Related Manuals for Midtronics INTELLECT EXP HD
Summary of Contents for Midtronics INTELLECT EXP HD
- Page 1 Battery Management Innovation Midtronics Expandable Electrical Diagnostic Platform For testing 6- and 12-volt heavy-duty, automotive, and commercial batteries, and 12-volt and 24-volt charging systems. INSTRUCTION MaNUal...
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Page 2: Chapter 1: Before You Begin
Chapter 1: Before You Begin Chapter 1: Before You Begin For safe, efficient, and accurate testing, review the safety and operating instructions in this manual before usng the analyzer. We also recommend that you regster the analyzer to actvate your warranty. Safety Precautions Inspect the battery for damages and check the electrolyte level. -
Page 3: Chapter 2: Overview
Chapter 2: Overview Chapter 2: Overview The nTELLECT EXP-1000 HD tests 6- and 12-volt heavy-duty automotve and commercal batteres, and 12-volt and 24-volt chargng systems. In addton to a standard sngle-battery test, the EXP has a test rou- tne desgned for multple-battery vehcles and a specalzed heavy-duty battery algorthm for larger batter- es. - Page 4 Chapter 2 : Overview Test Leads, Connections, and Data Ports The top of the EXP has two connectors for test cables: RJ45 connector (Accessores Port) wth a release lever for accessory test cable. 6-pn connector, wth a lockng rng, for the battery test leads.
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Page 5: Connecting The Battery Test Cable
Chapter 2 : Overview The bottom and rght sde of the EXP have two data ports: DB-9 connector for future expandablty. Sprng-loaded SD card slot for test data storage and software upgrades. Connecting the Battery Test Cable Connect the battery test cable to the EXP by first aligning the cable connector’s 6 holes with the 6 pins on top of the EXP. -
Page 6: Display And Keypad
Chapter 2: Overview Display and Keypad The analyzer keypad and display work together to help you quickly find and use the right tools at the right tme. The dsplay also keeps you on track wth on-screen navgaton ads, drectons, and messages. The llustraton below shows how the elements on the screen relate to the keypad. - Page 7 Chapter 2: Overview When dsplayed under a lst of optons, the You also use the Alphanumerc Keys to cre- Drectonal Arrows show you whch keypad ate and edt customer coupons and your shop arrow to press to hghlght a character or an contact nformaton on prnted test results, and manage techncan IDs.
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Page 8: Data Entry Methods
Chapter 2: Overview Data Entry Methods To perform a partcular test or functon, the EXP wll ask for dfferent types of nformaton. Ths means that the methods you use to enter nformaton wll change dependng on the type of nformaton requested. The four types of entry methods are descrbed below. -
Page 9: Alphanumeric Entry
Chapter 2: Overview alphanumeric Entry Some selections require you to use the alphanumeric keypad. These “user-defined” selections have a blnkng horzontal lne (cursor) to the rght of the last character. Use the UP/DOWN ARROW keys to hghlght a lne for edtng. Dsplay the character, symbol, or number you want by rapdly pressng ts key as many tmes as needed. - Page 10 Chapter 2: Overview Menu Maps Ths secton wll help you get to your destnaton whle lettng you know what test leads you may need when you arrve. The test leads are represented by symbols for ther connectors. Main Menu The Man Menu s the startng pont for all tools and utltes, whch are depcted as cons. Some cons lead drectly to the functon they represent, whle others are menu cons that lead to two or more functons.
- Page 11 Chapter 2: Overview DMM Menu The DMM Menu has cons for a temperature sensor and 8 test meters, some of whch requre dfferent test leads. The avalable leads depend on the EXP model purchased. Requred test leads Battery test clamp clamps or probes METERS (Screen 1)
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Page 12: Print/View Menu
Chapter 2: Overview Info Menu The Info Menu has three utltes to help you manage your test data, and track the analyzer’s usage and hstory. REPORTS An optonal IR software Dsplays the software Dsplays the total num- and hardware package verson, total tests from ber of test n three cat- first use, and the serial... - Page 13 Chapter 2: Overview Utility Menu The Utltes Menu allows you customze your analyzer. Before testng, check the default values to see whch optons you may want to change. SETUP (Screen 1) Add, edt, or delete User Settngs to adjust date Allows you to add IDs usng up to seven al- and tme.
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Page 14: Chapter 3: Utility Menu
Chapter 3: Utility Menu Chapter 3: Utility Menu The Utlty Menu has several utltes that customze the EXP—from the language of the user nterface to the contrast of the text on the dsplay. The utltes have default settngs that you can change, dependng on your requrements. - Page 15 Chapter 3: Utility Menu The Utlty Menu has nne utltes to customze your analyzer. Each utlty descrbed n ths secton s lsted n order by ts con ttle. If you use the alphanumerc keypad to enter the number precedng the opton button, no addtonal keypress s needed to save or contnue to the next step.
- Page 16 Chapter 3: Utility Menu If you used the ARROW keys, press the SAVE soft key to save your settng or the BACK soft key to return to the CLOCK ADJUST screen wthout savng the changes. Date Use the LEFT/RIGHT ARROWS to hghlght the month, day, or year. To rapdly scroll, hold down an ARROW key.
- Page 17 Chapter 3: Utility Menu Insert a character by pressng the alphanumerc key assocated wth the character as many tmes as needed. Press the SAVE soft key to store the new user ID n memory. ENTER USER ID BOB R Deleting a User ID To delete a USER ID, select: ENTER NEW DELETE...
- Page 18 Chapter 3: Utility Menu Shop The SHOP INFO utlty allows you to create a header for your prnted test results showng your busness locaton nformaton. The utlty’s two nformaton screens contan eght lnes of text wth a maxmum of 17 characters per lne.
- Page 19 Chapter 3: Utility Menu Display The LCD OPTIONS utlty allows you to adjust the contrast of the text on the dsplay and the backlght tme. Contrast level The contrast level s 0 (lghtest) to 10 (darkest). To change t: Press the UP or DOWN ARROW key to hghlght the opton. CONTRAST LEVEL BACKLIGHT TIME Press the ADJUST soft key to dsplay the opton’s numercal scroll box.
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Page 20: Edit Coupon
Chapter 3: Utility Menu Coupon The COUPON SELECT utlty allows you to prnt one of the three custom coupons or messages created n the EDIT COUPON utlty. Use the UP or DOWN ARROW key, or press the correspondng numercal key (1, 2) to move the dot to the opton button of your choce. - Page 21 Chapter 3: Utility Menu Language The LANGUAGE utlty enables you to select a language for the dsplay and prntouts. To set your preference: Use the UP/DOWN ARROWS or press the correspondng numercal key to move the dot to the opton button of your choce. ENGLISH ESPAÑOL FRANÇAIS...
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Page 22: Chapter 4: Test Preparation
Chapter 4: Test Preparation Chapter 4: Test Preparation Inspecting the Battery Before startng the test vsually nspect the battery for: • Cracked, buckled, or leakng case. If you see any of these defects, replace the battery. • Corroded, loose, or damaged cables and connectons. Repar or replace them as needed. •... -
Page 23: Connecting To A Battery
Chapter 4: Test Preparation Connecting to a battery CAUTION: Do not connect the EXP to a voltage source greater than 60 Vdc. Testing Individual Batteries If the batteres have threaded studs, screw the negatve (–) stud adapter onto the negatve termnal, and the postve (+) adapter onto the postve termnal. -
Page 24: Chapter 5: Battery Test
Chapter 5: Battery Test Chapter 5: Battery Test The Battery Test functon tests one battery n or out of the vehcle. To test the battery pack the analyzer wll gude you through the steps of selectng your battery test parameters and nterpretng the results. Before you start the test, revew the nstructons n “Test Preparaton.”... - Page 25 Chapter 5: Battery Test Select the battery’s RATING UNITS. The unts and the ratng requred n step 6 are prnted on the battery label. If the nformaton s unreadable, contact the battery manufacturer. CCA (Cold Crankng Amps) CA (Crankng Amps) MCA (Marne Crankng Amps) JIS (Japanese Industral Standard) DIN (Deutsch Industry Norm)
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Page 26: Battery Test Results
Chapter 5: Battery Test In some cases the EXP may ask for addtonal nformaton before t makes a decson on the battery. See “Addtonal Test Requrements” on page 28 for more nformaton. If the battery decson s REPLACE or BAD CELL, the EXP-1000 HD BMP asks you to enter the battery seral number. - Page 27 Chapter 5: Battery Test Battery Decision Recommended Action GOOD BATTERY Return the battery to servce. GOOD–RECHARGE Fully charge the battery and return t to servce. CHARGE & RETEST Fully charge the battery usng a Mdtroncs Dagnostc Charger and retest. Failure to fully charge the battery before retesting may cause false readings.
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Page 28: Additional Test Requirements
Chapter 5: Battery Test Additional Test Requirements For a more decsve result the analyzer may ask for addtonal nformaton or further explore the battery’s condton. The followng messages and nstructons may appear before the analyzer dsplays the results of your test. System Noise Detected The analyzer has detected computer, gnton nose, or parastc dran, and wll attempt to retest. - Page 29 Chapter 5: Battery Test 5-Minute Discharged Battery Test Durng ths test a deeply dscharged battery s dagnosed n mnutes, elmnatng the need to charge the battery for hours n advance. The EXP dsplays ths test opton after the Deep Scan Test and before t arrves at the battery decson.
- Page 30 Chapter 6: Battery and Starter System Test—auto/Van Chapter 6: Battery and Starter System Test—Auto/Van The System test evaluates the battery, startng and chargng systems. Before the test, nspect the alternator drve belt. A belt that s glazed or worn, or lacks the proper tenson, wll prevent the engne from achevng the rpm levels needed for the test.
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Page 31: Auto/Van Starter System Test Results
Chapter 6: Battery and Starter System Test—auto/Van auto/Van Starter System Test Results To send the results to the IR prnter, algn the analyzer’s IR transmtter wth the prnter’s recever, and press the PRINT soft key. To contnue testng, press the NEXT soft key. NOTE: In some cases, the EXP may not detect the vehicle’s starting profile and display the soft key optons STARTED and NO START. -
Page 32: Battery Pack Test
Chapter 7: Battery and Starter System Test—Truck Chapter 7: Battery and Starter System Test—Truck Before startng the test, nspect the alternator drve belt. A belt that s glazed or worn, or lacks the proper tenson, wll prevent the engne from achevng the rpm levels needed for the test. The System Test first evaluates the battery pack (with up to 6 batteries), then the starter and charging systems. -
Page 33: Break Pack Down
Chapter 7: Battery and Starter System Test—Truck Break Pack Down If you choose to test ndvdual batteres, the EXP uses the parameters from the pack test and prompts you through the steps of dsconnectng the pack, testng each battery, and reconnectng. To test ndvdual batteres after a CHECK BATTERY PACK decson: Select BREAK PACK DOWN and press the NEXT soft key to contnue. -
Page 34: Battery Pack Test Results
Chapter 7: Battery and Starter System Test—Truck Battery Pack Test Results If the result s GOOD PACK, the EXP contnues to the Starter System Test. The EXP generates a Pack Code for all decsons. If you tested ndvdual batteres, the EXP dsplays the results for each battery wth a test code for REPLACE decsons. - Page 35 Chapter 7: Battery and Starter System Test—Truck Truck Starter System Test The performance of the startng and chargng systems depends on the battery’s condton. It s mportant that the battery or pack s good and fully charged before any further system testng. Start the engne at the prompt.
- Page 36 Chapter 8: Charging System Test—auto/Van and Truck Chapter 8: Charging System Test—Auto/Van and Truck If you are usng the amp clamp (AMP CLAMP AVAILABLE) n the AUTO/VAN Chargng System Test, keep t clamped around the negatve (–) battery cable. If you are usng the amp clamp (AMP CLAMP AVAILABLE) n the TRUCK Chargng System Test, keep t clamped around the postve (+) alternator cable.
- Page 37 Chapter 8: Charging System Test—auto/Van and Truck analyzer tells you to HOLD the rev level as the bar on the dsplay moves to the rght. 11. ACQUIRING DATA..HOLD ENGINE RPM: Contnue to hold the rpm whle the EXP takes system measurements. 12.
- Page 38 Chapter 8: Charging System Test—auto/Van and Truck Charging System Decision Action NO PROBLEMS The system s showng normal output from the alternator. No problem detected. NO VOLTAGE The alternator s not provdng chargng current to the battery. √ Check the belts to ensure the alternator s rotatng wth the engne runnng. Replace broken or slppng belts and retest.
- Page 39 Chapter 8: Charging System Test—auto/Van and Truck Diode Decision Action EXCESSIVE RIPPLE One or more dodes n the alternator are not functonng or there s stator damage, whch s shown by an excessve amount of AC rpple current suppled to the battery. √...
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Page 40: Chapter 9: Cable Drop Test
Chapter 9: Cable Drop Test Chapter 9: Cable Drop Test If the test results for the starter or chargng systems ndcate that there may be a problem, you may want to perform the Cable Drop Test to determne f t s due to worn cables or bad connectons between the battery and the alternator or starter. - Page 41 Chapter 9: Cable Drop Test To start a test, select the Cable Drop con n the Man Menu. Select AUTO/VAN. AUTO/VAN TRUCK Use the UP/DOWN ARROWS or the numercal keypad to select a crcut. STARTER CIRCUIT ALT CIRCUIT CHASSIS GROUND OTHER Press the NEXT soft key to contnue.
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Page 42: Chapter 10: Dmm (Digital Multimeter)
Chapter 10: DMM (Digital Multimeter) Chapter 10: DMM (Digital Multimeter) The DMM’s nfrared temperature sensor also allows you to determne the surface temperature of components before you service them or as a diagnostic aid. Specifications for each tool are listed at the table at the end of ths chapter. - Page 43 Chapter 10: DMM (Digital Multimeter) In the tme dsplay the horzontal axs s n seconds and the vertcal axs s n volts. In the frequency dsplay the horzontal axs s n hertz and the vertcal axs s n volts. Press the rght soft key to alternate between the optons to RUN (measure and dsplay the sgnal) and HOLD (freeze the sgnal).
- Page 44 Chapter 10: DMM (Digital Multimeter) Ohmmeter The meter s connected n parallel wth the crcut under test and uses the power suppled by the analyzer’s nternal batteres to detect open or excessve resstance. CAUTION: Always remove power from the crcut before connectng the ohmmeter to avod damagng the analyzer.
- Page 45 Chapter 10: DMM (Digital Multimeter) The accuracy specification is defined as ± (n% reading + [count resolution]) at 77 °F. 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. Range Resolution Accuracy...
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Page 46: Chapter 11: Info Menu
Chapter 11: Info Menu Chapter 11: Info Menu The Info Menu has three utltes to help you manage your test data and track the usage and hstory of your analyzer. Totals The TOTALS report dsplays the total number of battery tests n three categores. Use the UP/DOWN ARROW keys or press the correspondng numercal key to move the dot to the opton button of your choce or enter ts number. - Page 47 Chapter 11: Info Menu Clear Counters To reset a total to 0, press the numercal key that corresponds to the number precedng a check box, and press the NEXT soft key. Transfer The TRANSFER utlty lets you transfer test data to a PC usng an optonal IR recever and software package.
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Page 48: View Cable Test
Chapter 12: Print/View Chapter 12: Print/View The Prnt/Vew Menu allows you to vew and prnt the results of the Battery, System, and Cable Drop Tests. The results of the last test are stored n memory untl the next test s performed. To prnt the results, algn the analyzer’s IR transmtter wth the prnter’s recever, and select the PRINT soft key. -
Page 49: Chapter 13: Troubleshooting
Chapter 13: Troubleshooting Chapter 13: Troubleshooting If you have problems wth the dsplay or the Mdtroncs prnter, try these troubleshootng suggestons: The Display Does Not Turn On • Check the connecton to the vehcle battery. • Press the POWER button. •... - Page 50 Chapter 13: Troubleshooting • Drect sunlght nterferes wth nfrared data transmsson and recevng. If the prnter s not recevng data, remove the prnter and EXP from drect sunlght. If the prnted characters are not clear or are partally mssng, recharge the batteres and reprnt.
- Page 51 Chapter 14: Testing the Cable Set Chapter 14: Testing the Cable Set If the analyzer frequently dsplays CHECK CLAMP CONNECTION! you may have an ntermttent open crcut along one or both of the battery test cables. You can check the crcut wth a smple test. The test requres an ohmmeter and a wre or paper clp f the ohmmeter probes are too large to nsert nto the pn holes.
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Page 52: Chapter 15: Exp Internal Batteries
Chapter 15: EXP Internal Batteries Chapter 15: EXP Internal Batteries The EXP uses sx AA, 1.5-volt batteres (alkalne recommended) to allow testng of batteres down to 1 volt and supply power whle the menu s actve. The analyzer can test batteres down to 5.5 volts when the nternal batteres are not functonng.