Midtronics VAS 6161 User manual

Vehicle Battery and
Electrical Diagnostic Platform
For testing 6 and 12-volt automotive batteries and
12- and 24-volt charging systems
INSTRUCTION MANUAL
Battery Management Innovation
VAS 6161

•3•
Contents
Chapter 1: Before You Begin ..................................................................................................7
Starting the tester for the rst time..................................................................................................................7
Safety ...........................................................................................................................................................................7
General Precautions ........................................................................................................................................................7
Conventions Used in This Manual .....................................................................................................................8
Utilisation in accordance with„intended purpose“ ....................................................................................8
Disposal.......................................................................................................................................................................8
Chapter 2: Description ..........................................................................................................9
Connections and Data Ports ...............................................................................................................................9
Connecting the Battery Test Cable................................................................................................................. 10
Removing and Inserting the Data Card........................................................................................................ 10
Display and Keypad............................................................................................................................................. 11
Data Entry Methods............................................................................................................................................. 12
Menu icons ......................................................................................................................................................................12
Option Buttons...............................................................................................................................................................12
Scrolling Lists..................................................................................................................................................................12
Alphanumeric Entries ..................................................................................................................................................12
Menu Maps............................................................................................................................................................. 13
Main Menu.......................................................................................................................................................................13
Info Menu.........................................................................................................................................................................14
Print/View Menu............................................................................................................................................................14
Utilities Menu..................................................................................................................................................................15
Contents

•4•
Chapter 3: Test Preparation ................................................................................................ 16
Inspecting the Battery ........................................................................................................................................ 16
Testing Out-of-Vehicle........................................................................................................................................ 16
Testing In-Vehicle ................................................................................................................................................. 16
Connecting the Battery Test Cable................................................................................................................. 16
Setting User Preferences.................................................................................................................................... 17
Chapter 4: Battery Testing .................................................................................................. 18
Warranty mode ..................................................................................................................................................... 18
Service mode ......................................................................................................................................................... 19
Maintenance mode ............................................................................................................................................. 20
Additional tester messages .............................................................................................................................. 21
Surface Charge...............................................................................................................................................................21
System Noise...................................................................................................................................................................21
Deep Scan Test ............................................................................................................................................................... 21
Battery Test Results for Warranty test and Service Mode....................................................................... 22
Battery Test Results for Maintenance Mode ............................................................................................... 22
Chapter 5: Dynamic Response Test .................................................................................... 23
Test Routine............................................................................................................................................................ 23
Chapter 6: System Test ........................................................................................................ 24
Battery Test ............................................................................................................................................................. 24
Starter Test .............................................................................................................................................................. 24
Alternator Test ....................................................................................................................................................... 25
Alternator Test Results.................................................................................................................................................26
Chapter 7: QC Test................................................................................................................ 29
Contents

•5•
Chapter 8: Utilities............................................................................................................... 32
Cong Tester .......................................................................................................................................................... 32
Display...................................................................................................................................................................... 33
Language ................................................................................................................................................................ 34
Shop .......................................................................................................................................................................... 35
Coupon .................................................................................................................................................................... 35
Edit Coupon............................................................................................................................................................ 36
Format Disk............................................................................................................................................................. 36
Update...................................................................................................................................................................... 36
Battery List (for QC Mode)................................................................................................................................. 36
Chapter 9: Info Menu...........................................................................................................37
Totals......................................................................................................................................................................... 37
Transfer..................................................................................................................................................................... 37
Version info............................................................................................................................................................. 37
Chapter 10: Print/View ........................................................................................................ 38
View Test.................................................................................................................................................................. 38
View QC Test........................................................................................................................................................... 38
Chapter 11: Troubleshooting.............................................................................................. 39
Problems with the display................................................................................................................................. 39
Data Will Not Print................................................................................................................................................ 39
Chapter 12: Tester Internal Batteries ................................................................................. 40
Battery Power Indicator ..................................................................................................................................... 40
Replacing the Tester Batteries.......................................................................................................................... 40
Contents

•6•
Contents

•7•
Chapter 1: Before You Begin
Starting the tester for the rst time
When the tester is rst used the operator is asked to enter a couple of items. Items such as dealer ID and
Region are used to set-up specic utilities such as date/time stamps and hour indication.
Changes can be made afterwards by going in to the Utility Menu and selecting CONFIG TESTER.
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.
The tester is manufactured in line with the latest state of the art and according to recognised safety standards.
If used incorrectly or misused, however, it can cause
- injury or death to the user or a third party,
- damage to the tester and other material assets belonging to the operator,
- inefficient operation of the tester.
All persons involved in commissioning, operating, maintaining and servicing the tester must
- be suitably qualified,
- have knowledge of and experience in dealing with testers and batteries and
- read and follow these operating instructions carefully.
Chapter 1: Before You Start

•8•
Conventions Used in This Manual
To help you learn how to use your 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.
Utilisation in accordance with„intended purpose“
The tester is to be used exclusively for its intended purpose. Utilisation for any other purpose, or in any
other manner, shall be deemed to be„not in accordance with the intended purpose“. The manufacturer is
not liable for any damage, inadequate or incorrect results arising out of such misuse.
Utilisation in accordance with the “intended purpose”also comprises
- carefully reading and obeying all operating instructions and safety and danger notices
- performing all stipulated inspection and servicing work.
- following all instructions from the battery and vehicle manufacturers.
Disposal
Do not dispose of this device with normal domestic waste!
To comply with the European Directive 2002/96/EC on Waste Electrical and Electronic
Equipment and its implementation as national law, electrical equipment that has
reached the end of its life must be collected separately and returned to an approved
recycling facility Any device that you no longer require must be returned to our agent,
or nd out about the approved collection and recycling facilities in your area. Ignoring
this European Directive may have potentially adverse aects on the environment and
your health!
Chapter 1: Before You Start
!
CAUTION
UP ARROW
POST TYPE

•9•
Chapter 2: Description
Chapter 2: Description
Connections and Data Ports
6-pin
connector
Accessories port
Integrated thermal printer
Release lever for door to paper compartment
Paper slot
LCD screen with Main Menu
Control Panel: keypad and power button
6-pin connector for the battery test cable
Spring-loaded data card slot for test data
storage and software upgrades.
Infrared temperature sensor with a range of
-28 °C to +93 °C (-20 °F to +200 °F).
Data transmitter: sends test results to a PC
using an optional hardware and software kit

•10 •
Chapter 2: Description
Connecting the Battery Test Cable
CAUTION: To prevent damage to the analyzer’s circuitry, do not connect the analyzer to a voltage
source greater than 30 Vdc.
To connect the battery test cable to the analyzer align the arrow on the cable connector with the arrows on
the analyzer’s housing. Hold the part of the cable connector as shown and rmly insert the connector into
analyzer’s six-pin receptacle. Do not twist.
To avoid damaging the battery test cable, always hold the ridged part of the cable connector (as shown in
the photo) when inserting and removing the cable.
Hold the cable
connector here
Arrows
Removing and Inserting the Data Card
The analyzer ships with a plastic insert in the data card slot to protect it from dust and debris. To remove the
plastic insert or a data card, push briey on its edge to release it and pull it from the slot.
When inserting a card, push it into the slot until it locks. The card is correctly inserted when it is not
protruding from the slot. To protect the card slot and enable the analyzer to read and write to the card,
leave the card in the slot.

•11 •
Chapter 2: Description
Display and Keypad
The 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.
Internal Batteries Status Indicator
This indicator appears in the screen’s top left corner, lets
you know the status and charge level of the analyzer’s six
1.5-volt batteries. The Xin the top left corner of the screen
shows that the analyzer is powered by the battery you’re
testing to conserve the analyzer’s internal batteries.
Voltmeter
When you rst connect the analyzer to a battery 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 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.
POWER Key
Press the POWER button to turn the analyzer on and
o. The analyzer also turns on automatically when you
connect its test leads to a battery.
Title Bar
The title bar shows you the name of the current menu,
test tool, utility, or function.
Selection Area
The selection area below theTitle Bar contains selectable
items or dialog boxes that display information or require
a response.
Menu Screen Arrows
When displayed in menu screens, the menu screen
arrows show you which ARROW key on the keypad to
press to display other icons or screens.The Up and Down
Menu Screen Arrows, for example, indicate when to
press the UP ( ) and DOWN ( ) ARROW keys to display
the screens above and below the current screen.
The Left and Right Menu Screen Arrows tell you when to
use the LEFT ( ) or RIGHT ( ) ARROW keys to select an
icon.
When displayed under a list of options, the menu screen
arrows show you which keypad arrow to press to
highlight a character or 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.
ARROW keys
Press the UP ARROW key to move up to the next
selectable item or row. When entering text, use the UP
ARROW key to move to the previous character.

•12 •
Data Entry Methods
To perform a particular test or function, the tester will ask for dierent 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 right half of the screen conrms your choice, although the word above it
may vary. 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. 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 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 Entries
Even though the tester does not use an alphanumeric keypad it is possible to enter alphanumeric values.
When applicable the alphanumeric values appear on the display. Use the UP/DOWN or LEFT/RIGHT ARROW
keys to scroll and conrm this with the > key. To return one or more steps use the < key.
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 for Warran-
ty purposes using the bat-
tery information you select
in a series of screens.
Tests a battery in regular Ser-
vice, this includes the possibil-
ity to perform the starting and
charging systems.
Includes a test counter,
data transfer utility and
displays the tester soft-
ware versions.
Enables you to view your
stored test results and
print them to the internal
printer.
Utilities, many of which
customize your user inter-
face in the tester.
*
*
*
Chapter 2: Description
Quality Control Mode for
testing Stock batteries or
compound batteries.
Tests vehicles on compount/
ports or at dealer before deliv-
ery to the customer.

•14 •
An optional IR software
and hardware package en-
ables you to transfer test
data to a PC.
Info Menu
Displays the total number
of Tests performed since
the tester was rst used.
Displays the software ver-
sion, total tests from rst
use, and the serial num-
ber.
REPORTS
to Main Menu an icon
Displays the last Test re-
sults. The results can be
printed to the integrated
printer.
REPORTS
to Main Menu an icon
Print/View Menu
The tester stores the last 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.
Chapter 2: Description
Displays the last Quality Con-
trol Test result. Sends the re-
sult to the integrated printer.

•15 •
SETUP (Screen 1)
SETUP (Screen 2)
SETUP (Screen 3)
Configur the tester by
selecting several specic
functions
Enables you to add a cus-
tom header to printed test
results.
Settings to adjust the
screen contrast and back-
light time.
If you’ve created a coupon
in the Edit Coupon utility,
use Coupon to turn it on
and o.
Enables you to create a
coupon at the bottom of
printed test results.
Sets the language of the
display and printouts.
an icon
Utilities Menu
The Utilities Menu lets you customize your analyzer to suit your needs.
to Main Menu an icon
to Main Menu an icon
to Main Menu
Formas the SD card to re-
ceive data. Also erases all
data on the card.
Enable you to Update the
software in the tester with
a specic SD Card
Chapter 2: Description
Setup Quality Control
Mode specic items

•16 •
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 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.
Testing In-Vehicle
The preferred test position is at the battery posts.
At the start of the test, make sure all vehicle accessory loads are o, the key is not in the ignition, and
the doors are closed. If systems in the vehicle are still active it might lead to a SYSTEM NOISE message, the
tester will automatically continue to test the battery until the noise is gone.
Connecting the Battery Test Cable
CAUTION: Do not connect the tester to a voltage source greater than 30 Vdc.
Connect the clamps to the battery: the red clamp to the positive (+) terminal and the black clamp to the
negative (–) terminal.
Chapter 3: Test Preparation

•17 •
If you connect the clamps in the wrong polarity (positive to negative or negative to positive), the tester
displays CLAMPS REVERSED! Reconnect the clamps correctly.
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 tester will display the message CHECK CONNECTION. If the
message reappears after you have correctly reconnected the clamps, clean the terminals and reconnect.
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, among others.
To conserve the analyzer’s internal batteries, the tester will turn o after 30 seconds of inactivity.
Chapter 3: Test Preparation

•18 •
Chapter 4: Battery Testing
The tester 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.
Warranty mode
This test mode is specically designed for warranty claims. At the end of the test the tester can create a
testcode that is needed when the claim is issued.
1. Select the battery LOCATION.
OUT OF VEHICLE
IN VEHICLE
Press the NEXT soft key to continue. The BACK soft key returns you to the Main Menu.
2. Select the POST TYPE. (IN-VEHICLE)
TOP POST
JUMP START POST
Press the NEXT soft key to continue.
3. Select the VEHICLE (JUMP START POST)
TOUAREG
TOUAREG V10 TDI
By selecting a vehicle the tester will use a pre-dened compensation factor to overcome the extra
resistance caused by the JUMP START POST cable. Selecting the wrong vehicle can lead to incorrect
measurements.
Press the NEXT soft key to continue.
4. Select the TEMPERATURE.
Aim the tester 2 inches (5 cm) from the sides or top of the battery case. As soon as the temperature
reading is stable the operator can press NEXT
5. Select the BATTERY TYPE
REGULAR
AGM
2 * 6V SPIRAL
GEL
Press the NEXT soft key to continue.
6. Press the
UP/DOWN ARROW keys to select the battery rating or in the case of JIS, the part
number.
Press the NEXT soft key to start the test.
Chapter 4: Battery Test

•19 •
Service mode
This test mode is specically designed for vehicles that are in service.
1. Select the TEST LOCATION
TOP POST
JUMP START POST
Press the NEXT soft key to continue.
2. Select the VEHICLE (JUMP START POST)
TOUAREG
TOUAREG V10 TDI
By selecting a vehicle the tester will use a pre-dened compensation factor to overcome the extra
resistance caused by the JUMP START POST cable. Selecting the wrong vehicle can lead to incorrect
measurements.
Press the NEXT soft key to continue.
3. Select the TEMPERATURE.
Aim the tester 2 inches (5 cm) from the sides or top of the battery case. As soon as the temperature
reading is stable the operator can press NEXT
4. Select the BATTERY TYPE
REGULAR
AGM
2 * 6V SPIRAL
GEL
Press the NEXT soft key to continue.
5. Select the RATING UNITS
CCA
JIS
DIN
SAE
IEC
EN
Press the NEXT soft key to continue.
6. Press the
UP/DOWN ARROW keys to select the battery rating or in the case of JIS, the part
number.
Press the NEXT soft key to start the test.
For the next few seconds the tester will display the word TESTING and a stopwatch while it evaluates the
battery.
Chapter 4: Battery Test

•20 •
Maintenance mode
This test mode is specically designed for new vehicles that are stored on a compound, in a port or at the
dealer storage before delivery to the customer.
1. POWERING UP SCANNER....
2. Scan the VIN bar code
When it’s impossible to scan the VIN code press the NEXT soft key to enter it manually.
3. Select the TEST LOCATION
TOP POST
JUMP START POST
Press the NEXT soft key to continue.
4. Select the VEHICLE (JUMP START POST)
TOUAREG
TOUAREG V10 TDI
By selecting a vehicle the tester will use a pre-dened compensation factor to overcome the extra
resistance caused by the JUMP START POST cable. Selecting the wrong vehicle can lead to incorrect
measurements.
Press the NEXT soft key to continue.
5. Scan the BATTERY VIN bar code
When it’s impossible to scan the VIN code press the NEXT soft key to select it from a pre-dened
list.
6. Select the TEMPERATURE.
Aim the tester 2 inches (5 cm) from the sides or top of the battery case. As soon as the temperature
reading is stable the operator can press NEXT
For the next few seconds the tester will display the word TESTING and a stopwatch while it evaluates the
battery.
Chapter 4: Battery Test