Related Manuals for Midtronics intellect EXP-1000
Summary of Contents for Midtronics intellect EXP-1000
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Page 1: Instruction Manual
Battery Management Innovation Expandable Electrical Diagnostic Platform For testing 6 and 12-volt automotive batteries and 12- and 24-volt charging systems INSTRUCTION MaNUal... -
Page 3: Table Of Contents
Contents Contents Chapter 1: Before You Begin ................7 Safety ..........................7 General Precautions ......................7 Conventions Used in This Manual ...................7 Registering Your Analyzer ....................8 Chapter 2: Description ..................9 Test Leads, Connectors, and Data Ports ..............10 Display and Keypad ...................... 11 Data Entry Methods .......................12 Menu icons .......................... - Page 4 Contents Setting User Preferences ....................18 Chapter 4: Battery Test ..................19 Additional Test Requirements ..................20 Temperature Compensation ....................20 Surface Noise/Unstable Battery ..................20 Deep Scan Test ........................21 Battery Test Results ......................22 Chapter 5: 5-Minute Discharged Battery Test ..........23 Test Routine ........................2 Chapter 6: System Test ..................
- Page 5 Contents Chapter 8: Jump Start (System Test) .............. 36 Chapter 9: DMM (Digital Multimeter) ............... 37 DC Volts ........................7 AC Volts .........................8 Scope ..........................8 DC AMP (requires the optional amp clamp) ...............9 AC AMP (requires the optional amp clamp) ...............9 Temp ..........................40 Ohm Meter ........................40 Diode ..........................40...
- Page 6 View Test ........................49 View Cable Test ......................49 Chapter 13: Troubleshooting ................50 The Display Does Not Turn On ..................50 The STATUS LED Flashes (Midtronics Printer) ............50 Data Will Not Print ......................50 Chapter 14: EXP Internal Batteries ..............52 Battery Power Indicator ....................52 Replacing the EXP Batteries ..................52...
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Page 7: Chapter 1: Before You Begin
Chapter 1: Before You Start Chapter 1: Before You Begin Safety Because of the possibility of personal injury, always use extreme caution when working with batteries. Follow all manufacturers’ instructions and BCI (Battery Council International) safety recommendations. General Precautions • DANGER—RISK OF EXPLOSIVE GASES: Batteries can produce a highly explosive mix of hydrogen gas and oxygen, even when the battery is not in operation. -
Page 8: Registering Your Analyzer
The number is at the bottom of the label on the back of the analyzer (Figure 1). If your analyzer needs repair, call Midtronics Customer Service. Servicing the analyzer yourself may void your warranty. Refer to the Figure 1: Limited Warranty section of this manual. -
Page 9: Chapter 2: Description
Chapter 2: Description Chapter 2: Description Every inTELLECT™ EXP model includes a handy, hard-sided, molded carrying case, as shown in Figure 2. Regardless of which configuration you choose, the carrying case will hold all accessories, with room for future options, so you can add to your EXP at any time. Printer batteries Printer paper Cable storage... -
Page 10: Test Leads, Connectors, And Data Ports
Chapter 2: Description Test Leads, Connectors, and Data Ports For the cable test leads (Figure 5), there are two connectors on the top of the EXP (Figure 3). • For the battery test cable, the EXP has a 6-pin connector with a locking ring. •... -
Page 11: Display And Keypad
Chapter 2: Description Display and Keypad The EXP 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. Figure 6 shows how the elements on the screen relate to the keypad. -
Page 12: Data Entry Methods
Chapter 2: Description Data Entry Methods To perform a particular test or function, the EXP will ask for different types of information. This means that the methods you use to enter information will change depending on the type of information re- quested. -
Page 13: Menu Maps
Chapter 2: Description Menu Maps 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. 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. -
Page 14: Dmm Menu
Chapter 2: Description DMM Menu The DMM Menu has icons for a temperature sensor and 8 test meters, some of which require different test leads. The available leads depend on the EXP model purchased. The cable drop leads with probes is an option that you can purchase separately. Required test leads Battery test... -
Page 15: Info Menu
Chapter 2: Description Info Menu The Info Menu has three utilities to help you manage your test data, and track the usage and history of your EXP analyzer. REPORTS An optional IR software Displays the software Displays the total Bat- and hardware package version, total tests from tery and System Tests... -
Page 16: Utilities Menu
Chapter 2: Description Utilities Menu The Utilities Menu lets you customize your analyzer to suit your needs. Before testing, check the default values to see what options you may want to change. SETUP (Screen 1) Settings to adjust the Enables you to add a Settings to adjust the date and time. -
Page 17: Chapter 3: Test Preparation
Chapter 3: Test Preparation Chapter 3: Test Preparation 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. -
Page 18: Connecting An Accessory Cable
Chapter 3: Test Preparation If you connect the clamps in the wrong polarity (positive to negative or negative to positive), the EXP 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 EXP will display the message CHECK CONNECTION. -
Page 19: Chapter 4: Battery Test
Chapter 4: Battery Test Chapter 4: Battery Test The EXP will guide you through the steps of selecting your battery test parameters and interpreting the results. Before you start the test, review the instructions in Chapter 3: Test Preparation. Select the battery LOCATION. OUT OF VEHICLE IN VEHICLE Press the NEXT soft key to continue. -
Page 20: Additional Test Requirements
Chapter 4: Battery Test Press the UP/DOWN ARROW keys or use the numeric keys to select the RATING UNITS or in the case of JIS, the part number. To increase your scrolling speed, hold down the UP or DOWN ARROW key. The default selection is 500 for all rating standards except JIS , which consists of part numbers. -
Page 21: Deep Scan Test
Chapter 4: Battery Test Deep Scan Test In some cases the EXP 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. -
Page 22: Battery Test Results
Chapter 4: Battery Test Battery Test Results After the test the EXP will display one of five battery decisions with the complete results in a series of screens as shown in Figure 14. Use the UP/DOWN ARROW keys to scroll through each result. To send the results to an IR printer, press the PRINT soft key. -
Page 23: Chapter 5: 5-Minute Discharged Battery Test
Chapter 5: 5-Minute Discharged Battery Test Chapter 5: 5-Minute Discharged Battery Test This test is an out-of-vehicle dynamic response test in which a deeply-discharged battery can be diagnosed in minutes instead of the hours needed to charge it. The EXP displays the option to perform the test after a deep scan and before it arrives at the battery decision. - Page 24 Chapter 5: 5-Minute Discharged Battery Test The EXP will begin testing while the charger applies the charge current to the battery. After the initial boost charge, the EXP will count down the test time in minutes and seconds. CAUTION: Do not leave the battery unattended while the charger is in operation. 11.
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Page 25: Chapter 6: System Test
Chapter 6: System Test Chapter 6: System Test Before starting the test, inspect the alternator drive belt. A belt that is glazed or worn, or lacks the proper tension, will prevent the engine from achieving the rpm levels needed for the test. The System Test includes tests that provide a complete diagnosis of the vehicle’s electrical system: •... -
Page 26: Starter System Test Results
Chapter 6: System Test Starter System Test Results Average cranking voltage Loop ohms (starter Average cranking current if l o o p r e s i s t a n c e ) amp clamp is used displa y ed if amp clamp used Cranking time in milliseconds... -
Page 27: Alternator Test
Chapter 6: System Test Alternator Test ANALYZING CHARGING SYSTEM DATA: After you press the NEXT soft key to begin the alternator test, the EXP will immediately begin testing for alternator voltage. TURN ALL VEHICLE LOADS OFF, IDLE ENGINE: Turn off vehicle loads (blowers, interior light, radio, etc.) and idle the engine. -
Page 28: Alternator Test Results
Chapter 6: System Test 11. ENGINE REV DETECTED, IDLE ENGINE: The EXP has detected the rev. Press the NEXT soft key to continue. 12. ANALYZING CHARGING SYSTEM DATA: The EXP is completing its final analysis of the charging system data. 1. - Page 29 Chapter 6: System Test Table 3: Alternator Decisions and Recommendations 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. √ Check the belts to ensure the alternator is rotating with the engine running. Replace broken or slipping belts and retest.
- Page 30 Chapter 6: System Test Table 4: Diode Decisions and Recommendations Decision Action EXCESSIVE RIPPLE One or more diodes in the alternator aren’t functioning or there’s stator damage, which is shown by an excessive amount of AC ripple current supplied to the battery. √...
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Page 31: Chapter 7: Cable Drop Test
There’s no need to run the engine. The Cable Drop Test uses Midtronics’ conductance technology to send a signal through the circuit at the component under test. The EXP then simultaneously calculates voltage drop on the positive (+) and negative (–) sides of any circuit as well as the total voltage drop. -
Page 32: Battery Ground Test
Chapter 7: Cable Drop Test To begin, select the Cable Drop Test icon in the Main Menu and follow the instructions on the display. IMPORTANT: For accurate results the battery should be good and fully charged before you perform a test. Battery Ground Test The Battery Ground Test measures the voltage drop for the ground strap. -
Page 33: Starter Circuit
Chapter 7: Cable Drop Test Starter Circuit The Starter Circuit Test measures the voltage drop of the starter circuit. SELECT CIRCUIT: Use the UP/DOWN ARROWS or the numerical keypad to select STARTER CIRCUIT. BATTERY GROUND STARTER CIRCUIT ALT CIRCUIT OTHER Press the NEXT soft key to continue. -
Page 34: Alternator Circuit
Chapter 7: Cable Drop Test Alternator Circuit The Alternator Circuit Test measures the voltage drop of the alternator circuit. SELECT CIRCUIT: Use the UP/DOWN ARROWS or the numerical keypad to select ALT CIRCUIT. BATTERY GROUND STARTER CIRCUIT ALT CIRCUIT OTHER Press the NEXT soft key to continue. -
Page 35: Other Circuit
Chapter 7: Cable Drop Test Other Circuit This test enables you to measure voltage drop across other components. SELECT CIRCUIT: Use the UP/DOWN ARROWS or the numerical keypad to select the OTHER. BATTERY GROUND STARTER CIRCUIT ALT CIRCUIT OTHER Press the NEXT soft key to continue. SET AMPS: Use the UP/DOWN ARROWS or the keypad to select the rated amperage of the circuit you are testing. -
Page 36: Chapter 8: Jump Start (System Test)
Chapter 8: Jump Start (System Test) Chapter 8: Jump Start (System Test) The EXP’s Jump Start routine assists a discharged battery so that you can complete the Starter Test portion of the System Test. When the JUMP START instruction screen is displayed, disconnect the analyzer’s clamps from the battery posts. -
Page 37: Chapter 9: Dmm (Digital Multimeter)
Chapter 9: Digital Multimeter Chapter 9: DMM (Digital Multimeter) The EXP’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 Voltmeter • Scope • DC Ammeter •... -
Page 38: Ac Volts
Chapter 9: DMM (Digital Multimeter) 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 EXP’s accessories port. 2. -
Page 39: Dc Amp (Requires The Optional Amp Clamp)
Chapter 9: Digital Multimeter DC AMP (requires the optional amp clamp) The DC ammeter measures DC magnitude and flow of the DC current in a circuit. 1. Connect the amp clamp lead to the EXP’s accessories port. 2. Select the meter’s icon. . -
Page 40: Temp
Chapter 9: DMM (Digital Multimeter) Temp The IR temperature sensor measures surface temperature within a range of –20 to 200 °C. The tool can be used for checking the transmission for overheating, and the temperature levels of the heater and air conditioner. Figure 12 shows how to aim the EXP’s temperature sensor at a component you are testing. -
Page 41: Volts/Amp (Requires The Optional Amp Clamp)
Chapter 9: Digital Multimeter Volts/Amp (requires the optional amp clamp) The volts/amp meter simultaneously measures charging voltage and charging current. 1. Connect the amp clamp lead to the EXP’s accessories port. 2. Select the meter’s icon. . Select the amp clamp range. 70 AMP MAX. - Page 42 Chapter 9: DMM (Digital Multimeter) Table 5: EXP Multimeter Specifications 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 43: Chapter 10: Utilities
Chapter 10: Utilities Chapter 10: Utilities The EXP’s Utility Menu has nine utilities that you can easily set up to customize your analyzer: • Language (English, French or Spanish) • Format (memory disk) • Update (software) • Clock (adjustments to date and time) •... -
Page 44: Shop
Chapter 10: Utilities 2. Press the SAVE soft key to save your setting or BACK to return to the CLOCK ADJUST screen. Format Use the UP/DOWN ARROWS or press the corresponding numerical key to move the dot to the option button of your choice or enter its number. -
Page 45: Display
Chapter 10: Utilities To create or overwrite a header: Press the UP or DOWN ARROW to highlight the line you want to change. The cursor will be blinking to the right of the last character in the line. To move the cursor backward to erase a character, press the LEFT ARROW key; to move the cursor forward, press the RIGHT ARROW key. -
Page 46: Coupon
Chapter 10: Utilities Backlight Time Backlight time is from 0 to 60 seconds. To change it: Press the UP or DOWN ARROW to highlight the option. CONTRAST LEVEL Current settings BACKLIGHT TIME Press the ADJUST soft key to display the option’s numerical scroll box. Press the UP/DOWN ARROW keys or the corresponding numerical key to select your preference. -
Page 47: Temp
Chapter 10: Utilities Temp The TEMP. UNITS utility enables you to set the units of measure to either Celsius or Fahrenheit. To set your preference: Use the UP/DOWN ARROWS or press the corresponding numerical key to move the dot to the option button of your choice. DEGREES F DEGREES C Press the SAVE soft key to save your setting. -
Page 48: Chapter 11: Info Menu
Chapter 11: Info Menu Chapter 11: Info Menu The Info Menu has utilities to help you manage your test data and track the usage and history of your analyzer. Totals The TOTALS report displays the total number of battery tests performed since the EXP was first used. Press the LEFT and RIGHT ARROW keys simultaneously to clear the total and reset the starting date. -
Page 49: Chapter 12: Print/View
Chapter 12: Print/View Chapter 12: Print/View The Print/View Menu enables you to view and print the results of the Battery, System, and Cable Drop Tests before you perform another test and overwrite the results in memory. View Test VIEW TEST gives you the option of viewing and printing the results of the Battery and System Tests. To print the results, align the analyzer’s IR transmitter with the printer’s receiver, and select the PRINT soft key. -
Page 50: Chapter 13: Troubleshooting
Chapter 13: Troubleshooting Chapter 13: Troubleshooting If you have problems with the display or the Midtronics printer, try these troubleshooting suggestions: The Display Does Not Turn On • Check the connection to the vehicle battery. • Press the POWER button. - Page 51 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 800-776-1995 for assistance. (See “Patents, Limited Warranty, Service” for more information.) •...
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Page 52: Chapter 14: Exp Internal Batteries
Chapter 14: EXP Internal Batteries Chapter 14: EXP Internal Batteries The EXP uses 6 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. -
Page 53: Patents, Limited Warranty, Service
This analyzer is warranted to be free of defects in materials and workmanship for a period of one year from date of purchase. Midtronics will, at our option, repair or replace the unit with a remanufactured unit. This limited warranty applies only to the EXP analyzer, 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.