Midtronics PowerSensor Micro700 User manual

INSTRUCTION MANUAL
For testing 6- and 12-volt heavy-
duty automotive, commercial, and
marine batteries and 12- and 24-volt
charging systems.

•i •
TABLE OF CONTENTS
TEST PREPARATION ........................................................................1
CONNECTING THE ANALYZER ................................................1
Testing Individual Batteries .................................................1
Testing the Battery Pack .....................................................2
USING THE KEYPAD ........................................................................3
OUT-OF-VEHICLE TEST ................................................................... 3
BATTERY TEST RESULTS ........................................................5
Testing the Next Battery ......................................................5
Battery Code (for Micro700BMP only)...............................6
IN-VEHICLE TEST ..............................................................................6
BATTERY PACK TEST ...............................................................7
Battery Pack Test Results ...................................................8
Testing Individual Batteries .................................................8
STARTING SYSTEM TEST ........................................................9
Starting System Test Results ..............................................9
Charge Code (for Micro700BMP only) ............................ 10
CHARGING SYSTEM TEST .................................................... 10
Charging System Test Results ......................................... 11
Charging System Decision ............................................... 11
Load Voltage Measurements ............................................ 12
Alternator Ripple Evaluation ............................................. 12
Charge Code (for Micro700BMP only) ............................ 12
ADDITIONAL FEATURES .............................................................. 12
TEMPERATURE COMPENSATION ........................................ 12
SURFACE CHARGE REMOVAL ............................................. 12
BEFORE AND AFTER CHARGE TESTS ................................ 13

•ii •
GLOW PLUG DETECTION...................................................... 13
SYSTEM SAVER ..................................................................... 13
OPTIONS MENU ............................................................................. 14
PRINT RESULTS ..................................................................... 14
PRINTER SELECT................................................................... 14
VIEW RESULTS ....................................................................... 14
VOLTMETER ........................................................................... 15
SET ADDRESS ........................................................................ 15
PERFORM TEST ..................................................................... 15
TROUBLESHOOTING .................................................................... 16
DISPLAY PROBLEMS ............................................................. 16
PRINTING PROBLEMS ........................................................... 17
Status LED ........................................................................ 17
Solutions ........................................................................... 17
REPLACING THE MICRO700 BATTERY ...................................... 18
PATENTS, LIMITED WARRANTY, SERVICE ............................... 19

TEST PREPARATION
• Clean the battery terminals with a wire brush before testing.
• At the start of the test make sure all vehicle accessory loads are
off and the ignition is in the OFF position.
CONNECTING THE ANALYZER
IMPORTANT: To ensure accurate test results for Group 31 batteries,
the clamps are designed to connect to lead stud adapters (provided
with the Micro700) or to the lead bases of threaded studs. (See
Figures 1 and 2 on the next page.) Never connect the clamps directly
onto the threaded studs.
Testing Individual Batteries
Every battery in the pack should be disconnected before testing.
If the analyzer detects that the batteries are connected at the start
of the Battery Pack Test, it will remind you to disconnect the pack.
To connect to batteries with threaded studs:
1. Screw the negative (–) terminal adapter onto the negative stud,
and the positive (+) adapter onto the positive stud.
2. Connect the red clamp to the positive (+) adapter.
3. Connect the black clamp to the negative (–) adapter.
4. For a proper connection, rock the clamps back and forth. Both
sides of the clamp must be firmly connected before testing
(Figure 1). If the message CHECK CONNECTION appears,
clean the terminals and/or reconnect the clamps
CAUTION: Because of the possibility of personal injury,
always use extreme caution when working with batteries.
Follow all BCI (Battery Council International) safety
recommendations.
WARNING: Battery posts, terminals, and related accesso-
ries 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.
!
!
•1 •

SIDE
VIEW
Figure 1. Clamp connection to stud adapter
TOP
VIEW
Testing the Battery Pack
1. Connect the red clamp to the positive (+) lug on the battery at
one end of the pack (Figure 3).
2. Connect the black clamp to the negative (–) lug on the battery at
the other end of the pack.
3. For a proper connection, rock the clamps back and forth. Both
sides of the clamp must be firmly connected before testing. If the
message CHECK CONNECTION appears, clean the terminals
and/or reconnect the clamps.
Figure 2. Clamp connection to stud pad
.
Figure 3. Clamp connections to lugs
•2 •

Press the ARROW buttons to scroll to menu choices.
Press and hold to rapidly scroll through lists of battery
rating values.
Press the ENTER button to make selections.
Press the BACK button to move back a step.
Press and hold the MENU button to make these options
available:
• PRINT RESULT
• PRINTER SELECT
• VIEW RESULT
USING THE KEYPAD
USING THE KEYPAD
•3 •
OUT-OF-VEHICLE TEST
In the Out-of-Vehicle Test the Micro700 performs a conductance test
on one or more batteries not connected to the vehicle. The analyzer
measures open circuit voltage, cranking amps, and displays a
decision on the battery’s condition.
To begin testing, connect the Micro700 to the battery. The display
will turn on and the analyzer will prompt you to enter your test
parameters. Use the ARROW keys to scroll to your selection and
press ENTER.
NOTE: The display will not turn on if you connect the clamps in
reverse polarity (negative to positive and positive to negative).
1. Select the BATTERY TYPE:
GROUP 31
COMMERCIAL
AUTOMOTIVE
• VOLTMETER
• PERFORM TEST
• SET ADDRESS
When the analyzer’s clamps are not connected to a battery or pack,
it will turn itself off after 20 seconds (except while printing) if it
detects you are not using the keypad. This helps prolong the life of
the analyzer’s internal battery. (Refer to the section “System Saver.”)

•4 •
2. Select the BATTERY CHEMISTRY:
LEAD ACID
AGM-SPIRAL
AGM-OTHER
3. CHOOSE TEST:
OUT-OF-VEHICLE
Out-of-Vehicle tests individual batteries that are electrically
disconnected from the vehicle. Although you can test more than
one battery in succession, the analyzer stores for printing or
viewing only the results and battery test code from the last
battery that you test. The analyzer will delete the test results and
code when you connect the clamps again.
4. SELECT RATING, TEST USING:
CCA
Cold Cranking Amps. The most common rating system for
cranking batteries rated at 0 ºF (–17.8 ºC)
CA
Cranking Amps. Used in southern climates where some batteries
are rated at 32 ºF (0 ºC).
MCA
Marine Cranking Amps. For marine batteries rated at 32 ºF (0 ºC).
JIS
Japanese Industrial Standard. A rating system combining
numbers and letters, for example: 8D26.
5. SET RATING, TEST USING (or SET JIS#):
Scroll to the rating specified on the battery (for example,
625 CCA). Press ENTER.
If necessary, the analyzer will ask if the battery temperature is
above or below 32 ºF or whether you are testing before or after
charging. Refer to “Additional Features” for more information.

•5 •
BATTERY TEST RESULTS
The Micro700 will display the open circuit voltage, cranking amps
based on the units are based on rating system you selected, and
one of five battery decisions. The analyzer also generates a battery
code that you can view separately. Refer to “Viewing the Battery Test
Code.”
GOOD BATTERY
The battery is in good condition. Return to service.
GOOD-RECHARGE
Fully charge the battery. Return to service.
CHARGE & RETEST
Fully charge the battery, remove the surface charge, and retest.
Failure to fully charge the battery before retesting may cause false
readings.
REPLACE BATTERY
A battery evaluated as “replace” may still start the vehicle, but it no
longer measures up to its minimum standard and will fail soon.
BAD CELL-REPLACE
Replace the battery and retest to perform a complete system
analysis
IMPORTANT: A REPLACE BATTERY result may mean a poor
connection exists between the vehicle’s cables and the battery. After
disconnecting the vehicle’s cables from the battery, retest the battery
using the Out-Of-Vehicle Test before replacing.
Testing the Next Battery
The display will alternate between the test results and the message
CONNECT TO NEXT BATTERY. If you want to retest the battery or
test a new battery, connect the clamps and press ENTER when
instructed. The analyzer will ask you to enter only the rating system
and rating value before displaying the next result.
IMPORTANT: In the Out-of-Vehicle test the analyzer stores only the
last test result and battery test code for printing or later viewing. They
will be deleted when you connect the clamps again.

NOTE: if you want to test up to 6 batteries in succession and store
each test result and code for printing and viewing, use the In-Vehicle
Battery Pack Test. When you start a new test by connecting to a
battery after completing the Battery Pack Test, the analyzer will
delete the last test result.
Battery Code (for Micro700BMP only)
To display the battery code and review the result of the last test:
1. Press and hold the MENU button.
2. Scroll to VIEW RESULTS in the Options menu and press
ENTER.
3. Press the ENTER button three times to move past the test
results to the battery code (9 characters including the hyphen).
IN-VEHICLE TEST
1. Select the BATTERY TYPE:
GROUP 31
COMMERCIAL
AUTOMOTIVE
2. Select the BATTERY CHEMISTRY:
LEAD ACID
AGM-SPIRAL
AGM-OTHER
3. CHOOSE TEST:
IN-VEHICLE
In-Vehicle tests the battery pack (up to 6 batteries) and individual
batteries when they are connected to the vehicle. It also tests the
starting and the charging systems.
4. SELECT TEST:
BATTERY PACK
Tests the condition of the battery pack and provides the option to
test batteries individually.
•6 •

FULL SYSTEM
Tests the battery pack, provides the option to test batteries
individually, tests the starting system and the charging system.
STARTING SYSTEM
Tests the starting system only.
CHARGING SYSTEM
Tests the charging system only.
BATTERY PACK TEST
You can perform the Battery Pack Test by itself or within a Full
System Test
The Micro700 can measure battery packs up to 3500 CCA. It is
designed to give you a quick approximation of the pack’s state of
health and its capability to deliver current. The Battery Pack Test
can only test the pack as a whole. The Micro700 does not determine
the condition of an individual battery within the pack unless you
disconnect the batteries from the pack and test them individually.
Several factors can skew test results such as the pack configuration,
the age and type of battery cables, testing on steel bolts, and
corrosion. To get a true determination of the battery pack, you must
disconnect and test each battery by connecting to the stud pads or
lead stud adapters.
IMPORTANT: The Micro700 will compensate for cable resistance
and steel bolt connections. Because pack configuration, cable age,
and corrosion are unpredictable, the Pack Test CCA result will
always be less than that of the true pack CCA. You should always
test the pack at the terminals leading off to the vehicle.
Performing the Micro700 Battery Pack Test on battery packs that
have load-shedding technology, an isolated battery for accessories,
or multiple cables going to the electrical system, can give misleading
results.
1. Select the NUMBER OF BATTERIES in the pack (from 1 to 6).
•7 •

•8 •
2. Select the BATTERY TYPE:
12 VOLTS
6 VOLTS
3. Select the battery rating system and rating value as required in
the Out-of-Vehicle Battery Test.
If necessary, the analyzer will ask if the battery temperature is
above or below 32 ºF or whether you are testing before or after
charging. Refer to “ Additional Features” for more information.
Battery Pack Test Results
The Micro700 will display the open circuit voltage, cranking amps
(the units are based on rating system you selected) and a one of five
battery conditions.
NOTE: The analyzer generates battery codes when you test
individual batteries only.
GOOD BAT. PACK
Compensating for cable and connector resistance, the analyzer has
determined that the battery pack is in good condition compared to its
rating.
CHECK BAT. PACK
Compensating for cable and connector resistance, the analyzer has
determined that the battery pack is in poor condition compared to its
rating. Check the connections and test the batteries separately.
Testing Individual Batteries
At the end of the Battery Pack Test, the analyzer will give you the
option to test the batteries individually. If you choose YES, the
analyzer will prompt you through the steps of disconnecting, testing
each battery, and reconnecting the battery pack. The analyzer will
store the test result and battery code for each battery until you start a
new test by connecting to a battery after completing the Battery Pack
Test. Refer to “Battery Test Results” and “Battery Code” in the “Out-
of-Vehicle Test” section.
If you choose NO, the analyzer will store the Battery Pack Test
results. If you selected a Full System Test, the analyzer will proceed
to the Starting System Test.

•9 •
STARTING SYSTEM TEST
You can perform the Starting System Test by itself or within a Full
System Test
IMPORTANT: Make sure the battery or battery pack is in a good
state of charge before the Starting System Test. If the result for the
Battery Pack Test was CHECK BAT. PACK, or the result for any
battery in the pack was CHARGE & RETEST or REPLACE, charge
or replace the batteries before the Starting System Test. (As a
reminder, the analyzer will display RECHARGE AND/OR REPLACE
BAT. if any individual battery result in the pack test was not GOOD
BATTERY.)
NOTE: If you test older model diesel engines in cold weather, pre-
heating and post-heating of the glow plugs may skew the test results.
Warm up the engine for 5 minutes and retest the vehicle.
1. START ENGINE.
2. Select the STARTER TYPE: (Full System Test only).
AIR
The vehicle has an air starter. This selection will bypass the
starting (electrical) system test. You will be prompted to start the
engine, and then press ENTER to continue. The Micro700 will
proceed to the Charging System Test.
CONVENTIONAL
The vehicle has a conventional electrical starter. You will be
prompted to start the engine. During the engine crank or starting
cycle, the Micro700 will analyze the starter for proper operation.
Starting System Test Results
The Micro700 will display the cranking voltage of the starter and one
of two decisions.
CRANKING VOLTAGE NORMAL
The starting system is showing normal starter draw.
CRANKING VOLTAGE LOW
The cranking voltage is below typical limits. Troubleshoot the starter
electrical system using the manufacturer’s recommended procedure.
If you are performing a Full System Test, press ENTER to begin the
Charging System Test.

•10 •
Charge Code—Starting System (for Micro700BMP only)
The display will alternate between screens showing the test results
and a 9-character charge code.
CHARGING SYSTEM TEST
You can perform the Starting System Test by itself or within a Full
System Test. When the engine is running, the Micro700 will help you
perform the procedure for a charging system analysis.
IMPORTANT: If you test older model diesel engines in cold weather,
pre-heating and post-heating of the glow plugs may skew the test
results. Warm up the engine for 5 minutes and retest the vehicle.
(If the analyzer asks if the vehicle has glow plugs, see “Glow Plug
Detection” in the “Additional Features” section.)
Check the belts to ensure that the alternator is rotating when the
engine is running. If the belts are slipping or broken, replace the
belts and retest. Check all connections to and from the alternator,
especially the connection to the battery. If the connection is loose or
heavily corroded, clean or replace the cable and retest.
1. Press ENTER at the prompt to begin the Charging System Test..
2. The Micro700 displays real-time alternator output voltage.
Press ENTER to continue.
3. Testing at rev. The Micro700 will prompt you to rev the engine
for 5 seconds. When it has detected the rev, it will collect data.
If the analyzer does not detect a rev, it will prompt you to press
ENTER to continue.
IMPORTANT:In vehicles that idle at a high rpm after starting, the
analyzer may detect the rev without prompting you. The test
results will not be affected.
4. Testing at idle. The Micro700 will analyze the charging system
output at idle for comparison to other readings.
5. Diode ripple test. The Micro700 will look for the amount of ripple
from the charging system to the battery. Excessive ripple usually
means one or more diodes have failed in the alternator or there
is stator damage.

6. Testing with accessory loads. After the Diode Ripple Test, the
Micro700 will ask you to:
a. Turn on accessory loads (headlights, blower motor,
defogger, etc.) of at least 40 amps.
b. Test at idle with loads on.
c. Rev engine for another 5 seconds with loads on.
IMPORTANT: When asked to turn on the accessory loads, turn
on the blower to high (heat), turn on the high-beam headlights
and rear defogger. DO NOT use cyclical loads such as air
conditioning or windshield wipers.
6. Analyzing data. The Micro700 will analyze all readings and
provide the results of the Charging System Test.
Charging System Test Results
The Micro700 will display screens that alternate between the
charging decision, a detail of any problem, load voltage
measurements, an evaluation of diode ripple, and a charge code:
Charging System Decision
CHARGING SYSTEM NORMAL
The charging system is operating within a normal voltage range.
CHARGING SYSTEM PROBLEM
A problem was detected in the charging system:
NO CHARGING VOLTAGE
The alternator is not providing charging current to the battery
(pack).
LOW CHARGING VOLTAGE
The alternator is not providing sufficient current for the system’s
electrical loads or for charging the battery (pack).
HIGH CHARGING VOLTAGE
The voltage output from the alternator to the battery (pack)
exceeds the normal limits of a functioning regulator and could
overcharge the battery (pack) and decrease its life.
•11 •

•12 •
Load Voltage Measurements
LOAD OFF
Displays the measured voltage taken at idle with accessories off.
LOAD ON
Displays the measured voltage taken at idle with accessories on.
Alternator Ripple Evaluation
DIODE RIPPLE NORMAL
The alternator’s rectifier is functioning within its normal operating
range.
EXCESS RIPPLE DETECTED
One or more diodes of the alternator’s rectifier may be defective.
DIODE RIPPLE NOT DETECTED
The analyzer is unable to detect diode ripple through the battery
cables or the alternator is not spinning.
Charge Code—Charging System (for Micro700BMP only)
The display will alternate between screens showing the test results
and a 9-character charge code.
ADDITIONAL FEATURES
TEMPERATURE COMPENSATION
If necessary, the analyzer will ask you to choose if the battery
temperature is above or below 32 ºF. Use the ARROW buttons to
select ABOVE or BELOW and press ENTER.
SURFACE CHARGE REMOVAL
If the analyzer detects surface charge during the In-Vehicle Test, it
will prompt you to turn on loads to remove it. Follow the instructions
on the display. When finished, press ENTER and testing will
continue.
IMPORTANT: When asked to turn on the accessory loads, turn on
the blower to high (heat), turn on the high-beam headlights and rear
defogger. DO NOT use cyclical loads such as air conditioning or
windshield wipers.

BEFORE AND AFTER CHARGE TESTS
If necessary, the analyzer will ask you if the battery has just been
charged. At the CHOOSE TEST prompt, select AFTER CHARGE or
BEFORE CHARGE and press ENTER.
GLOW PLUG DETECTION
If necessary during the Charging System Test, the analyzer will ask
you if the vehicle has glow plugs.
If you select NO, the analyzer concludes the test and displays the
charging system results. If you performed a Full System Test, press
ENTER to view the results.
If you select YES, the Micro700 begins a 40-second countdown.
The countdown allows post-heating of the glow plugs to finish so that
the Micro700 can properly evaluate the charging system. If post-
heating finishes within 40 seconds, the Charging System Test
continues.
If post-heating does not finish, the test is concluded and the charging
system results are displayed. If you conducted a full system test,
press ENTER to review the test results.
SYSTEM SAVER
When the analyzer’s clamps are not connected to a battery or pack,
it will turn itself off after 20 seconds (except while printing) if it
detects you are not using the keypad. This helps prolong the life of
the analyzer’s internal battery.
If the analyzer times out during a test, it will save the test sequence
and data. You can reactivate the analyzer by pressing the MENU
button or by reconnecting the battery clamps.
The analyzer will ask you if you want to continue the previous test.
If you select NO, the analyzer will return to the Options menu or to
the Test menu if the clamps were reconnected to the battery. If you
want to continue the test, reconnect the battery clamps and select
YES, then press ENTER.
•13 •

OPTIONS MENU
To display the Options menu, press and hold the MENU button. To
select an option, use the ARROW buttons and press ENTER.
IMPORTANT: The last test result in the analyzer’s memory will be
erased when you connect to a battery and start a new test.
PRINT RESULTS
The Micro700 prints the last test result using the IR output at the top
of the analyzer and the Midtronics printer’s IR receiver below the
MODE button.
IMPORTANT: If you are using the Midtronics printer for the first time,
charge the printer battery for 16 hours before beginning your test
session. Refer to the printer manual for more information.
Turn on the printer and align the IR transmitter on the top of the
analyzer with printer’s IR receiver. Press the MENU button and scroll
to PRINT RESULTS. When you are ready to print, press ENTER.
If the IR transmitter and receiver are not aligned, all the data may not
print. Press MENU to cancel the print job. Verify alignment between
the analyzer and printer, then try to print the test results again.
PRINTER SELECT
Select IRDA or HP 82240B. IRDA is compatible with the IRDA Mode
setting in the Midtronics printer (P/N 182-003A). The IRDA Mode
described in the printer’s user guide is called IRDA PHYSICAL
LAYER in the printer’s self-test printout.
HP 82240B is compatible with the printer’s HPIR Mode setting. The
HPIR Mode setting described in the printer’s user guide is called
INFRARED 33kHZ ENCODED in the printer’s self-test printout.
Refer to the IR/RS232 Thermal Printer User Guide included with the
Midtronics printer.
VIEW RESULTS
Use the ENTER and BACK buttons to scroll through the last test
results.
•14 •

•15 •
VOLTMETER
The Micro700 can also function as a voltmeter. The operating range
of the voltmeter is 0 to 30 volts.
IMPORTANT: If the Micro700 is connected to a voltage source
greater than 30 volts, the circuit board might be damaged.
To use the voltmeter function, press and hold the MENU button.
Scroll to the VOLTMETER option and press ENTER.
Use the red and black clamps as probes. If the analyzer is connected
in reverse polarity it will not detect voltage and will turn itself off.
To turn off the voltmeter function, disconnect from the voltage source
and press the MENU button. To conserve its 9-volt battery, the
analyzer will automatically shut off if 0 Vdc is detected for 20
seconds.
SET ADDRESS
This option enables you to include your shop name and address on
test result printouts.
Scroll to the SET ADDRESS option and press ENTER. The analyzer
will prompt you through each line of the name and address. Use the
ARROW buttons to change characters. Use the ENTER and BACK
buttons to move to the next or previous position.
PERFORM TEST
This option enables you to begin a new test without disconnecting
from the battery.

TROUBLESHOOTING
DISPLAY PROBLEMS
If the display does not turn on:
• Check the connection to the vehicle battery or pack.
• The vehicle battery may be too low to power the analyzer (below
1 volt). Fully charge the battery and retest.
• The analyzer’s 9-volt battery may need to be replaced. Follow
the directions in “Replacing the Micro700 Battery” and replace
the 9-volt battery (alkaline recommended).
• If the analyzer detects computer or ignition noise, it will display
SYSTEM NOISE. Verify that all vehicle accessory loads are off
and the ignition switch is in the OFF position. The analyzer will
automatically retest when the system noise is no longer
detected. If the SYSTEM NOISE message continues after
several retest attempts, disconnect the battery cables and retest.
• Batteries that are very weak or that have just been charged may
have enough electrical activity to affect test results. Should this
occur, the analyzer will display UNSTABLE BATTERY and retest
when the battery has stabilized. Fully charged batteries should
stabilize quickly. Weak batteries should be fully charged, then
retested.
• If troubleshooting does not solve the problem, call 800-776-1995
to obtain service. See “Patents, Limited Warranty, Service” for
more information.
• If the analyzer does not power on when you press and hold the
MENU button, replace the 9-volt battery.
•16 •

PRINTING PROBLEMS
Status LED
When a printer fault occurs, the STATUS LED will flash. You can
identify the fault by the number of sequential flashes:
Solutions
• If the IR transmitter and receiver are not aligned, all the data may
not print. The infrared ports on the top of the Micro700 and on
the front of the printer below the MODE button should be pointed
directly at each other. The maximum distance for reliable
transmission between the ports is 18 inches (45 cm). To realign,
press MENU to cancel the print job. Verify alignment between
the analyzer and printer; then try to print the test results again.
• If the analyzer displays PRINTING RESULTS, but the test results
are not printing, press MENU to cancel. Turn off the printer and
charge the printer battery for at least 15 minutes before
attempting to print again.
• Make sure the printer is on. The printer turns itself off after 2
minutes of inactivity to conserve the battery. To turn the printer
on, briefly press the MODE button. The green STATUS light
should turn on. Make sure you are using the Midtronics printer
provided with the Micro700. Other printers may not be
compatible.
• Direct sunlight interferes with infrared data transmission/
receiving. If the printer is not receiving data, remove the printer
and Micro700 from direct sunlight. If the printed characters are
not clear or are partially missing, recharge the battery and
reprint.
•17 •
Sequence Condition Solution
Paper out
Thermal head too hot
Fit new paper
Allow head to cool
* * *
** ** **
*** *** *** Battery low Recharge printer
battery for 16 hours