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

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.
METERS (Screen 1)
METERS (Screen 2)
METERS (Screen 3)
Measures voltage within
a range of 0 to 60 Vdc. Measures voltage within
a range of 0 to 24 Vac. Voltage trace with time
and frequency measure-
ments.
Tests the strength of
the direct current flow
through a circuit.
Tests the strength of the
alternating current ow
through a circuit.
Sensorthatdisplaystem-
perature in degrees F
or C (units you can select
in the Utilities Menu.)
Tests a circuit for con-
tinuity and resistance
measured in ohms ( ).
Tests a diode for forward
voltage drop. Measures two signals simultaneously: DC volt-
age and amperage.
Required test leads
Amp
clamp
Battery
test DMM clamps or
probes
Probes
only
Chapter 2: Overview

Info Menu
The Info Menu has three utilities to help you manage your test data, and track the analyzer’s usage
and history.
An optional IR software
and hardware package
allows you to transfer
test data to a PC.
Displays the total num-
ber of test in three cat-
egories: Lifetime of the
analyzer, by User ID,
and by decision.
Displays the software
version, total tests from
rst use, and the serial
number.
REPORTS
Print/View Menu
The EXP stores the last battery, system, and cable test results in its memory until you perform another
test. To review or print results before you retest, select a test type in the Print/View Menu.
Displays the last Battery
and System Test results.
Sends the results to an
optional IR printer.
REPORTS
Displays the last Cable
Drop Test result. Sends
the result to an optional
IR printer.
Chapter 2: Overview

Utility Menu
The Utilities Menu allows you customize your analyzer. Before testing, check the default values to see
which options you may want to change.
SETUP (Screen 1)
SETUP (Screen 2)
SETUP (Screen 3)
Settings to adjust date
and time. Add, edit, or delete User
IDs using up to seven al-
phanumeric characters.
Settings to adjust the
screen contrast and
backlight time.
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.
Allows you to create
and store up to three
separate coupons to be
printed on test results.
Allows you to select de-
grees in C or F for tem-
perature measurements.
Sets the language of the
display and printouts. Formats the SD card to receivedata.Also erases
all data on the card.
Updates the analyzer
software via les on an
SD card.
Allows you to add
a custom header to
printed test results.
SETUP (Screen 4)
Chapter 2: Overview

Chapter 3: Utility Menu
The Utility Menu has several utilities that customize the EXP—from the language of the user interface to the
contrast of the text on the display. The utilities have default settings that you can change, depending on your
requirements.
Setup Function Default Settings
CLOCK
TIME The current Central Standard Time
MODE AM
DATE Current
FORMAT MM/DD/YYYY (month/day/year)
SHOP Generic header for printouts with 12 lines of text and a maximum of 17
characters per line
USERS USER01 through USER24 are placeholder IDs used to create user
names.
DISPLAY
CONTRAST LEVEL
BACKLIGHT TIME Range: 0 (lightest) to 10 (darkest). The default is set at 9.
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.
Default: USER COUPON LINE 1 through USER COUPON LINE 8
TEMPERATURE 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.
Chapter 3: Utility Menu

The Utility Menu has nine utilities to customize your analyzer. Each utility described in this section is listed
in order by its icon title.
If you use the alphanumeric keypad to enter the number preceding the option button, no additional
keypress is needed to save or continue to the next step.
Clock
The CLOCK ADJUST utility has four settings. Use the UP/DOWN ARROW keys to highlight the setting
you want to change.
MODE : AM/PM
TIME : 9:07 PM
FORMAT : MMM/DD/YYYY
DATE : 6/17/6/17/2005
Mode
Use the UP/DOWN ARROW keys or press the corresponding numerical key to move the dot to the
option button of your choice or enter its number.
1. Select the 24-hour or AM/PM mode
124 HOUR
2AM/PM
2. If you used the ARROW keys, press the SAVE soft key to save your setting or the
BACK soft key to return to the CLOCK ADJUST screen without saving the changes.
Time
1. Use the LEFT/RIGHT ARROWS to highlight the hour, minutes, or AM or PM. To rapidly
scroll, hold down an ARROW key.
9: 19 PM
2. Press the SAVE soft key to save your setting or BACK to return to the CLOCK ADJUST
screen.
Format
Use the UP/DOWN ARROW keys or press the corresponding numerical key to move the dot to the
option button of your choice or enter its number.
1. Select the 24-hour or AM/PM mode
1 MM/DD/YYYY (month/day/year)
2 DD/MM/YYYY (day/month/year)
Chapter 3: Utility Menu

2. If you used the ARROW keys, press the SAVE soft key to save your setting or the
BACK soft key to return to the CLOCK ADJUST screen without saving the changes.
Date
1. Use the LEFT/RIGHT ARROWS to highlight the month, day, or year. To rapidly scroll,
hold down an ARROW key.
4/ 01 / 2006
2. Press the SAVE soft key to save your setting or the BACK soft key to return to the
CLOCK ADJUST screen without saving the changes.
Users
The USERS utility allows you to create and edit a USER ID with one to seven alphanumeric characters
and link it to a test counter. It also allows you to delete a USER ID and its associated test total.
Entering a New User ID
1. To create a USER ID, select:
1 ENTER NEW
2 DELETE
3 EDIT
Press the NEXT soft key to display the list of available IDs.
2. Use the UP or DOWN ARROW keys to scroll to the ID placeholder you want to use.
Scrolling past the first line will go to the previous page. Scrolling past the fourth line will
go to the next page. To display more placeholders, continue scrolling or use the LEFT
or RIGHT ARROW key to jump up or down through the list four lines at a time.
1 USER01
2 USER02
3 USER03
4 USER04
Press the NEXT soft key to continue.
3. To clear the default characters, press the LEFT ARROW key. To add a space, move the
cursor forward by pressing the RIGHT ARROW key.
ENTER USER ID
USER01 —Blinking cursor shows the starting
location for editing
Chapter 3: Utility Menu

4. Insert a character by pressing the alphanumeric key associated with the character as
many times as needed. Press the SAVE soft key to store the new user ID in memory.
ENTER USER ID
BOB R
Deleting a User ID
1. To delete a USER ID, select:
1 ENTER NEW
2 DELETE
3 EDIT
Press the NEXT soft key to display the list of IDs.
2. Use the ARROW keys to select a USER ID as described in step 2 in Entering a New
User ID. (You cannot delete placeholder USER IDs, i.e., USER03).
1 BOB R
2 JIM F
3 PETER
4 USER04
Press the DELETE soft key.
Edit (Editing a User ID)
1. To edit a USER ID, select:
1 ENTER NEW
2 DELETE
3 EDIT
Press the NEXT soft key to display the list of IDs.
2. Follow steps 2, 3 , and 4 in “Entering a New User ID” above.
Chapter 3: Utility Menu

Shop
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.
Screen 1 Screen 2
1–YOUR SHOP NAME —
2–1000 ANY STREET
3–YOUR TOWN, STATE
5–YOUR COUNTRY —
6–YOUR PHONE NUMBER
4–YOUR POSTAL CODE
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.
Header and Coupon Template
Line 1
Line 2
Line 3
Line 4
Line 5
Line 6
Line 7
Line 8
To create or overwrite a header:
1. 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.
2. Press the LEFT ARROW key to move the cursor backward to erase a character. To move the
cursor forward, press the RIGHT ARROW key.
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 the SAVE soft key to save your setting or the BACK soft key to return to the SHOP
INFO screen without saving the changes.
Chapter 3: Utility Menu

Display
The LCD OPTIONS utility allows you to adjust the contrast of the text on the display and the backlight
time.
Contrast Level
The contrast level is 0 (lightest) to 10 (darkest). To change it:
1. Press the UP or DOWN ARROW key to highlight the option.
CONTRAST LEVEL 10
BACKLIGHT TIME 60
2. Press the ADJUST soft key to display the option’s numerical scroll box.
10 (1-10)
3. Press the UP or DOWN ARROW key or the corresponding numerical key to select your
preference.
4. Press the SAVE soft key to save your setting or the BACK soft key to return to the
CONTRAST LEVEL screen without saving the changes.
Backlight Time
Backlight time is from 0 to 60 seconds. To change it:
1. Press the UP or DOWN ARROW key to highlight the option.
CONTRAST LEVEL 10
BACKLIGHT TIME 60
2. Press the EDIT soft key to display the option’s numerical scroll box.
60 SEC
3. Press the UP or DOWN ARROW key or the corresponding numerical key to select your
preference. To erase a character, press the LEFT ARROW key.
4. Press the SAVE soft key to save your setting or the BACK soft key to return to the
BACKLIGHT screen without saving the changes.
Chapter 3: Utility Menu

Coupon
The COUPON SELECT utility allows you to print one of the three custom coupons or messages created
in the EDIT COUPON utility.
1. Use the UP or DOWN ARROW key, or press the corresponding numerical key (1, 2) to move
the dot to the option button of your choice.
1 NO COUPON PRINTED
2 USER COUPON
2. Press the SAVE soft key to save your setting or the BACK soft key to return to the Utility
Menu without saving the changes.
Edit Coupon
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, see the procedure under Shop in this chapter for using the keypad to enter
and backspace over characters. Use the template to plan and center your text.
Temp
The TEMP. UNITS utility enables you to set the units of measure to either Celsius or Fahrenheit.
To set your preference:
1. Use the UP/DOWN ARROWS or press the corresponding numerical key to move the dot to
the option button of your choice.
1 DEGREES F
2 DEGREES C
2. Press the SAVE soft key to save your setting.
Chapter 3: Utility Menu