Midtronics intellect EXP-1000 User manual

Expandable Electrical
Diagnostic Platform
For testing 6 and 12-volt automotive batteries
and 12- and 24-volt charging systems
INSTRUCTION MANUAL
Battery Management Innovation

•3•
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.......................................................................................................................... 12
Option Buttons .................................................................................................................... 12
Scrolling Lists ...................................................................................................................... 12
Alphanumeric Entry............................................................................................................. 12
Menu Maps....................................................................................................................13
Main Menu .......................................................................................................................... 13
DMM Menu.......................................................................................................................... 14
Info Menu ............................................................................................................................ 15
Print/View Menu .................................................................................................................. 15
Utilities Menu....................................................................................................................... 16
Chapter 3: Test Preparation............................................................................. 17
Inspecting the Battery....................................................................................................17
Testing Out-of-Vehicle ...................................................................................................17
Testing In-Vehicle ..........................................................................................................17
Connecting the Battery Test Cable................................................................................17
Connecting an Accessory Cable ...................................................................................18
Contents

•4•
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 ..................................................................................................................23
Chapter 6: System Test.................................................................................... 25
Battery Test ...................................................................................................................25
Starter Test....................................................................................................................25
Starter System Test Results................................................................................................ 26
Alternator Test ...............................................................................................................27
Alternator Test Results ........................................................................................................ 28
Chapter 7: Cable Drop Test ............................................................................. 31
Battery Ground Test ......................................................................................................32
Battery Ground Test Results ............................................................................................... 32
Starter Circuit ................................................................................................................33
Starter Circuit Test Results.................................................................................................. 33
Alternator Circuit............................................................................................................34
Alternator Circuit Test Results............................................................................................. 34
Other Circuit ..................................................................................................................35
Other Circuit Test Results.................................................................................................... 35
Contents

•5•
Chapter 8: Jump Start (System Test).............................................................. 36
Chapter 9: DMM (Digital Multimeter)............................................................... 37
DC Volts ........................................................................................................................37
AC Volts.........................................................................................................................38
Scope ............................................................................................................................38
DC AMP (requires the optional amp clamp) .......................................................................39
AC AMP (requires the optional amp clamp) .......................................................................39
Temp..............................................................................................................................40
Ohm Meter ....................................................................................................................40
Diode.............................................................................................................................40
Volts/Amp (requires the optional amp clamp)....................................................................41
Chapter 10: Utilities.......................................................................................... 43
Clock .............................................................................................................................43
Shop..............................................................................................................................44
Display...........................................................................................................................45
Coupon..........................................................................................................................46
Edit Coupon...................................................................................................................46
Temp..............................................................................................................................47
Language ......................................................................................................................47
Format Disk...................................................................................................................47
Update...........................................................................................................................47
Chapter 11: Info Menu ...................................................................................... 48
Totals.............................................................................................................................48
Transfer .........................................................................................................................48
Version ..........................................................................................................................48
Contents

•6•
Chapter 12: Print/View ..................................................................................... 49
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
Patents, Limited Warranty, Service................................................................. 53
Contents

•7•
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. 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.
Conventions Used in This Manual
To help you learn how to use your EXP analyzer, the manual uses these symbols and typographical
conventions:
The safety symbol followed by the word WARNING or CAUTION indicates
instructions for avoiding hazardous conditions and personal injury.
The word CAUTION without the safety symbol indicates instructions for
avoiding equipment damage.
The wrench symbol indicates procedural notes and helpful information.
The text for keypad buttons and soft-key functions are in bold capital letters.
The text for screen options are in regular capital letters.
!
CAUTION
UP ARROW
POST TYPE
Chapter 1: Before You Start

•8•
Registering Your Analyzer
Before using your EXP, we recommend that you register it online
to activate your warranty. Registration will also make it faster and
easier for you to obtain technical support and service, and order
parts and accessories. In addition, you’ll be alerted to any important
information, like product updates and special offers.
To register, log on at www.midtronics.com/warranty.html and have
your serial number ready. 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
Limited Warranty section of this manual.
Figure 1:
Serial Number Location
Chapter 1: Before You Begin

•9•
Chapter 2: Description
Every inTELLECT™ EXP model includes a handy, hard-sided, molded carrying case, as shown in
Figure 2. Regardless of which conguration you choose, the carrying case will hold all accessories,
with room for future options, so you can add to your EXP at any time.
Figure 2: Model EXP-1000 AMP KIT
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: Description

•10 •
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.
• For the amp clamp and the multimeter test cables, the EXP has an accessories port, which
is a RJ45 connector with a release lever.
6-pin
connector
IR data
transmitter
IR temperature
sensor DB-9
connector
for future
expandability
Accessories
port
SD card slot
for future
upgrades
There are two IR data ports on the top of
the EXP (Figure 3).
• An IR data transmitter, which
transmits test results to the optional
IR printer.
• An IR temperature measurement
sensor.
The EXP also has a DB-9 connector for
future expandability and an SD card slot
for future software upgrades or data
logging. (Figure 4).
The EXP ships with an unprogrammable
card to protect the slot from dust and
debris.
Figure 3: Top of EXP Figure 4: Bottom of EXP
Battery
test cable
Amp clamp
DMM cable
with probes
DMM cable with
clamps
Figure 5: Test Leads

•11 •
T h e Internal Batteries
Status Indicator, which appears
in the screen’s top left
corner, lets you know the
status and charge level
of the analyzer’s 6 1.5 V batter-
ies. The X shown in the gure
shows that the EXP is powered
by the battery you’re testing to
conserve the internal batteries.
Press the two Soft Keys linked
to the bottom 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
appearing above them as part
of the keys. Some of the more
common soft-key functions are
SELECT, BACK, and END.
When you rst connect the EXP
to a battery it functions as a
voltmeter. The voltage read-
ing appears
above the left
soft key until you move to other
menus or functions.
In some cases, you can use
the Alphanumeric Keypad to
enter numerical test parameters
instead of scrolling to them with
the ARROW keys.
You’ll also use the Alphanu-
meric Keys to create and edit
customer coupons. The keypad
includes characters for punctua-
tion. To add a space, press the
RIGHT and LEFT ARROW keys
simultaneously.
The Selection Area below the
Title Bar contains items you se-
lect or into which you enter infor-
mation. The area also displays
instructions and warnings.
The Directional Arrows on the
display show you which Arrow
Keys to press to move to other
icons or screens. The Up
and Down Directional
Arrows, for example, let
you know to press the
UP and DOWN ARROW
keys to display the screens that
are above and below the current
screen.
The Left and Right Directional
Arrows let you know to use the
LEFT or RIGHT ARROW keys
to highlight an icon for selection.
Another navigational aid is the
Scroll Bar along the right side
of the screen. The position of its
scroll box tells you which menu
screen you’re viewing.
The Title Bar shows you the
name of the current menu, test
tool, utility, or function.
Press the POWER button to
turn the EXP on and off. The
EXP also turns on automatically
when you connect its test leads
to a battery.
Whichever way you turn on the
EXP, it always highlights the icon
and setting you last used for
your convenience.
Top
or only
screen
Middle
screen
Last
screen
Scroll Bar
Scroll
Box
Chapter 2: Description
Display and Keypad
The EXP 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.
Figure 6 shows how the elements on the screen relate to the keypad.
Figure 6: Main Menu and Keypad

•12 •
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. The four types of entry methods are described below.
Typically, the soft key below the right half of the screen conrms your choice, although the word above
it may vary. In Figure 7, for example, the word is SELECT; in Figures 8 and 9, NEXT; and in Figure 10,
SAVE. In a similar fashion, the soft key below the left half of the screen cancels your choice or returns
you to the previous screen, although the word above it may also vary.
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 as shown in Figure 7. 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 into the button next to the
item you want. 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 this type of 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.
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 (Figure 10).
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.
Figure 7: Highlighted Icon
Figure 9: Scrolling List
Figure 8: Option Buttons
Figure 10:
Alphanumeric Entry
Chapter 2: Description

•13 •
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 a battery using
the battery information
you select in a series of
screens.
Tests a battery, and the
starting and charging
systems.
Tests both sides of a
circuit simultaneously
for voltage. Three preset
tests and 1 user-dened.
Digital multimeter with
8 test meters, a tempera-
ture sensor, and options
for clamps and probes.
Includes a test counter,
data transfer utility, the
EXP software version
and serial number.
Enables you to view your
stored test results and
print them to an optional
IR printer.
Nine utilities, many of
which customize your
user interface.
*
*
* *
(voltmeter reading) an icon
(voltmeter reading) an icon
(voltmeter reading) an icon
Required test leads
Amp
clamp
Battery
test
Cable
drop
Optional
Chapter 2: Description
Clamps
only

•14 •
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.
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.
Sensor that displays tem-
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 (Ω).
Tests a diode for forward
voltage drop.
Measures two signals
simultaneously: DC volt-
age and amperage.
to Main Menu
to Main Menu
to Main Menu
an icon
an icon
an icon
Required test leads
Amp
clamp
Battery
test
DMM
clamps or
probes
Probes
only
Chapter 2: Description

•15 •
An optional IR software
and hardware package
enables you to transfer
test data to a PC.
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.
Displays the total Bat-
tery and System Tests
performed since the EXP
was rst used.
Displays the software
version, total tests from
rst use, and the serial
number.
REPORTS
to Main Menu an icon
Displays the last Battery
and System Test results.
Sends the results to an
optional IR printer.
REPORTS
to Main Menu an icon
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 Cable
Drop Test result. Sends
the result to an optional
IR printer.
Chapter 2: Description

•16 •
SETUP (Screen 1)
SETUP (Screen 2)
SETUP (Screen 3)
Settings to adjust the
date and time.
Enables you to add a
custom header to printed
test results.
Settings to adjust the
screen contrast and
backlight time.
If you’ve created a cou-
pon in the Edit Coupon
utility, use Coupon to
turn it on and off.
Enables you to create a
coupon at the bottom of
printed test results.
Enables you to select
degrees C or F for tem-
perature measurements.
Sets the language of the
display and printouts.
an icon
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.
to Main Menu an icon
to Main Menu an icon
to Main Menu
Formas the SD card to
receive data. Also erases
all data on the card.
Updates the EXP soft-
ware using les on an
SD card.
Chapter 2: Description

•17 •
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.
• Corrosion on the battery terminals, and dirt or acid on the case top. Clean the case and
terminals using a wire brush and a mixture of water and baking soda.
• Low electrolyte level. If the electrolyte level is too low, add distilled water to fill up to 1/2
above the top of the plates and fully charge the battery. Do not overfill.
• Corroded or loose battery tray and hold-down fixture. Tighten or replace as needed.
Testing Out-of-Vehicle
The preferred battery test location is in the vehicle. However, if you plan to test out of the vehicle:
• Always disconnect the negative cable from the battery first and reconnect it last.
• Always use a carry tool or strap to lift and transport the battery.
CAUTION: When testing side-post or group 31 batteries, always test using lead terminal adapters
provided with the EXP; do not test at the battery’s steel bolts. To avoid damage, never use a wrench
to tighten the adapters more than 1/4 turn. Failure to properly install lead terminal adapters, or using
adapters that are dirty or worn, may cause false test results.
Testing In-Vehicle
The preferred test position is at the battery posts. If you must test at a remote-post location, it should
have both a positive and negative post. Otherwise, you must remove the battery and perform an out-
of-vehicle test.
At the start of the test, make sure all vehicle accessory loads are off, the key is not in the ignition, and
the doors are closed.
Connecting the Battery Test Cable
CAUTION: Do not connect the EXP to a voltage source greater than 30 Vdc.
Connect the battery test cable to the EXP by rst aligning the cable connector’s 6 pins with the holes
on top of the EXP. Firmly insert the connector and tighten the locking ring.
Connect the clamps to the EXP: the red clamp to the positive (+) terminal and the black clamp to the
negative (–) terminal.
Chapter 3: Test Preparation

•18 •
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.
If the message reappears after you have correctly reconnected the clamps, clean the terminals and
reconnect.
Connecting an Accessory Cable
If you are using an accessory cable, plug it as you would a phone jack into the accessories port on
top of the EXP. It locks automatically into the port. To remove it after testing, press the lever and pull
the connector out.
Setting User Preferences
Before starting your test you may want to customize the use of your analyzer by setting preferences
in the Utility Menu. The menu has settings for the display’s date and time, the contrast and backlight
time, a utility to customize printouts for the optional IR printer, among others. The utilities are described
in Chapter 10.
To conserve the analyzer’s internal batteries, the EXP will turn off after 30 seconds of
inactivity.
Chapter 3: Test Preparation

•19 •
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.
1. Select the battery LOCATION.
1 OUT OF VEHICLE
2 IN VEHICLE
Press the NEXT soft key to continue. The BACK soft key returns you to the Main Menu at the
start of the test and to the previous screen as you progress.
2. Select the POST TYPE. The REMOTE option appears for the IN VEHICLE test.
1 TOP
2 SIDE
3 REMOTE
Press the NEXT soft key to continue.
3. Select the BATTERY TYPE.
1 REGULAR/AUTO
2 AGM
3 AGM/SPIRAL
4 GEL
Press the NEXT soft key to continue.
4. Select the battery’s capacity rating standard. The standard, and the rating units required
in step 5, are printed on the battery label. If the information is unreadable, contact the
battery manufacturer.
1 CCA
2 CA
3 MCA
4 JIS
5 DIN
6 SAE
7 IEC
8 EN
Press the NEXT soft key to continue.
Chapter 4: Battery Test

•20 •
5. 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. The entry range is 100 to 3000 except for DIN and IEC, which has a range of
100 to 1000. If you scroll the values they increase and decrease by 5 units.
Press the NEXT soft key to start the test.
For the next few seconds the EXP will display the word TESTING and a stopwatch while
it evaluates the battery. The analyzer will also display your selected rating standard and
units or JIS part number.
Additional Test Requirements
For a more decisive result the EXP may ask for additional information or probe deeper into the
battery’s condition. The following messages and instructions may appear before the analyzer displays
the results of your test.
Temperature Compensation
Surface Noise/Unstable Battery
The battery will hold a surface charge if the engine has been running or after the battery has been
charged. The analyzer may prompt you to remove the surface charge before it begins testing.
1. Follow the EXP’s instructions indicating when to turn the headlights on and off.
2. The analyzer will resume testing after it detects that the surface charge is removed.
If the analyzer detects that the temperature of the battery
may make a difference in the result, it will ask you to
measure the battery’s temperature with the analyzer’s
built-in temperature sensor.
The sensor is located in the top left corner of the EXP.
An arrow moving diagonally across the display will show
you how to angle the EXP so that the sensor is pointed
directly at the battery.
Press the NEXT soft key to continue.
Figure 11: Temperature Message
Battery Case
(Top)
Sensor
Aim the EXP
2 inches (5 cm)
from the sides
or top of the
battery case.
Figure 12:
Aiming the Temperature Sensor
Chapter 4: Battery Test