Midtronics INTELLECT EXP HD User manual

Midtronics Expandable
Electrical Diagnostic Platform
INSTRUCTION MANUAL
Battery Management Innovation
For testing 6- and 12-volt
heavy-duty, automotive,
and commercial batteries,
and 12-volt and 24-volt
charging systems.

Chapter 1: Before You Begin
For safe, efcient, and accurate testing, review the safety and operating instructions in this manual before
using the analyzer.
We also recommend that you register the analyzer to activate your warranty.
Safety Precautions
Inspect the battery for damages 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
preventsevereinjuryordeath.Followallmanufacturers’instructionsandBCI(BatteryCouncilInternational)
safety recommendations, which include the following 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. Always work in a well-
ventilated area. Never smoke or allow a spark or flame in the vicinity of a battery.
•WARNING—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. Wash hands after handling.
•Battery acid is highly corrosive. If acid enters your eyes, immediately flush them thoroughly
with running cold water for at least 15 minutes and seek medical attention. If battery acid gets
on your skin or clothing, wash immediately with 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 it.
Chapter 1: Before You Begin

Chapter 2: Overview
The inTELLECT EXP-1000 HD tests 6- and 12-volt heavy-duty automotive and commercial batteries, and
12-volt and 24-volt charging systems. In addition to a standard single-battery test, the EXP has a test rou-
tine designed for multiple-battery vehicles and a specialized heavy-duty battery algorithm for larger batter-
ies. Other tools in the EXP include a digital multimeter with a scope, and a conductance cable drop test.
The large backlit graphical screen and icon-based user interface make diagnostics simple for the novice
and experienced electrical technician.An alphanumeric keypad with selection scrolling and soft (multifunc-
tion) keys make the EXP as easy to use as a remote control or cell phone. A memory card system allows
for upgrades, quick storage, and transfer of test data.
Case Layout
The EXP-1000 HD kit includes a hard-sided, molded carrying case. The case holds all accessories, with
room for future options.
Printer batteries
Printer paper
Cable storage
Side-post
stud adapters
Printer charger
Group 31
stud adapters
IR printer
inTELLECT EXP
Battery
test cable
Amp clamp
Chapter 2: Overview

Standard and optional test cables include:
Heavy duty battery test cable
(15-foot)
Amp clamp
DMM (Digital Multimeter)
cable
Banana Jack adapter
and probes
Test Leads, Connections, and Data Ports
The top of the EXP has two connectors for test cables:
RJ45 connector (Accessories Port) with a
release lever for accessory test cable.
6-pin connector, with a locking ring, for the
battery test leads.
In addition, the top-left corner of the EXP has two IR data
ports:
Temperature measurement sensor.
Data transmitter, which transmits test results to
an IR printer
RJ456-pin
Chapter 2 : Overview

The bottom and right side of the EXP have two data ports:
DB-9 connector for future expandability.
Spring-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 rst aligning the cable connector’s 6 holes with the 6 pins on
top of the EXP. Firmly insert the connector and nger-tighten the locking ring.
Connecting an Accessory Cable
If you are using an accessory cable, plug it into the accessories port on top of the EXP as you would a
phone jack. To remove it, press the lever and pull out the cable connector.
Inserting an SD Card
The SD card slot contains a plastic ller card for protection. The EXP can store test results on an SD card.
To remove the ller card, push briey on its edge to release it and pull it from the slot.
When inserting an card, push it into the slot until it locks. The card is correctly inserted when it is not
protruding from the slot.
Chapter 2 : Overview

Display and Keypad
The analyzer keypad and display work together to help you quickly nd 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.
Status Indicator: EXP Internal Batteries
This indicator appears in the screen’s top left
corner. It lets you know the status and charge
level of the analyzer’s six 1.5 volt batteries.
The X in the indicator shows that the EXP is
powered by the battery you are testing, a fea-
ture which conserves the internal batteries.
Voltmeter
When you rst connect the analyzer to a bat-
tery 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 bot-
tom 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 appear-
ing above them as part of the keys. Some
of the more common soft-key functions are
SELECT, BACK, and EXIT.
POWER Button
Press the POWER button to turn the analyzer
on and off. The analyzer also turns on auto-
matically when you connect its test leads to a
battery.
Title Bar
The Title Bar shows you the name of the cur-
rent menu, test tool, utility, or function.
Selection Area
The Selection Area below the Title Bar con-
tains items you select or into which you enter
information. The area also displays instruc-
tions and warnings.
Directional Arrows
When displayed in menu screens, the Direc-
tional Arrows show you which ARROW key
on the keypad to press to display other icons
or screens. The Up and Down Directional Ar-
rows, for example, let you know when to press
the UP and DOWN ARROW keys to display
the screens above and below the current
screen.
The Left and Right Directional Arrows tell you
when to use the LEFT or RIGHT ARROW
keys to select an icon.
Chapter 2: Overview

When displayed under a list of options, the
Directional Arrows show you which keypad
arrow to press to highlight a character or an
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.
Keypad Arrows
While the Directional Arrows serve as road
signs, the KeypadArrows are the vehicle to its
functions and features. You use the keypad to
log on, navigate to menus and options, cus-
tomize settings, and perform tests.
Alphanumeric Keypad
In some cases, you can use theAlphanumeric
Keypad to enter numerical test parameters
instead of scrolling to them with the ARROW
keys.
Top
or only
screen
Middle
screen Last screen
Scroll
Box
You also use the Alphanumeric Keys to cre-
ate and edit customer coupons and your shop
contact information on printed test results, and
manage technician IDs.
To add a space, press the RIGHT ARROW
key. To erase a space and insert a character,
press the LEFT ARROW key.
Refer to the table below for the characters as-
sociated with each alphanumeric key.
Chapter 2: Overview
Keypad Character Assignment
1 $ - ( ) 1
2a b c 2
3d e f 3
4g h i 4
5j k l 5
6 m n o 6
7p q r s 7
8t u v 8
9w x y z 9
0% , . # 0
Backspace
Space
Key Character

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 requested. The
four types of entry methods are described below.
Typically, the soft key below the left half of the screen cancels your choice or returns you to the previous
screen, although the command above it may vary. (Examples: BACK and PRINT.) In a similar fashion, the
soft key below the right half of the screen conrms your choice, although the word above it may also vary
(examples: SELECT and NEXT).
Menu icons
A menu icon is a graphical representation of a function you can select, such as the Diode Icon in
the DMM Menu. To select an icon, use the LEFT or RIGHT ARROW key to highlight it. Highlighting
changes the icon to a white picture on a black background. To conrm your selection, press the
appropriate soft key.
Option Buttons
Some lists have option buttons before each item. To select an item, use the UP/DOWN ARROW keys
to move the dot to the button next to the item. You can also use the alphanumeric keypad to enter the
number preceding the option button. To conrm your selection, press the appropriate soft key.
Scrolling Lists
Scrolling lists contain items that extend above and below the screen or the selection box that contains
them. To indicate that there are more items, the symbols appear to the right of the rst visible or
highlighted item on the list.
To select from the list, use the UP/DOWN ARROW keys to scroll to the item, or use the keypad to
enter your choice, and press the appropriate soft key. Scrolling increases and decreases the units by
ve. To increase your scrolling speed, hold the UP or DOWN ARROW key.
Chapter 2: Overview

Alphanumeric Entry
Some selections require you to use the alphanumeric keypad. These “user-dened” selections have
a blinking horizontal line (cursor) to the right of the last character.
Use the UP/DOWN ARROW keys to highlight a line for editing. Display the character, symbol, or
number you want by rapidly pressing its key as many times as needed. If you pause, the cursor
moves to the right. To backspace, press the LEFT ARROW key. Use the RIGHT ARROW key to add
a space. Use the UP/DOWN ARROW keys to highlight a line for editing. When nished, press the
appropriate soft key to save your settings.
Chapter 2: Overview

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. Menu icons are marked here with an asterisk (
*
) and are mapped on the following pages.
Main Menu (Screen 1)
Main Menu (Screen 2)
Main Menu (Screen 3)
Tests one battery using
the battery information
you select in a series of
screens.
Tests the battery pack or
individual batteries (and
the starting and charging
systems.
Digital multimeter with
eight test meters, a tem-
perature sensor, and
options for clamps and
probes.
Includes a test counter,
data transfer utility, the
EXP software version
and serial number.
Allows you to view your
stored test results and
print them to an optional
IR printer.
Nine utilities, many of
which customize your
user interface.
*
*
*
*
Required test leads
Amp
clamp
Battery
test Cable drop
Optional
Tests both sides of a
circuit simultaneously for
voltage drop. Three pre-
set tests and one user-
dened.
Clamps
only
Chapter 2: Overview