN Europa-Norm 100 to 1700 Press or to select the BATTERY RATING or use the numeric keys and press NEXT to continue. a) If CCA, use the keypad or scroll to the rating and press SELECT. The entry range is 100 to 3000, except for DIN and IEC, which have a range of 100 to 1000. Use or to select the BATTERY TYPE and press NEXT to continue or press the corresponding number key. 1 CCA CCA SIDE Use or to select the APPLICATION and press NEXT to continue. 1 500 CCA b) If JIS, scroll to the JIS number. REGULAR FLOODED AGM 26A17 AGM/SPIRAL 26A19 GEL 26B17 28A19 Midtronics Inc. 7000 Monroe Street Willowbrook, IL 60527 14 www.midtronics.com EXP-1002 8. Chapter 3: System Test Battery Test Results If prompted, measure the ambient battery temperature by aiming the temperature sensor and press NEXT to continue the test. After the test the tester will display one of five battery decisions with the complete results in a series of screens. Use or to scroll through each result. To send the results to an IR printer, press PRINT. To return to the Main Menu, press END, or to continue testing if you’ve selected the system text, press NEXT. You’ll have the opportunity to print all the results at the end of the System Test. Battery Case (Top) Sensor Measured Voltage Measured Capacity Temperature (If required) Battery Decision Rating Units Additional Test Requirements For a more decisive result the tester may require additional information. The following messages and instructions may appear before the analyzer displays the results of your test. Surface Noise/Unstable Battery State Of Health The battery will hold a surface charge if the engine has been running or after the battery has been charged. The analyzer may prompt you to remove the surface charge before it begins testing. 1. Follow the tester’s instructions indicating when to turn the headlights on and off. 2. The analyzer will resume testing after it detects that the surface charge is removed. Decision Deep Scan Test In some cases the tester may need to further analyze the battery to determine whether the battery should be replaced or it has a significant chance to be recovered. It will then conduct a Deep Scan Test of the battery for a few seconds. After the Deep Scan Test the tester will either display the results or give you the option to perform the 5-Minute Discharged Battery Test. Although this test takes several minutes, it gives a more precise result for difficult-to-diagnose batteries. GOOD BATTERY Return the battery to service. GOOD–RECHARGE Fully charge the battery and return it to service. CHARGE & RETEST * Fully charge the battery and retest. Failure to fully charge the battery before retesting may cause false readings. If CHARGE & RETEST appears again after you fully charge the battery, replace the battery. REPLACE BATTERY ** Replace the battery and retest. A REPLACE BATTERY result may also mean a poor connection between the battery cables and the battery. After disconnecting the battery cables, retest the battery using the out-of-vehicle test before replacing it. BAD CELL–REPLACE ** Replace the battery and retest. For a more decisive result, the analyzer may ask if you are testing the battery before or after charging. If the vehicle has just been driven, select BEFORE CHARGE. Press NEXT to continue. www.midtronics.com Recommended Action * If the result is CHARGE & RETEST, the tester will calculate and display the time needed to charge the battery at 10, 20, and 40 A. ** When testing at the jump start posts, the tester may need to verify the result. It will give you the option of retesting at the battery posts 15 Midtronics Inc. 7000 Monroe Street Willowbrook, IL 60527 Chapter 3: System Test EXP-1002 Starter System Test Decision Action If you are using the amp clamp, keep it clamped around the negative (–) battery cable. CRANKING NORMAL The starter voltage is normal and the battery is fully charged. 1. Start the engine at the prompt. LOW VOLTAGE 2. The tester will display one of 1 of 7 starter decisions with the complete results in a series of screens. Use or to scroll to each screen. The starter voltage is low and the battery is fully charged. CHARGE BATTERY The starter voltage is low and the battery is discharged. Fully charge the battery and repeat the starter system test. To send the results to an IR printer, press PRINT. To continue testing, press NEXT. REPLACE BATTERY (If the battery test result was (REPLACE or BAD CELL.) The battery must be replaced before testing the starter. LOW CRANKING AMPS The starter voltage is high but the cranking amps are low. NO START The engine didn’t start and the test was aborted. CRANKING SKIPPED The tester didn’t detect the vehicle’s starting profile and skipped the Starter Test. NOTE: In some cases, the tester may not detect the vehicle’s starting profile. It will display the soft key options STARTED and NO START. If you select STARTED, the tester will skip to the alternator test. If you select NO START, the test process ends. Starter System Test Results Average Cranking Amps Average Cranking Voltage Cranking Time Loop Ohms starter resistance (requires Amp Clamp) Y axis = Cranking Voltage X axis = Time Y axis = Cranking Current X axis = Time Midtronics Inc. 7000 Monroe Street Willowbrook, IL 60527 16 www.midtronics.com EXP-1002 Chapter 3: System Test Charging System Test 3. ANALYZING CHARGING SYSTEM DATA: After you press NEXT to begin the alternator test, the tester will immediately begin testing for alternator voltage. 4. TURN ALL VEHICLE LOADS OFF, IDLE ENGINE: Turn off vehicle loads (blowers, interior light, radio, etc.) and idle the engine. Press NEXT to continue. 11. REV ENGINE WITH LOADS ON FOR 5 SECONDS: The tester will test the charging system with the loads on and prompt you to rev the engine. Gradually increase the rev until the analyzer tells you to HOLD the rev level as the bar on the display crosses the rpm target line. 12. ACQUIRING DATA....HOLD ENGINE RPM: Continue to hold the rpm while the tester takes system measurements. 13. ENGINE REV DETECTED, IDLE ENGINE: The tester has detected the rev. Press NEXT to continue. NOTE: If necessary the analyzer will ask if you are testing a diesel engine. It will resume testing after you make your selection. 5. 14. ANALYZING CHARGING SYSTEM DATA: The tester is completing its final analysis of the charging system data. REV ENGINE WITH LOADS OFF FOR 5 SECONDS: Rev the engine with the loads off. Gradually increase the rpm until the analyzer tells you to HOLD the rev level as the bar on the display crosses the rpm target line. 15. TURN OFF LOADS AND ENGINE: Press NEXT to display the results. Charging System Test Results NOTE: Some 8-cylinder and older vehicles idle at a high level after starting, allowing the analyzer to detect the rev automatically. 6. ACQUIRING DATA....HOLD ENGINE RPM: Continue to hold the rpm while the tester takes system measurements. 7. ENGINE REV DETECTED, IDLE ENGINE: The tester has detected the rev. Press NEXT to continue. 8. TESTING ALTERNATOR AT IDLE, LOADS OFF: The analyzer will next test the engine at idle for comparison to other readings, and then test the diode ripple. Excessive ripple usually means one or more diodes have failed in the alternator or there is stator damage. 9. TURN HIGH BEAMS AND BLOWER MOTOR ON, IDLE ENGINE: After a few seconds, the tester will ask you to turn on the accessory loads. It will determine if the charging system is able to provide enough current for the demands of the electrical system. IMPORTANT: Turn on the high-beam headlights, the blower to high and the rear defogger. Don’t use cyclical loads such as air conditioning or windshield wipers. 10. TESTING ALTERNATOR AT IDLE, LOADS ON: The analyzer will determine if the charging system is able to provide sufficient current for the demands of the vehicle’s electrical system. www.midtronics.com 17 Midtronics Inc. 7000 Monroe Street Willowbrook, IL 60527 Chapter 3: System Test EXP-1002 Decision Action NO PROBLEMS The system is showing normal output from the alternator. No problem detected. NO OUTPUT The alternator is not providing charging current to the battery. LOW OUTPUT HIGH OUTPUT √ Check the belts to ensure the alternator is rotating with the engine running. √ Check all connections to and from the alternator, especially the connection to the battery. Clean or replace cable if necessary and retest. √ If the belts and connections are in good working condition, replace the alternator. (Older vehicles use external voltage regulators, which may require only replacement of the voltage regulator.) The alternator is not providing enough current to power the system’s electrical loads and charge the battery. √ Check the belts to ensure the alternator is rotating with the engine running. √ Check the connections from the alternator to the battery. If the connection is loose or heavily corroded, clean or replace the cable and retest. The voltage output from the alternator to the battery exceeds the normal limits of a functioning regulator. √ Check for loose connections and a normal ground connection. If there are no connection problems, replace the regulator. The normal high limit of a typical automotive regulator is 14.5 volts +/–0.5. Refer to the manufacturer specifications for the correct limit, which may vary by vehicle type. Diode Decisions Decision Action EXCESSIVE RIPPLE One or more diodes in the alternator are not functioning or there is stator damage, which is shown by an excessive amount of AC ripple current supplied to the battery. √ Make sure the alternator mounting is sturdy and that the belts are in good shape and functioning properly. If the mounting and belts are good, replace the alternator. OPEN PHASE OPEN DIODE Replace the alternator. SHORTED DIODE Midtronics Inc. 7000 Monroe Street Willowbrook, IL 60527 18 www.midtronics.com EXP-1002 Chapter 4: Cable Drop Test Chapter 4: Cable Drop Test When starting or charging system test results indicate there may be a problem, a Cable Drop Test can determine if it is due to worn cables or bad connections between the battery and the alternator or starter. 1. IMPORTANT: For accurate results the battery should be good and fully charged before you perform a test. Worn cables or bad connections create higher resistance, which causes a drop across the circuit. The voltage drop reduces current carrying capability that displays the same symptoms as a weak alternator or starter and causes premature battery failure. Performing A Test The Battery Ground Test measures the voltage drop for the ground strap. There’s no need to run the engine. The Cable Drop Test sends a signal through the circuit at the component under test. The tester then simultaneously calculates voltage drop on the positive (+) and negative (–) sides of any circuit as well as the total voltage drop. The amperage range for each of the four tests is 0 to 1000 A. When you change the setting from the factory defaults, the tester will store your setting in memory for your next test. 2. BATTERY GROUND •• STARTER CIRCUIT •• ALTERNATOR CIRCUIT Use or to select the circuit type and press NEXT to continue, or press the corresponding number key. 1 2 3 There are three preset tests: •• To begin, select the Cable Drop Test icon in the Main Menu and follow the instructions on the display. 4 3. A fourth test, OTHER CIRCUIT, tests other grounds and circuits against your specified amperage capacity. BATTERY GROUND STARTER CIRCUIT ALT CIRCUIT OTHER Use or to select the rated amperage or output of the circuit and press NEXT to continue, or press the corresponding number key. The default value will vary depending on the circuit type selected. 80 The test requires two test lead connections, as shown. Red Red R1 + Component Under Test Battery – DMM Test Lead •• •• Black Battery Test Lead Connect the main clamps (battery test leads) to the battery and ground: positive (+) clamp to the battery’s positive post; negative (–) clamp to the vehicle chassis. 5. Connect the DMM cable to the battery posts: positive (+) clamp to the positive post; negative clamp (–) to the negative post. Cable Drop Test Results Battery test leads at the component’s output lead (the B+ or output screw on the alternator) and the component’s housing as ground Total circuit voltage drop DMM test leads at the battery terminals NOTE: The test requires a complete circuit. If you’re testing a system with a remote solenoid, you can test from the battery to the solenoid, but not from the battery to the starter. www.midtronics.com 4. For the next few seconds the tester will display the word TESTING and a stopwatch while it evaluates the battery ground. R2 Black A Voltage drop across positive side of circuit Voltage drop across negative side of circuit If there is a problem, the decision is CLEAN AND RETEST OR REPLACE. To print the results, align the tester’s IR transmitter with the printer’s receiver, and select PRINT. To return to the Main Menu, press END. 19 Midtronics Inc. 7000 Monroe Street Willowbrook, IL 60527 Chapter 5: Inventory Test EXP-1002 Chapter 5: Inventory Test Printing Test Results 1. To print the test results for an individual battery, use or to scroll to the screen showing the battery that was tested. Select PRINT. Use the Inventory Test in the Main Menu to quickly check batteries in inventory. The test can verify up to 100 batteries in succession using the user-specified battery rating along with the minimum voltage limit. This test differs from the Battery Test in that the decision is either Good or Needs Charge. Neither decision will tell you that a battery is bad, but rather that the measured voltage and CCA fall in or out of your requirements. 2. Select option 1 to print the screen result of the selected battery. Select option 2 to print the results of all the batteries listed by the order in which they were tested. Press PRINT to print the results. Selecting Test Parameters 1 1. Select the Inventory Test icon in the Main Menu. 2 2. The tester displays the total number of Inventory Tests completed out of 100. To clear the results from memory and reset the total to 0, simultaneously press and . Press NEXT to continue. Enter the information required in steps 4 through 7 in the Battery Test section of this manual. 4. Enter the BATTERY RATING voltage (between 12.20 - 12.80v). 5. For the next few seconds the tester evaluates the battery, writes the results to the data card, and displays the results starting from the last battery tested. To view a previous result for a battery, use or to scroll to the screen showing the battery that was tested. INVENTORY BATTERY INVENTORY SUMMARY Clearing Test Results The analyzer will not be able to continue inventory testing until you clear all tests from its memory. IMPORTANT: Be sure to monitor the number of tests performed and be ready to print the results as the number approaches 100. When the limit is reached you will no longer be able to test until you clear all results from memory. 3. NOTE: To retain a record, use PRINT to print the results. To clear the results and reset the counter to 0: 1. Press EXIT to return to the Main Menu. 2. Select the Inventory Battery Test icon. 3. In the INVENTORY STAT screen press and simultaneously to clear the results and reset the counter to 0. Example of displayed results for a test of two batteries 6. To continue testing, connect to the next battery. The analyzer starts the test automatically using the same parameters. To test another type of battery press END, then follow steps 1 through 4 above. Midtronics Inc. 7000 Monroe Street Willowbrook, IL 60527 20 www.midtronics.com EXP-1002 Chapter 6: DMM (Digital Multimeter) Chapter 6: DMM (Digital Multimeter) Scope The tester’s 8 digital meters make it versatile enough to test everything from a vehicle’s entire electrical system to a board-level component: •• DC Voltmeter •• AC Ammeter •• AC Voltmeter •• Ohmmeter •• Scope •• Diode Drop •• DC Ammeter •• Volts/Amp The scope is a voltmeter that provides a graph of voltage difference as it varies over time. After you select the scope icon, note the instructions in the next screen before proceeding. You’ll need the them after you press SELECT to continue: •• Press 1 on the keypad to autoscale the scope. The DMM’s infrared temperature sensor also enables you to determine the surface temperature of components before you service them or as a diagnostic aid. Specifications for each tool are listed in the table at the end of this chapter. •• Press 3 on the keypad for the time display. •• Press 4 on the keypad for the FFT (frequency) display. Select the DMM icon to display its METERS menu. The tools in this menu are available in a series of three screens. In the time display the horizontal axis is in seconds and the vertical axis is in volts. A measurement that is out of the limit displays as OL. Refer to the manufacturer specifications for the correct limits, which may vary by component or vehicle type. In the frequency display the horizontal axis is in hertz and the vertical axis is in volts. Press SELECT to continue. Press the right soft key to alternate between the options to RUN (measure and display the signal) and HOLD (freeze the signal). DC Volts The scope enables you to print the voltage trace to the optional IR printer when you freeze the signal. Align the tester’s IR transmitter with the printer’s receiver, and select PRINT. The DC voltmeter measures voltage between two points in a circuit. The voltmeter is connected in parallel with the circuit. 1. Connect the DMM test lead to the tester’s accessories port. 2. Use or to select the DC Volts icon and press NEXT to continue, or press the corresponding number key. 3. Connect the clamps or probes in the correct polarity: red clamp or probe to positive (+); black to negative (–). 4. The meter will autorange and display the measurement. 5. To return to the METERS menu, press END. To return to the METERS menu, press END. DC Amp The DC ammeter measures DC magnitude and flow of the DC current in a circuit. NOTE: Performing this test requires the optional amp clamp. AC Volts The AC voltmeter measures the AC volts between two points in a circuit. The voltmeter is connected in parallel with the circuit. 1. Connect the DMM test lead to the tester’s accessories port. 2. Use or to select the AC Volts icon and press NEXT to continue, or press the corresponding number key. 3. Connect the clamps or probes in the correct polarity: red clamp or probe to positive (+); black to negative (–). 4. The meter will autorange and display the measurement. 5. To return to the METERS menu, press END. www.midtronics.com 21 1. Connect the amp clamp lead to the tester’s accessories port. 2. Use or to select the DC Amp icon and press NEXT to continue, or press the corresponding number key. 3. Use or to select the Amp Clamp range and press NEXT to continue, or press the corresponding number key. The meter will zero itself. 1 70 AMP MAX. 2 700 AMP MAX. 4. Place the clamp’s jaws around the negative (–) cable. 5. The tester will display the measurement. 6. To return to the METERS menu, press END. Midtronics Inc. 7000 Monroe Street Willowbrook, IL 60527 Chapter 6: DMM (Digital Multimeter) EXP-1002 AC Amp The DC ammeter measures the magnitude and flow of the AC current through a circuit during normal operations. NOTE: Performing this test requires the optional amp clamp. 1. Connect the amp clamp lead to the tester’s accessories port. 2. Use or to select the AC Amp icon and press NEXT to continue, or press the corresponding number key. 3. Use or to select the Amp Clamp range and press NEXT to continue, or press the corresponding number key. The meter will zero itself. 1 70 AMP MAX. 2 700 AMP MAX. 3. Connect the clamps or probes in the correct polarity: red clamp or probe to positive (+); black to negative (–). 4. The meter will autorange and display the measurement. 5. When finished, press END. 6. To return to the METERS menu, press END. Diode This test measures the voltage drop across components, such as diodes. 1. Connect the probes test lead to the tester’s accessories port. 2. Use or to select the Diode icon and press NEXT to continue, or press the corresponding number key. 3. Connect the probes in the correct polarity: red clamp or probe to positive (+); black to negative (–). 4. Place the clamp’s jaws around the negative (–) cable. 4. The meter will autorange and display the measurement. 5. The tester will display the measurement. 5. When finished, press END. 6. To return to the METERS menu, press END. Volts/Amp Temp The volts/amp meter simultaneously measures charging voltage and charging current. The IR temperature sensor measures surface temperature within a range of –20 to 200 °C. The tool can also be used for checking the transmission for overheating, and the temperature levels of the heater and air conditioner. NOTE: Performing this test requires the optional amp clamp. Battery Case (Top) Sensor Ohm Meter The meter is connected in parallel with the circuit under test and uses the power supplied by the tester’s internal batteries to detect open or excessive resistance. Always remove power from the circuit before connecting the ohmmeter to avoid damaging the analyzer. 1. Connect the DMM test lead to the tester’s accessories port. 2. Use or to select the Ohm Meter icon and press NEXT to continue, or press the corresponding number key. Midtronics Inc. 7000 Monroe Street Willowbrook, IL 60527 22 1. Connect the amp clamp lead to the tester’s accessories port. 2. Use or to select the Volt/Amp icon and press NEXT to continue, or press the corresponding number key. 3. Use or to select the Amp Clamp range and press NEXT to continue, or press the corresponding number key. The meter will zero itself. 1 70 AMP MAX. 2 700 AMP MAX. 4. Place the clamp’s jaws around the negative (–) cable. 5. Connect the battery test cable to the tester. 6. Connect the battery test clamps in the correct polarity: red clamp or probe to positive (+); black to negative (–). 7. The tester will display the measurement. 8. To return to the METERS menu, press END. www.midtronics.com EXP-1002 Chapter 6: DMM (Digital Multimeter) The accuracy specification is defined as ± (n% reading + [count * resolution]) at 77 °F. Vdc Range Resolution Accuracy Overload Protection 0–60 V 0.01 V 0.05% + 2 120 Vrms Accuracies are specified from 2% to 100% of range. Vac Range Resolution Accuracy Overload Protection 0–24 Vac rms 0.01 Vac 0.1% + 3 120 Vrms Accuracies are specified from 2% to 100% of range. Adc Range Resolution Accuracy Overload Protection 0–70 A 0.01 A ± 3% of reading ± 1A 1000 Arms 0–700 A 0.1 A ± 3% of reading ± 1A 1000 Arms Accuracies are specified from 2% to 100% of range. Aac Range Resolution Accuracy Overload Protection 0–70 A 0.01 A ± 3% of reading ± 1A 1000 Arms 0–700 A 0.1A ± 3% of reading ± 1A 1000 Arms Accuracies are specified from 2% to 100% of range. Ohm Range Resolution Accuracy Overload Protection 10Ω–2 M Ω 1Ω 2.0% + 4 120 Vrms Resolution Accuracy Overload Protection 1Ω 2.0% + 4 120 Vrms Range Resolution Accuracy Overload Protection 0–1.5 V 0.01 V 0.05% + 2 120 Vrms Range Resolution Accuracy Overload Protection -20–200 °F -28–93 °C 1 °F 1 °C 1.0% + 5 -------- Continuity Range < 10 Ω Diode Temperature www.midtronics.com 23 Midtronics Inc. 7000 Monroe Street Willowbrook, IL 60527 Chapter 7: Info EXP-1002 Chapter 7: Info Totals The Info Menu has three utilities to help you manage your test data and track the usage and history of your analyzer. The TOTALS report displays the total number of battery tests performed since the tester was first used. Press the and keys simultaneously to clear the total and reset the starting date. Print/View The Print/View Menu allows you to view and print the results of the Battery, System, and Cable Drop Tests. The results of the last test are stored in memory until the next test is performed. Transfer The TRANSFER utility lets you transfer test data to a PC using an optional IR receiver and software package. To print the results, align the analyzer’s IR transmitter with the printer’s receiver, and select PRINT. To return to the Main Menu, press END. 1. In the Main Menu, select the Print/View icon. 2. Select the icon for the report or function you want to use. Version Version displays the analyzer’s software version, the date the software was released, and the serial number of the analyzer. The utility keeps a permanent count of the number of battery tests performed since the analyzer was first used. View Cable Test VIEW CABLE TEST allows you to view and print the results of the Cable Drop Test. Internal Batteries View Inventory Test Selecting the Internal Batteries function will display a graphic showing the amount of power remaining in the tester’s internal batteries. This report displays and prints the results for an individual battery or for all batteries tested using the Inventory Battery Test. 1. To print the test results for an individual battery, use or to scroll to the screen showing the order in which the battery was tested. Select PRINT to print out the results. 2. Select option 1 to print the screen result of the selected battery. Select option 2 to print the results of all the batteries listed by the date and order in which they were tested. Select PRINT. 1 2 Midtronics Inc. INVENTORY BATTERY INVENTORY SUMMARY 7000 Monroe Street Willowbrook, IL 60527 24 www.midtronics.com EXP-1002 Chapter 8: Utility Chapter 8: Utility Mode 1. Use or to select the desired Mode and press NEXT or press the corresponding number key. Use the Utility Menu to customize the tester—from interface language to display contrast The utilities also have default settings that can be user-adjusted. Setup Function 1 Default Settings CLOCK 2 TIME The current Central Standard Time MODE AM DATE Current FORMAT MM/DD/YYYY (month/day/year) SHOP 2. 24 HOUR AM/PM Press SAVE to save your setting or BACK to return to the CLOCK ADJUST screen without saving. Time 1. Use or to highlight the hour, minutes, or AM or PM. To rapidly scroll, hold down an ARROW key. Generic header for printouts with 12 lines of text and a maximum of 17 characters per line 9 : 19 DISPLAY CONTRAST LEVEL Range: 0 (lightest) to 10 (darkest). The default is set at 9. BACKLIGHT TIME 2. Range: 0 to 60 seconds. The default is set at 15 seconds. COUPON Disabled (NO COUPON PRINTED) EDIT COUPON Eight lines of text with 17 characters per line. DEGREES F (Fahrenheit) LANGUAGE English is the default language. French-Canadian and Spanish are also available. 1. In the Main Menu, select the Utility icon. 2. Select the icon of the utility you want to adjust. 1 2 2. 2. www.midtronics.com Press SAVE to save your setting or BACK key to return to the CLOCK ADJUST screen without saving. 2013 Press SAVE to save your setting or BACK to return to the CLOCK ADJUST screen without saving. The SHOP INFO utility allows you to create a header for your printed test results showing your business location information. The utility’s two information screens contain eight lines of text with a maximum of 17 characters per line. The CLOCK ADJUST utility has four settings. Use the ARROW keys to highlight the setting you want to change. DATE : DD/MM/YYYY (day/month/year) Shop Clock FORMAT : MM/DD/YYYY (month/day/year) 6 / 04 / If you use the keypad to enter the number preceding the option button, no additional keypress is needed to save or continue to the next step. TIME : Date 1. Use or to highlight the month, day, or year. To rapidly scroll, hold down or . The Utility Menu has nine utilities to customize your analyzer. Each utility described in this section is listed in order by its icon title. MODE : Press SAVE to save your setting or BACK to return to the CLOCK ADJUST screen without saving. Format 1. Use or to select the desired time display Format and press NEXT or press the corresponding number key. Default: USER COUPON LINE 1 through USER COUPON LINE 8 TEMPERATURE PM AM/PM Screen 1 9:07 PM 1–YOUR SHOP NAME MMM/DD/YYYY 6/17/5/17/2013 25 Screen 2 — 5–YOUR COUNTRY 2–1000 ANY STREET 6–YOUR PHONE NUMBER 3–YOUR TOWN, STATE 7–WWW.WEBSITE.CO 4–YOUR POSTAL CODE 8–SHOP ID NUMBER Midtronics Inc. 7000 Monroe Street — Willowbrook, IL 60527 Chapter 8: Utility EXP-1002 To create or overwrite a header: 1. Press or to highlight the line you want to change. The cursor will be blinking to the right of the last character in the line. 2. Press to move erase a character. Press to move the cursor forward. 3. Insert a character by pressing the key associated with the character as many times as needed. 4. You can center text by selecting blank spaces before and after lines of text or insert spaces between words. 5. Press SAVE to save your setting or BACK to return to the SHOP INFO screen without saving the changes. 3. Press or to change the value up or down, or press the corresponding number key. Press to erase a character. Backlight time is from 0 to 60 seconds. 4. Press SAVE to save your setting or BACK to return to the BACKLIGHT TIME screen without saving. Coupon The COUPON SELECT utility allows you to print custom coupons or messages created in the EDIT COUPON utility. 1. To help you edit and center your header, use a pencil to write the information in the template below before entering it into the analyzer. Use or to select the desired option and press NEXT or press the corresponding number key. 1 2 2. Display Use the DISPLAY option to adjust the contrast of the text on the display and the backlight time. 2. 10 BACKLIGHT TIME 60 3. 4. The EDIT COUPON utility allows you to create a promotional coupon or message for your customers that prints at the bottom of every test result. Its two information screens contain eight lines of text with a maximum of 17 characters per line. To create and edit a coupon, use same procedure described in the Shop section of this chapter. Use the template at the back of this manual to plan and center your text. (1-10) Temp Press or to change the value up or down, or press the corresponding number key. The contrast level is 0 (lightest) to 10 (darkest). The TEMP utility enables you to set the units of measure to either Celsius or Fahrenheit. Press SAVE to save your setting or BACK to return to the CONTRAST LEVEL screen without saving. 1. Backlight Time 1. Use or to select BACKLIGHT TIME and press NEXT. 2. CONTRAST LEVEL 10 BACKLIGHT TIME 60 2. Press EDIT to display the option’s numerical scroll box. 60 Midtronics Inc. 7000 Monroe Street USER COUPON Edit Coupon Press ADJUST key to display the numerical scroll box. 10 NO COUPON PRINTED Press SAVE to save your setting or BACK to return to the Utility Menu without saving the changes. Contrast Level 1. Use or to select CONTRAST LEVEL and press NEXT. CONTRAST LEVEL Use or to select the TEMP. UNITS and press SAVE, or press the corresponding numbers keys and press SAVE. 1 DEGREES F 2 DEGREES C Press BACK to return to the UTILITY menu without saving any changes. SEC Willowbrook, IL 60527 26 www.midtronics.com EXP-1002 Chapter 8: Utility Language 1 Select this setting to enable (ON) or disable (OFF) the USER ID login screen. The LANGUAGE utility enables you to select a language for the display and printouts. To set your preference: 1. 2 3 2. 2 Use or to select the desired LANGUAGE and press SAVE, or press the corresponding numbers keys and press SAVE. 1 ENGLISH 3 – PRINT HEADER ESPAÑOL Select this setting to enable (ON) or disable (OFF) the address header on the printout. FRANÇAIS 4 – LANGUAGE Select this setting to enable (ON) or disable (OFF) the language selection option when the tester boots up. Format 5 – DATE CODE Select this setting to enable (ON) to require the entry of a battery date code. Select this utility to format a data card to receive data or erase all data on the card. The tester will warn you before formatting the disk, and ask if you want to continue. 6, 7, 8 – SCREEN INPUT Select this setting to enable (ON) to display user-defined text fields. Update When software updates are released, this utility enables you to update the analyzer’s software using files on a data card. Clear Test Totals This function allows you to clear the test totals by User ID and battery test decision. The analyzer verifies that you want the counter reset to 0 before it continues. Admin NOTE: This will not clear the lifetime test total available in the VERSION information screen. This section explains how to use the Admin utility to control User ID access to the tester. It also describes functions that clear test totals and restore settings to factory defaults. Reset Defaults This function allows you to reset Administrative options to their original settings. It will clear all registered users and restrict access to the tester. Use or to select the ADMIN icon to display a list of administrative functions: 2 3 4 UNREG. USER Select this setting to enable (ON) or disable (OFF) unregistered login access to the analyzer when option 1 – USER ID is ON. Press BACK to return to the UTILITY menu without saving any changes. 1 USER ID OPTIONS Option Default Settings ENABLE BMIS 1 – USER ID ON CLEAR TEST TOTALS 2 – UNREG. USER ON 3 – PRINT HEADER OFF 4 – LANGUAGE ON 5 – DATE CODE OFF 6, 7, 8 – SCREEN INPUTS OFF RESET DEFAULTS Options In the OPTIONS section there are three functions that allow you to control user access to the Main Menu and Admin Menu. Each option is easily enabled or disabled by turning it ON or OFF. To save your settings after each selection, press SAVE. To return to the administrative functions list without saving, press BACK. www.midtronics.com 27 Midtronics Inc. 7000 Monroe Street Willowbrook, IL 60527 Chapter 9: Maintenance & Troubleshooting EXP-1002 Chapter 9: Maintenance & Troubleshooting Testing Clamp Continuity 4. If the analyzer frequently displays CHECK CLAMP CONNECTION! you may have an intermittent open circuit in one or both of the battery test cables. If any of the four connections shows more than 1 Ω, contact Midtronics Customer Service at www.midtronics.com or (630) 323-2800 to order a new set of cables. You are testing the continuity between the clamp jaws and the cable connector. The test is the same for clamps with one or two sets of teeth. Internal Batteries This includes four different connections. •• The positive (Red) clamp jaw without teeth and corresponding pin hole. •• The positive (Red) clamp jaw with teeth and corresponding pin hole. •• The negative (Black) clamp jaw without teeth and corresponding pin hole. •• The negative (Black) clamp jaw with teeth and corresponding pin hole. Repeat the test procedure for the other three cable connections. In all instances, the resistance reading should always be less than 1 Ω. The tester uses six AA, 1.5-volt batteries (alkaline recommended) to allow testing of batteries down to 1 volt and supply power while the menu is active. The analyzer can test batteries down to 5.5 volts when the internal batteries are not functioning. Battery Power Indicator The square in the upper left corner of the display indicates the charge level of the battery pack. The square is black when the battery pack is fully charged. It gradually changes to white as the charge level declines. The Tester will display a warning message when the batteries need replacing. You will need to a pencil, plastic marker or other nonconductive item to keep the test clamp jaws apart. You will also need an ohmmeter with a good set of test probe leads. Performing A Continuity Test 1. Grip the pencil with one of the test clamps. Do not grip the metal part of the eraser or any other area that may conduct electricity. Full Top Jaw Decreasing Low Powered by test battery Replacing The Tester Batteries 1. Turn the tester face down. Screw Latch Press here Slide in this direction Cable Bottom Jaw 2. Insert one of the ohmmeter probes into one of the four holes indicated at the tip of the cable connector. With the tip of the other probe, touch the corresponding part of the appropriate clamp. Black Clamp: Top Jaw Red Clamp: Top Jaw Black Clamp: Bottom Jaw Red Clamp: Bottom Jaw Cable Connector Pin-outs NOTE: Use a small wire or a paper clip if your ohmmeter probe tip is too large to insert into the connector holes. 3. Wiggle the test cables. The resistance reading for that connection should be less than 1 Ω. Midtronics Inc. 7000 Monroe Street Willowbrook, IL 60527 28 2. Remove the screw. 3. Press gently on the ridges above the arrow on the battery compartment cover. www.midtronics.com EXP-1002 Chapter 9: Maintenance & Troubleshooting 4. Slide the cover in the direction of the arrow and remove the cover. 5. Remove the discharged batteries. 6. Insert new batteries. Make sure the positive and negative terminals are positioned correctly. 7. Insert the battery door tabs into the slots on the analyzer and slide the door closed, making sure the latch locks. 8. Data Will Not Print •• If the IR transmitter and receiver are not aligned, all the data may not print. The infrared ports on the top of the analyzer and on the printer below the MODE button should be pointed directly at each other. The maximum distance for reliable transmission between the ports is 17 in (45 cm). •• To realign, press the END button to cancel the print job. Verify alignment between the analyzer and printer; then try to print the test results again. •• Make sure the printer is on. The printer shuts off after two minutes of inactivity to conserve the batteries. To turn the printer on, briefly press the MODE button. The green STATUS light should turn on. Make sure you are using the Midtronics printer. Other printers may not be compatible. •• Direct sunlight interferes with infrared data transmission and receiving. If the printer is not receiving data, remove the printer and tester from direct sunlight. If the printed characters are not clear or are partially missing, recharge the batteries and reprint. •• If you are unable to print after ensuring the analyzer is functioning, the printer is on, the batteries are good, and the IR transmitter and receiver are aligned, check the printer manual for further instructions or call Midtronics at 1-630-323-2800 for assistance. Insert and tighten the screw. Troubleshooting The Display Does Not Turn On •• Check the connection to the vehicle battery. •• Press the POWER button. •• The vehicle’s battery may be too low to power the analyzer (below 1 volt). Fully charge the battery and retest. •• The analyzer’s 6 AA batteries may need to be replaced. •• If troubleshooting does not solve the problem, contact Midtronics at 1-630-323-2800 to obtain service. See the warranty information on the back cover of this manual for more information. The STATUS LED Flashes When a printer fault occurs, the STATUS LED flashes. You can identify the fault by the number of sequential flashes: If the analyzer frequently displays CHECK CLAMP CONNECTION! there may be an intermittent open circuit along one or both of the battery test cables. You can check the circuit with a simple test. The test requires an ohmmeter and a wire or paper clip if the ohmmeter probes are too large to insert into the pin holes. You will also need to a pencil or plastic marker to keep the clamp jaws apart. The test is the same for cable sets with clamps having two or one set of teeth. Printer STATUS LED Sequence * * * ** ** ** *** *** *** Condition Solution No paper Insert new paper Thermal head too hot Allow head to cool Batteries weak Recharge printer batteries for 16 hours www.midtronics.com 29 Midtronics Inc. 7000 Monroe Street Willowbrook, IL 60527 Appendix: Templates EXP-1002 Appendix: Templates Header And Coupon Templates To help you edit and center your coupon, use the template below to lay out your coupon information below before entering it into the Battery Diagnostic Station. Line 1 Line 2 Line 3 Line 4 Line 5 Line 6 Line 7 Line 8 Line 1 Line 2 Line 3 Line 4 Line 5 Line 6 Line 7 Line 8 Line 1 Line 2 Line 3 Line 4 Line 5 Line 6 Line 7 Line 8 Midtronics Inc. 7000 Monroe Street Willowbrook, IL 60527 30 www.midtronics.com PATENTS This product is made by Midtronics, Inc., and is protected by one or more U.S. and foreign patents. For specific patent information, contact Midtronics, Inc. at +1 630 323-2800. LIMITED WARRANTY Midtronics products are warranted to be free of defects in materials and workmanship for a period of one (1) year from date of purchase. Midtronics will, at our option, repair or replace the unit with a re-manufactured unit. This limited warranty applies only to Midtronics products, and does not cover any other equipment, static damage, water damage, overvoltage damage, dropping the unit, or damage resulting from extraneous causes including owner misuse. Midtronics is not liable for any incidental or consequential damages for breach of this warranty. The warranty is void if owner attempts to disassemble the unit or to modify the cable assembly. SERVICE To obtain service, contact Midtronics at 1-630-323-2800. Have your model and serial numbers ready. This first step is critical as we will trouble-shoot the problem(s) over the phone, and many perceived problems are in fact resolved during this step. If the problem cannot be resolved, then the CS Agent will issue you a Return Material Authorization or RMA. This number becomes your tracking number. The final step is to return the unit to Midtronics freight prepaid (you pay), to the attention of the RMA number obtained. In USA: Midtronics, Inc. Attn: RMA # xxxxx (this is the RMA number that you must obtain from Midtronics) 7000 Monroe St. Willowbrook, IL 60527 If Midtronics determines that the failure was caused by misuse, alteration, accident, or abnormal condition of operation or handling, purchaser will be billed for the repaired product and it will be returned freight prepaid with shipping & handling charges added to the invoice. Midtronics products beyond the warranty period are subject to the repair charges in place at that time. www.midtronics.com Corporate Headquarters Willowbrook, IL USA Phone: 1.630.323.2800 Canadian Inquiries Toll Free: +1 1 866 592 8053 Midtronics b.v. European Headquarters Houten, The Netherlands Serving Europe, Africa, the Middle East, and The Netherlands Phone: +31 306 868 150 Midtronics China China Operations Shenzhen, China Phone: +86 755 8202 2036 Midtronics India Navi Mumbai, India Phone: +91 22 27564103/1513 Asia/Pacífic (excluding China) Contact Corporate Headquarters Phone: +1.630.323.2800 167-000502EN-A 9/13 2013 ©Midtronics, Inc. All rights reserved.
