CareUcar Battery Analyzer User manual
Do-It-Auto
Battery Analyzer
Series
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Battery Analyzer
User’sManual
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Version: 2.0
Battery Analyzer Series
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Table of Contents
1.0 Introduction------------------------------------------------------------------------------------------
1.1 The Product-------------------------------------------------------------------------------------------------------3
1.2 Specifications----------------------------------------------------------------------------------------------------4
2.0 Safety Measures-----------------------------------------------------------------------------------
2.1 Safety Precautions---------------------------------------------------------------------------------------------4
2.2 Other Precautions----------------------------------------------------------------------------------------------6
3.0 Working with Batteries--------------------------------------------------------------------------7
4.0 Types of Batteries--------------------------------------------------------------------------------9
5.0 The Analyzer----------------------------------------------------------------------------------------
5.1 Main Unit---------------------------------------------------------------------------------------------------------11
5.2 Key Functions--------------------------------------------------------------------------------------------------12
5.2.1Functions of Individual Key--------------------------------------------------------------------------------12
6.0 Battery Diagnosis----------------------------------------------------------------------------------
6.1 Start Analyzing-------------------------------------------------------------------------------------------------13
7.0 False Capacity-----------------------------------------------------------------------------------21
8.0 Ampere-Hour (AH) Rating--------------------------------------------------------------------22
9.0 State Of Charge (SOC) --------------------------------------------------------------------------
9.1 Measuring the State Of Charge---------------------------------------------------------------------------22
9.2 Temperature Compensation-------------------------------------------------------------------------------24
10. Recharging Batteries ----------------------------------------------------------------------------
10.1 Bulk Charge-----------------------------------------------------------------------------------------------------25
10.2 Absorption Charge------------------------------------------------------------------------------------------- 26
10.3 Equalizing Charge --------------------------------------------------------------------------------------------26
10.4 Float Charge --------------------------------------------------------------------------------------------------- 26
10.5 Charging Voltage and Current ----------------------------------------------------------------------------27
11. Removal of Surface Charge------------------------------------------------------------------29
12. How to Revive a Sulfated Battery-------------------------------------------------------------
12.1 Light Sulfation--------------------------------------------------------------------------------------------------30
12.2 Heavy Sulfation ----------------------------------------------------------------------------------------------- 31
13. Common Causes of Battery Failures -----------------------------------------------------31
14. Myth about Batteries---------------------------------------------------------------------------32
15. Battery Rating Charts-----------------------------------------------------------------------------
15.1 Japanese Industrial Standards (JIS#) Rating Chart----------------------------------------------- 34
15.2 DIN & EN Standards Rating Charts--------------------------------------------------------------------- 36
15.3 YUASA Battery Rating Chart------------------------------------------------------------------------------38
15.4 Rough CCA Guide-------------------------------------------------------------------------------------------- 38
16. Alternator Test -------------------------------------------------------------------------------------
16.1 Start Testing----------------------------------------------------------------------------------------------------39
17. Cranking Test --------------------------------------------------------------------------------------
17.1 Begin Testing---------------------------------------------------------------------------------------------------42
18. Notice-------------------------------------------------------------------------------------------------
18.1 Disclaimer-------------------------------------------------------------------------------------------------------43
19. Warranty Information-----------------------------------------------------------------------------
19.1 Limited Warranty----------------------------------------------------------------------------------------------44
19.2 Limitations of Warranty-------------------------------------------------------------------------------------45
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1.0 - Introduction
1.1-The Product:
This Battery Analyzer is designed to test the condition of the automotive
battery using conductance method. Unlike the conventional method of draining
the battery by applying resistance load to it and obtain the result from the
meter gauge; this analyzer utilizes a series of pulsed voltage across the battery
cells and observes the AC current that flows in response to it.
The benefits of this test method are:
•Conductance correlates directly to the battery capacity
•Passive testing method is safe.
•Never discharges or drain the battery.
•Able to test condition of discharged battery.
•Consistent and repeatable results.
•Provides unique indication of battery conditions.
Besides, this analyzer also provides check the Alternator’s charging and
Starter’s cranking conditions.
It is maintenance free and no internal batteries required. It powers up when
connected to the battery posts during testing.
The operation is fast and simple. When hooked up to the battery posts, the
displayed instructions on the screen will lead you through and a warning tone to
caution you to perform the correct steps.
Its result is consistent and repeatable and can be performed numerous times
without heating up the unit. It is very safe as it does not create any sparks
when connected to the battery terminals during testing on the vehicle.
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1.2 Specifications:
Operating Voltage: 9V ~ 15V (max)
Analyzing Capacity (Amps): CCA 100 ~ 1700
EN
100 ~ 1000
IEC 100 ~ 1700
DIN 100 ~ 1000
JIS# (100 ~ 1700 CCA)
Battery analyzing time: Less than 5 seconds.
2.0 Safety Measures:
For safety reasons, read this manual thoroughly before operating the Tool.
Always refer to and follow the safety instructions and testing procedures
provided by the car or equipment manufacturer. The safety messages
presented below and throughout this user’s manual are reminders to the
operator to exercise extreme care when using this test instrument.
2.1 Safety Precautions:
When the engine is running, it produces carbon
monoxide, a toxic and poisonous gas. Always operate
the vehicle in a well ventilated area. Do not breathe
exhaust gases – they are hazardous that can lead to
death.
To protect your eyes from propellant object such as
caustic liquids, always wear safety eye protection.
Fuel and battery vapors are highly flammable.
DO NOT SMOKE NEAR THE VEHICLE DURING TESTING.
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When engine is running, many parts (such as pulleys,
coolant fan, belts, etc) turn at high speed. To avoid
serious injury, always be alert and keep a safe distance
from these parts.
Before starting the engine for testing or trouble
shooting, always make sure the parking brakes is firmly
engaged. Put the transmission in Park (automatic
transmission) and Neutral (manual transmission).
Always block the drive wheels.
Never leave vehicle unattended while testing.
Never lay tools on vehicle battery. You may short the
terminals together causing harm to yourself, the tools or
the battery.
Engine parts become very hot when engine is running.
To prevent severe burns, avoid contact with hot engine
parts.
Do not wear loose clothing or jewelry while working on
engine. Loose clothing can get caught in fan, pulleys,
belts, etc. Jewelry can conduct current and can cause
severe burns if comes in contact between power source
and ground.
When the engine is running, be cautious when working
around the ignition coil, distributor cap, ignition wires
and spark plugs. They are HIGH VOLTAGE components
that can cause electrical Shock.
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Always keep a fire extinguisher readily available and
easily accessible in the workshop.
2.2 Other Precautions:
•This battery analyzer is meant for testing of 12 Volts batteries only.
•Its operating voltage is from 9V ~ 15V DC and should not be tested on
24V directly. It will cause damage the unit. For 12V x 2 batteries (in
series or parallel), disconnect the connections and test them
individually.
•Battery that has just been charged by the charger contains surface
charge and it should be discharged by turning ON the Head lights for
3~5 minutes before testing.
•Always attached the analyzer clips on the lead side of the battery
terminal posts during testing so that it has a good contact. This will
provide better and accurate results.
•Do not attach the analyzer clips directly onto the steel bolt that tightened
to the battery terminal posts; this may give inaccurate readings or
inconsistent results. (Note: This also applies to all other battery testing
methods.)
•If the battery terminal posts were oxidized or badly corroded and the
connections were bad, the analyzer will prompt you to check the
connections. In this case, clean the terminal posts and performs testing
directly on the terminal posts it-self.
•During testing on the battery whist it is still in the car, make sure the
engine is OFF.
•Do not store the battery analyzer near high humidity or temperature
area. Exposing to extreme temperatures will cause damage to the unit.
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3.0 Working with Batteries
Lead-acid batteries contain a sulfuric acid electrolyte, which is a highly
corrosive poison and will produce gasses when recharged and explode if
ignited. This will hurt you--BAD!
When working with batteries, you need to have plenty of ventilation, remove
your jewelry, wear protective eyewear (safety glasses) and clothing, and
exercise caution.
Do not allow battery electrolyte to mix with salt water. Even small quantities of
this combination will produce chorine gas that can KILL you!
Whenever possible, please follow the manufacturer's instructions for testing,
jumping, installing, charging and equalizing batteries.
¾Never disconnect a battery cable from a vehicle with the engine
running because the battery acts like a filter for the electrical
system.
Unfiltered [pulsating DC] electricity can damage expensive
electronic components, e.g., emissions computer, radio, charging
system, etc.
Turn off all electrical switches and components, turn off the
ignition and then disconnect the battery.
¾For non-sealed batteries, check the electrolyte level. Make sure it
is covering the plates, and it is not frozen before starting to
recharge.
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¾Do not add distilled water if the electrolyte is covering the top of
the plates because during the recharging process, it will warm
and expand. After recharging has been completed, recheck the
level.
¾Reinstall the vent caps BEFORE recharging, recharge ONLY in
well-ventilated areas, and wear protective eye ware.
Do NOT smoke or cause sparks or flames while the battery is
being recharged because batteries give off explosive gasses.
¾If your battery is an AGM or a sealed flooded type, do NOT
recharge with current ABOVE 12% of the battery's RC rating (or
20% of the ampere-hour rating).
Gel cells should be charged over a 20-hour period and never over
the manufacturer's recommended level or over 14.1 VDC.
¾Follow the battery and charger manufacturer's procedures for
connecting and disconnecting cables and other steps to minimize
the possibility of an explosion or incorrectly charging the battery.
You should turn the charger OFF before connecting or
disconnecting cables to a battery.
Do not wiggle the cable clamps while the battery is recharging,
because a spark might occur, and this could cause an
explosion. Good ventilation or a fan is recommended to disperse
the gasses created by the recharging process.
¾If a battery becomes hot, over 110° F (43.3° C), or violent gassing
or spewing of electrolyte occurs, turn the charger off temporarily
or reduce the charging rate.
¾Ensure that charging with the battery in the car with an external
MANUAL charger will not damage the vehicle's electrical system
with high voltages.
If this is even a remote possibility, then disconnect the vehicle's
battery cables from the battery BEFORE connecting the charger.
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4.0 – Types of Batteries
Basically the major types of batteries are as follows:
•Starting Battery
Sometimes it is called SLI (Starting, Lighting and Ignition) battery and it
is designed to start and run engines. It delivers quick bursts of energy
(such as starting engines) and have a greater plate count.
The plates will also be thinner and are composed of a Lead "sponge",
similar in appearance to a very fine foam sponge. This gives a very
large surface area, but if deep cycled, this sponge will quickly be
consumed and fall to the bottom of the cells.
Automotive batteries will generally fail after 30-150 deep cycles if deep
cycled, while they may last for thousands of cycles in normal starting
use (2-5% discharge).
Starting batteries are usually rated at "CCA", or cold cranking amps, or
"MCA", Marine cranking amps - the same as "CA".
•Deep Cycle Battery
These batteries are used mainly on golf cart, scooter, solar, RV, etc
has less instant energy but greater long-term energy delivery.
They are designed to be discharged down as much as 80% time after
time, and have much thicker plates. The major difference between a
true deep cycle battery and others is that the plates are SOLID Lead
plates - not sponge.
Deep cycle batteries are usually rated at “AH” orAmperes Hour.
•Marine Battery
These batteries are usually actually a "hybrid", and fall between the
starting and deep-cycle batteries. The plates may be composed of
Lead sponge, but it is coarser and heavier than that used in starting
batteries.
"Hybrid" types should not be discharged more than 50%.
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Major types of battery construction:
•Wet Cell (Flooded)
Wet or Flooded cell batteries are divided into low
maintenance (the most common) and maintenance
free (or sealed), which is based on their plate
formulation.
Low maintenance batteries have
lead-antimony/antimony or lead-antimony/calcium
(dual alloy or hybrid) plates thus the maintenance free
batteries use lead-calcium/calcium.
•AGM
The Absorbed Glass Matt (AGM) are also sometimes
called "starved electrolyte" or "dry", because its
fiberglass mat is only 95% saturated with Sulfuric acid
and there is no excess liquid.
This construction allows the electrolyte to be
suspended in close proximity with the plate’s active
material. In theory, this enhances both the discharge
and recharge efficiency.
Nearly all AGM batteries are sealed valve regulated
(commonly referred to as "VRLA" - Valve Regulated Lead-Acid).
Most valves regulated are under some pressure - 1 to 4 psi at sea
level.
Popular usages are high performance engine starting, power sports,
deep cycle, solar and storage battery.
•GEL Cell
The Gel Cell is similar to the AGM style because the
electrolyte is suspended, but it is different because
technically the AGM battery is still considered to be a
wet cell. The electrolyte in a GEL cell has a silica
additive that causes it to set up or stiffen.
All Gel Cell batteries are sealed and a few are "valve
regulated", which means that a tiny valve keeps a
slight positive pressure.
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The recharge voltages on this type of cell are lower than the other
styles of lead acid battery. This is probably the most sensitive cell in
terms of adverse reactions to over-voltage charging. If the incorrect
battery charger is used on a Gel Cell battery, poor performance and
premature failure is certain.
Gel Cell batteries are best used in VERY DEEP cycle application and
may last a bit longer in hot weather applications.
The Gel Cell and the AGM batteries are specialty batteries. They store
very well and do not tend to sulfate or degrade as easily as Wet Cell.
Also, there is little chance of a hydrogen gas explosion or corrosion when
using these batteries which made them the safest lead acid batteries.
5.0-TheBatteryAn
alyzer
5.1 - Main Unit
LCD Display
Results and instructions
Keypad
Command keys Battery Terminal
toaccesstovari
ous Clips
functions.
Figure 1
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5.2 - Keypad Functions:
1
5
4 2
3
6
5.2.1 Functions of Individual key:
1. Use this key to scroll up to the next item OR when it is in
the keying-in Battery Ratings values mode, press this key
once will increase the value by step of 5 units.
2. Use this key to shift the selection tab to the right item OR
when it is in the keying-in Battery Ratings values mode,
press this key once will increase the value by step of 100
units.
3. Use this key to scroll down to the next item OR when it is in
the keying-in Battery Ratings values mode, press this key
once will decrease the value by step of 5 units.
4. Use this key to shift the selection tab to the left item OR
when it is in the keying-in Battery Ratings values mode,
press this key once will decrease the value by step of 100
units.
5. Press this key will ENTER into the selected function.
6. To EXIT, press this key once will return back to the
previous screen.
Figure 2
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6.0 - Battery Diagnosis
6.1 – Start Analyzing
This battery analyzer can perform testing while the battery is still fixed on the
vehicle. Please make sure the engine is OFF.
1. Attach the clips onto the battery terminal posts and the battery
analyzer will power up and lights up the LCD display screen as shown
(Fig.3).
2. It will run through a self-test and when completed it displays the Main
Menu as shown: (Fig. 4)
3. Pressing key once will scroll down to the next item if there is a
need to select it.
6. As an example (Fig.4) the selected item was on “Battery” and it is being
highlighted.
Figure 3
Figure 4
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7. Press key will proceed to do the battery testing and if it has
detected any surface voltage on the battery, it will start to clean and a
message is shown (Fig. 5) below.
8. If the surface voltage is too great for the Analyzer to handle, it will
prompt you with the instructions as shown: (Fig.6) below
9. Wait until the surface voltage cleaning had completed, the analyzer will
advise
as follows: (Fig.7) and then press key.
Figure 7
Figure 5
Figure 6
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4. If there is no surface voltage, then it will straight away enter into “Select
Input” menu screen as shown in Fig. 8
8. Before selecting the ratings ‘CCA, EN, IEC, and DIN & JIS #’ from the
menu, check the battery specification value. This value can be checked
on the battery labels as some of the examples shown below:
Figure 8
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If it is selected under JIS # (Japanese Industrial Standard) then the
display will prompt you as shown (Fig.9) below.
Refer to the battery model (example: 80D26L or NX110-5L) on the
Cold Cranking Amps (CCA) Table list either at the back of the Analyzer
or from this manual on page 35 (See example Fig.10 below.)
Press key and the display will show: (Fig.11) below
Figure 9
Figure 10
Figure 11
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9. Referring to the Table list (Fig.10) under 80D26L, check the battery type:
WET, MF, Sealed MF or Closed MF (CMF) as each category has
different CCAratings. For instance, if the battery is a Sealed MF (CMF)
then it is rated at 630 CCA.
Note: WET - Wet
Cell Type
MF - Maintenance Free Type
CMF - Closed or Sealed Maintenance Free
10. To enter the value 630, press key will increase the original value
of 500 (Fig.11) by step of 100 units to 600. Likewise use key to
increase the last two digits (00) to 30 by step of 5 units for each pressing.
(Fig. 12)
11. Once the CCA rating of the battery is confirmed, press key will
start the testing process. Refer to the display below (Fig. 13).
Figure 12
Figure 13
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12. For less than 5 seconds, the results of the testing will be displayed on
the LCD screen. (Fig. 14)
Interpretations of the above results:
1. RESULTS: Good
A very straight forward display of the final results basing on the
evaluation of the tested condition. ‘Good’ indicates the battery in
good condition. ‘Replace’ indicates that the battery needs to be
replaced. If not, the battery will fail anytime without any warning.
2. Voltage : 12.46V
This indicates the tested battery voltage (12.46V). It depends on
the state of charge on the battery:
100%
fully charged - 13.20V
90% charged - 12.90V
75% charged - 12.45V
3. CCA (Cold Cranking Amps): 406 CCA
CCA ratings has been used here, therefore the tested result is in
406 CCA. If other rating (DIN or JIS, or IEC, or EN) were selected,
it will base on the respective rating to calculate and show the
results in that selected rating.
4. Int. R (Internal Resistance): 6.72mΩ
In normal condition, the internal resistance should fall between
2.0 mΩ~ 15.0 mΩ. As a matter of fact, the higher the battery
CCA readings obtained the lower the internal resistance should
be.
5. LIFE: 50 %
This is an indication of the battery life expectancy in percentage. If
the life falls below 45 %, the RESULT will display “Replace” and it
is time to change to a new battery.
Figure 14
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Explanation of the following terms used as shown on the LCD display:
•CCA (Cold Cranking Amps) – most commonly used Standard.
CCA is a rating used in the battery industry to rate a battery’s ability to
start an engine in cold temperatures. This rating is the number of
amperes that a new fully charged battery can delivery at 0°F (-18°C) for
30 seconds, while maintaining a voltage of at least 7.2 Volts for a 12V
battery.
The bigger the CCA will have the greater starting power of the battery.
•IEC (International Electrotechnical Commission) Standard.
IEC amperes rating require that at 0°F (-18°C), the number of amperes
that the 12V battery can deliver while maintaining a voltage of at least of
8.4 Volts for 60 seconds during cranking.
•EN (European Norms) Standard
EN amperes rating require that at 0°F (-18°C), the number of ampere
that the 12V battery can deliver while maintaining a voltage of at least
6.0 Volts for 180 seconds during cranking.
•JIS# (Japanese Industrial Standard)
JIS # amperes’ rating is based on Ampere Hours and is calculated using
20 hours rating. In this manual, it is using CCA ratings reference table
list provided basing on the JIS model number (See page 34).
•DIN (Deutsches Institut für Normung) - German Institute for Standardization.
Taking an example: DIN 100 Amperes
Basing on DIN 100 Amp battery, the rating requires that at 0°F (-18°C),
the battery is able to deliver 100 amperes while maintaining a voltage of
at least of 9.0 Volts for 30 seconds and 8.0 Volts for 150 seconds during
cranking.
•Unknown
If you are not sure which ratings (CCA, EN, IEC, JIS or DIN) that the
battery is based on then choose this setting. It will show the battery’s
Voltage, CCA and the Internal Resistance (mΩ) only. This selection can
also be used to test 12V - Deep Cycle Batteries.
An example of the results display is shown below:
Figure 15
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Use Voltage (should not fall below 12.6V when fully charged) and the
Internal Resistance [Int.R] (should not more 15m
Ω
) readings to
determine the condition of the tested Deep Cycle Battery.
Batteries that had been left idle for long periods can still be tested with
this analyzer. To perform the test, just clamp the analyzer clips onto the
battery terminals and it will display the screen (Fig.16) as shown if its
voltage falls below the normal 12 volts and a buzzing sound is heard.
Press key to continue and the display will show: (Fig.17)
Check the battery ratings and enter it as described in step 10 (page 13)
and the results will show as an example below:
Figure 16
Figure 17
Figure 18
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