WilTec 62553 User manual

Operation Manual
Battery Tester for 6V and 12V Batteries
62553
Illustration similar, may vary depending on model
Read and follow the operating instructions and safety information before using for the first time.
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The information contained in this document may alter at any time without previous notice. It is prohib-
ited to copy or spread any parts of this document in any way without prior written allowance. ll rights
reserved.
The WilTec Wildanger Technik GmbH cannot be held accountable for any possible mistakes in this
operating manual, nor in the diagrams and figures shown.
Even though, the WilTec Wildanger Technik GmbH has undergone biggest possible efforts to ensure
that the operating manual is complete, faultless and up to date, mistakes cannot be entirely avoided.
If you should find a mistake or wish to make a suggestion for improvement, we look forward to hearing
from you.
Send an e-mail to:
[email protected]
or use our contact form:
https://www.wiltec.de/contacts/
The most recent version of this manual in various languages can be found in our online shop via:
https://www.wiltec.de/docsearch
Our postal address is:
WilTec Wildanger Technik GmbH
Königsbenden 12
52249 Eschweiler
Germany
Do you wish to pick goods up? Our pick-up address is:
WilTec Wildanger Technik GmbH
Königsbenden 28
52249 Eschweiler
Germany
To shorten the waiting time and allow for a rapid on-site transaction, we ask you to call us previously
or placing your order via the webshop.
E-mail: [email protected]
Tel:[phone]
Fax: [phone]
To return orders for exchange, repair or for other purposes, please use the following address. tten-
tion! To allow for a smooth execution of your complaint or return, it is important to contact our cus-
tomer service team before returning the goods.
Returns Department
WilTec Wildanger Technik GmbH
Königsbenden 28
52249 Eschweiler
E-mail: [email protected]
Tel:[phone]
Fax: [phone]
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ntroduction
Thank you for purchasing this quality product. To minimize the risk of injury we urge that our cli-
ents take some basic safety precautions when using this device. Please read the operation in-
structions carefully and make sure you have understood its content.
Keep these operation instructions safe.
Note!
In order to ensure perfect condition and safe operation, the user must observe and comply with the
safety and warning instructions in these instructions.
ntended use
The intended use of the device is to test 6V and 12V batteries and accumulators. ny other use than
specified is not permitted!
Operating conditions/Safety instructions
•The device may only be operated at the voltage specified for it.
•The operating position of the unit is horizontal and lying on the rubber feet so that the display
points upwards.
•It is essential to ensure that the technical specifications given in this manual are observed. Ex-
ceeding the specified values may cause damage to the unit or the object to be tested.
•The unit must not be placed in the vicinity of strong HF or magnetic fields, as this may cause
the unit to enter an undefined operating state, resulting in incorrect test results.
•Ventilation slits or vents prevent an excessive rise in temperature. Keep materials such as
flammable substances or paper away from the unit.
•Do not install the unit in a place where it is exposed to high humidity or vibrations.
•The device is intended for use in dry and clean rooms.
•If condensation forms, wait up to 2 hours for the unit to acclimatise.
•Protect the unit from moisture, splashes of water and the effects of heat.
•The unit must not be used in conjunction with highly flammable and combustible liquids.
•This device may only be used by persons with limited physical, sensory or mental abilities or a
lack of experience or necessary expertise if they have been introduced to the use of the de-
vice by a competent person familiar with the device and responsible for them, and if they are
supervised by this person.
•Children must not use the appliance and must be supervised in its vicinity to ensure that they
do not play with the appliance.
•Do not operate the assembly in an environment where flammable gases, vapours or dust are
present.
•Repairs may only be carried out by a trained electrician. Only original spare parts may be
used for repairs. The use of different spare parts can lead to serious damage to property and
personal injury.
•The unit must always be disconnected from the test object before use.
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• Before commissioning, always check whether the unit or assembly is suitable for the desired
application. In case of any uncertainties or queries, please contact a specialist.
Product description
•Portable
•No external power supply required
•Tests can be completed in a short time
•Impact resistant
•No annual calibration required
•Copper-plated high performance terminal blocks
•Ventilated
With this device the performance of a 6V or 12V battery or accumulators can be measured. The de-
vice measures the battery voltage at a current flow of approx. 100 amperes.
The voltage of a "good" and fully charged battery remains relatively constant under load. On the other
hand, with a "bad" battery, the voltage collapses quickly. The measurement results are displayed by a
precise analogue measuring unit, whose scale is designed for different battery sizes and types.
Operating the Tester
Warning!
When handling lead-acid batteries, highly explosive detonating gas may be produced. This oxyhydro-
gen gas can be ignited by a spark, cigarette or open flame, causing the battery or accumulator to
burst. This causes the sulphuric acid inside to be sprayed and can lead to severe burns.
Therefore, always wear protective goggles when handling lead-acid batteries. void contact of the bat-
tery with skin and clothing and wear rubber gloves. Do not smoke in the immediate vicinity of the bat-
tery and avoid naked flames. Ensure adequate ventilation.
Discharged lead-acid batteries freeze at extremely low temperatures. Never check a frozen lead-acid
battery! Never place the tester or tools on the battery! Never test a lead-acid battery for longer than 10
minutes!
In the event of eye contact with acid, immediately rinse the eyes with clear water for at least 5 minutes
and seek medical attention immediately! Under no circumstances use medication or eye drops without
doctor's instructions.
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Things to know about lead-acid batteries (rechargeable batteries)
•The efficiency of a lead-acid battery decreases as temperatures fall. fully charged battery
has only 40% of the starting power at -18°C that it normally has at 25°C.
•Most batteries break down due to overcharging.
•Heavy discharging does not damage the cells of a battery, but overcharging does.
• warm battery charges faster than a cold one.
•ll batteries are subject to normal self-discharge, which increases with increasing tempera-
ture. The self-discharge of maintenance-free batteries is less than that of normal lead-acid
batteries.
•Batteries should be stored in as cool a place as possible to keep self-discharge low.
Attention! The battery must not be frozen!
• fully charged battery freezes at approx. -65°C, a 50% charged battery at -26°C and a
25% charged battery already from -15°C.
• battery stored in a discharged state "sulphates" and loses its capacity.
Battery load test
1. Connect the battery tester to the battery
If the battery is still installed in a vehicle, switch off the engine of the vehicle and switch off all other
consumers in the vehicle. Please note that the on-board voltage can drop very sharply during the test
(especially if the batteries are severely discharged or defective), which can trigger an alarm system,
for example, or trigger a car radio with anti-theft protection (coding). In any case, make sure that the
coding of the radio is deactivated before the load test, or have the code ready to be deactivated.
Connect the black terminal of the test device directly to the negative battery pole (NEG, N, -). Connect
the red terminal of the tester directly to the positive battery terminal (POS, P, +).
battery voltage dependent on the battery's state of charge is now shown on the display instrument of
the device. If the displayed voltage is less than 12.4 volts (6.2 volts), the battery should be charged by
a load test. If the voltage is still below 12.4 volts (6.2 volts) after charging, it can be assumed that the
battery is defective.
If the needle of the display is at the extreme left end of the display, the battery tester is connected with
the wrong polarity.
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2. Determine the correct measuring range on the scale
Determine the capacity or cold test current of the battery under test. The cold test current is also prin-
ted on the battery as "CC " (Cold Cranking mps) in the unit " mpere" ( ).
On the scale there is a green area below 12 V which is graduated from 200-1000 CC . To evaluate
the test result, select the scale corresponding to the battery.
If no cold test current is printed on the battery, please use the table below to select the appropriate
scale.
Battery capacity cold test current
36 h - 44 h 200
55 h - 66 h 400
75 h - 88 h 600
95 h - 110 h 800
180 h- 1000
3. Press the test switch for 10 seconds!
Observe the indicator needle of the instrument carefully. Remember where the needle is at the end of
the 10 seconds. ssess the battery according to the following battery load analysis.
Battery Load Analysis
Loading test Battery condition
Ok (green field) The battery is in good condition and can be fully
charged if necessary.
Weak (yellow field) Battery performance is not satisfying. The battery
is either defective or partially discharged. Deter-
mine the battery charge level with a hygrometer
(measure acid density)
Bad (red field)
Needle drops constantly
The battery is faulty (e.g. due to a bad cell). s a
counter-check, release the switch and observe
the reaction of the voltmeter. If the display returns
to 12 V within a few seconds, the battery is defec-
tive. If, on the other hand, the battery voltage ri-
ses slowly, the battery is probably only very se-
verely discharged.
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Assessment of the state of charge via the battery acid density
If the acid density at 27°C is 1.24 kg/dm³ or less, please first charge the battery before carrying out fur-
ther tests and check the acid density again after one hour of standing time.
Acid density at 27°C in kg/dm³ State of charge Actions
1,25 - 1,28 Charged Test possible
1,20 - 1,24 Half charged Charging recommended
Lower as 1,20 Poorly charged Load immediately
The acid density should be the same in all cells of a good battery. Maximum permissible tolerance bet-
ween highest and lowest measured value of the 6 cells: 0.03 kg/dm³.
If the acid density is the same in all cells but less than 1.25 kg/dm³, please charge the battery.
Temperature compensation
Due to the chemical reactions that take place in a lead-acid battery, the test results depend on the bat -
tery temperature. In order to obtain the most accurate test results possible, compensation must be car-
ried out from approx. -8°C.
This is achieved by subtracting 50 amperes of cold test current from the printed value of the battery's
cold test current for each -10°C cold. This means that at -20°C 100 and at -30°C 150 cold test cur-
rent are subtracted.
Example: If the printed battery cold test current is 500 and the test is carried out at -18°C, use the
400 CC scale.
Testing the charging system
With the help of the battery tester, many small general faults in the charging circuit can be quickly and
easily detected.
The motor should be at normal operating temperature for testing.
•Connect the battery tester to the vehicle battery with the correct polarity.
•Start the engine and run it at a speed of at least 1500 rpm.
•Do not operate the test switch on the unit!
•Read the display when the electrical consumers (light, fan, etc.) are switched off. The need-
le should be in the green area (OK) at approx. 14 volts.
•When the electrical consumers are switched on, the needle should remain in the green
area.
•If the needle is in the red area above or below the green area, this indicates a fault in the
charging circuit (e.g. defective charge controller).
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Testing the starter motor
This test detects excessive current consumption of the starter motor. Excessive current consumption
of the starter motor leads to an overload of the battery and thus shortens its life. This test should only
be carried out if the battery load test was previously completed with "OK".
•For testing the motor should have normal operating temperature.
•Connect the test device to the vehicle battery with the correct polarity.
•Press the test button for max. 10 seconds and note down the voltage value while keeping the
test button pressed.
•Disconnect the engine ignition cable from the spark plug so that the engine does not start
when starting.
•Now try to start the engine. Make a note of the voltage during the starting procedure.
•Compare the two voltages with the yellow table printed in the display (ST RTER TEST). The
upper row of the table refers to the "LO D VOLTS" i.e. the voltage measured during the load
test with the unit. Below this voltage value the table shows the corresponding minimum star-
ting voltage (MIN. CR NK VOLTS).
Example: You measure a voltage of 10.4 V during the load test and the voltage collapses to 9.5 V du-
ring starting. ccording to the table a starting voltage of up to 8.2 V is acceptable. The starter engine is
ok. If a starting voltage of less than 8.2 V is measured, a short circuit in the starter, a fixed bearing in
the starter etc. could be the reason for excessive power consumption.
Technical Data
Dimensions 290 x 110 x 75 mm (l x w x h)
mpere range 300 – 1000
Testing procedure 100 load current
Cable length 2 x 30 cm
Miscellaneous 2 clamping pliers with 30 cm supply cable
Malfunctions on the device
If it can be assumed that safe operation is no longer possible, the device must be taken out of operati-
on and secured against inadvertent operation.
This applies if:
• the unit shows visible damage.
•the device is no longer functional.
•parts of the unit are loose or loose.
•the connecting cables show visible damage.
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Disposal regulations
EU guidelines regarding the disposal of scrap electric appliances (WEEE, 2012/19/EU) were imple-
mented in the law related to electrical and electronic equipment and appliances.
ll WilTec electric devices that fall under the WEEE regulations are labelled with the crossed-out
wheeled waste bin logo. This logo indicates that this electric equipment must not be disposed with the
domestic waste.
The company WilTec Technik GmbH has been registrated in the German registry E R under the
WEEE-registration number DE45283704.
Disposal of used electrical and electronic appliances
(intended for use in the countries of the European
Union and other European countries with a separate
collection system for these appliances).
The logo on the article or on its packaging points out
that this article must not be treated as normal house-
hold waste but must be disposed to a recycling collec-
tion point for electronic and electrical waste equip-
ment. By contributing to the correct disposal of this art-
icle you protect the environment and the health of your
fellow men. Environment and health are threatened by
inappropriate disposal.
Materials’ recycling helps reduce the consumption of raw materials.
dditional information on recycling this article can be provided by your local community, municipal
waste disposal facilities or the store where you purchased the article.
ddress:
WilTec Wildanger Technik GmbH
Königsbenden 12 / 28
D-52249 Eschweiler
Important notice:
The reprint or reproduction, even of excerpts, and any commercial use, even in part of this instructions
manual require the written permission of WilTec Wildanger Technik GmbH.
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