Battery System Analyser User`s Manual
Contents
1. 36B20R__ NS40Z 275 300 360 32A19R_ NX60 N24 270 295 36B20L NS40ZL 275 300 360 32A19L NX60 N24L 270 295 36B20RS_ NS40ZS_ 275 300 360 26A17R_ 200 36B20LS_ NS40ZLS 275 300 360 26B17L 200 38B20R__ NX60 N24 330 340 410 28B17R 245 38B20RS NT60 N24S 330 340 410 28B17L 24 38B20L_ NX60 24L_ 330 340 410 44 28B19R_ NS40S_ 245 38B20LS NX60 24LS 330 340 410 28B19L NS40LS 245 40B20L 30 32B20R_ NS40 270 40B20R_ 30 32B20L NS40L 270 42B20L_ 30 32C24R_ N40 240 325 400 42B20RS 30 32C24L N40L 240 325 400 42B20LS 830 34B17R 280 46B24L NS60L 325 360 420 S HE Battery System Analyser eS User s Manual Version 2 80e pg Model n bas Ratings rm Model a ban Ratings lee bauer Paes ra se war ma a na me oe 2 46B24RS NS60S_ 325 360 420 80D23R 580 46B24LS NS60LS 325 360 420 80D23L 580 46B26R_ NS60 360 80D26R__ NX110 5 580 580 630 46B26L 360 80D26L NX110 5L 580 580 630 46B26RS 360 BOOK J 500 46B26LS 360 85BR60K J 500 48D26R_ N50 280 360 420 95D31R__ NX120 7 620 660 850 48D26L N50L 280 360 420 95D31L NX120 7L 620 660 850 50B24L NT80 S6L 390 95E41R_ N100 515 640 770 50B24R_2. 900 58513 320 540 64318 540 900 58514 320 540 64323 540 900 58515 450 760 65513 540 900 58521 320 540 65514 570 900 320 540 65515 570 58527 395 640 67043 600 j 1000 58811 440 720 67045 600 j 1000 58820 395 640 68032 600 f 1000 58821 395 640 68034 600 j 1000 360 59018 360 600 70038 630 1050 59040 360 600 71014 700 f 1150 59215 450 760 71015 700 f 1150 59218 290 480 72512 680 1150 59219 290 480 73011 740 1200 59226 450 760 88038 175 300 59514 320 540 88046 210 360 59518 395 640 88056 265 450 59519 395 640 88066 300 5100 59615 360 600 88156 320 540 59616 360 600 88074 400 680 250 410 Battery System Analyser User s Manual Version 2 80e 26 6 3 YUASA Battery Rating Chart Battery Battery Model No CCA Model No CCA 24 500 500 75A 72 630 34 6MF 500 75 660 660 34 60 525 78A 72 670 34 610MF 610 78 710 710 35 580 580 T GRAOR CMF_ 820 55D23R_ 5 22 58 6MF_ 530 GTH40S 275 58 530 _ __ 74 60 GTH75DR 75 6MF GR96R MF 75 72 GR96R CMF 6 4 Rough CCA Guide Given below is a rough CCA ratings guide for any unknown battery model basing on the capacity of the vehicle Vehicle Capacity Approximate Battery CCA Rating 1200 1600 cc 350 CCA 1600 2000 cc 500 CCA 2000 3000 cc 650 CCA 3000 cc and above 750 CCA M Benz over 3000 cc
3. BASIC SET Battery System Analyser 4 in 1 User s Manual User s Manual Version 2 80e Table of Contents 1 1 The Product 2 22222222222 eennnn nen nnn nen nnen nnec 3 1 2 Specifications 2 2 2 2 nnn n nnn n nnn n nnn n nnn n enn n enn nennnennnennnene 4 2 1 Safety S e TH ls T mnnn 5 2 2 Other PrecautionS 22 00n sens nn nnn n 7 4 1 Main H T 200222222 nee enee nee neeen nnn n eee e eens 10 4 2 Key FUNCUtIONS 2 2 222 n nnn n nn nnn nn nn nnn nnn nen nen nnn nen n nen nen nnennnes 10 4 3 Functions of Individual Key 0 02 2neenennennnennennn 11 6 1 Japanese Industrial Standards JIS Rating Chart 22 6 2 DIN amp EN Standards Rating Charts 24 6 3 YUASA Battery Rating Chart 2 2 02nennsnenennnnenennnnnnnenennenensnnnns 26 6 4 Rough CCA Guide 222 02n reenn reenn neee e 26 9 1 Start TeStinG 2222 222 nn neces reenn repere neee penne peer 36 No load testing at 3 000 RPM 2 36 Testing with load at 2 000 RPM 2 2 reper
4. 450 54464 220 330 55811 360 540 54465 210 360 56012 230 420 54519 210 360 56068 250 390 54523 220 300 56069 250 390 54524 220 300 56073 250 390 54533 210 360 56077 300 5100 54537 190 300 56091 360 540 54545 190 300 56092 300 5100 54551 220 300 5611 300 540 54577 220 300 56216 300 5100 54578 220 300 56218 300 5100 54579 220 300 56219 300 5100 54580 220 300 56220 280 510 54584 220 300 56225 300 510 54590 210 330 56311 300 5100 54612 210 360 56312 300 5100 54801 190 300 56318 300 5100 i 54827 240 360 56322 300 0 55040 265 450 56323 300 5100 55041 220 360 56420 300 5100 55042 220 360 56530 300 5100 55044 265 450 56618 300 5100 55046 300 5i0o 56619 300 5100 55048 300 540 56620 300 5100 55056 320 540 56633 300 5100 Battery System Analyser 25 User s Manual Version 2 80e Battery ___Amps__ Battery Model No E S R Ta Model No DIN EN 56821 315 540 60527 410 680 57029 315 540 61023 450 760 57217 420 720 62034 420 680 57219 420 720 62045 420 680 57220 420 720 62529 450 760 57230 380 640 63013 470 680 57412 400 680 63545 420 680 57412L 400 680 63549 420 680 57513 350 570 64035 520 760 58424 450 760 64317 540
5. let s look at the wave form displays taken during the cranking tests with an oscilloscope Figure A above shows the voltage profile of a healthy battery during the cranking of an engine The graph starts off at the battery s nominal voltage and a voltage drop is detected when the vehicle is cranked The voltage recovers to the battery s nominal voltage and eventually rises to approximately 14 4 V when the alternator starts charging the battery For Figure B where a typical 2 year old battery you noticed the difference in the voltage drop which indicates that it is weaker but still usable Whereas Figure C represents a very weak battery that can barely crank a car and is due to fail in the very near future As voltage profiles can indicate the relative ability of the tested battery in starting an engine so there is no need for knowledge on the starter motor requirement or the battery s rating and size This Battery System Analyser utilises the mentioned voltage profile to ae determine the cranking power of the tested batteries and it will display the results after every test Battery System Analyser a User s Manual Version 2 80e 8 1 Begin Testing 1 After you have made your choice selecting New gt Clear Memory or Last gt Continue will proceed to the display below Fig 33 Figure 33 2 From the main MENU select Starter Test by scrolling down using amp key Fig 34
6. 760 CCA 96 s Battery System Analyser e User s Manual Version 2 80e 7 0 Grounding Test SS The engine body and the vehicle chassis are always connected to the battery negative terminal to provide the electrical return path grounding for all the electrical components Due to the surrounding environmental effect the surface contacts of these joints or connections of these circuits will subject to oxidation and corrosion in a matter of time rendering them to have high resistance in it One typical example is the connection at the battery terminals where oxidation and corrosion takes place very often If these contacts were no good then it will pose a lot of electrical problems to the vehicle To check the grounding condition this Analyser will measure the resistance from the engine body contact to the battery terminal then it will display the results and the recommendations 7 1 Start Testing 1 Attach the clips onto the battery terminal posts and the analyser will power up and lights up the LCD display screen as shown Fig 21 Figure 21 2 It will run through a self test and when completed it displays the Main Menu as shown Fig 22 27 Figure 22 Battery System Analyser User s Manual Version 2 80e Zone 3 After you have made your choice selecting New gt Clear Memory or Last gt Continue will proceed to the display below Fig 23 Figure 23 key once will scro
7. CCA is related to the actual power available in the battery in relation to that battery s rating 630 CCA On average a new battery s CCA as measured by this tester will read 10 15 higher than its stated rating 18 As the battery ages the CCA number measured by this tester will decrease so it reads near its rating While this value is not the same as a CCA test it is the best available measurement for showing a battery s current condition in relation to its rating Battery System Analyser i 2 User s Manual Version 2 80e From the above example a 630 CCA rated battery measuring 406 CCA available power does not mean that the battery would pass a CCA test at 406 CCA The available power reading shows that the battery is not able to perform up to its rated ability 630 CCA In comparison to another battery when fully charged the 630 CCA battery measuring 406 CCA is no stronger than a 400 CCA battery showing 400 CCA available power when fully charged The available power number is meant for comparison to its own rating In fact in this example the 630 CCA battery is failing to perform to its rating while the 400 CCA battery is still working Basing on SAE CCA test is a manufacturing process control test applicable only on new fully charged batteries It does not produce an actual value but is a PASS FAIL test It measures the discharge load in amps that a battery can supply for 30 seconds at 0 F 18 C while
8. Figure 34 2 Press QO key to continue and the display will show Fig 35 s33 Figure 35 Battery System Analyser User s Manual Version 2 80e C o 3 Switch the ignition key to ON and start cranking the engine until it starts Immediately after that press key and the results will show as follows Figure 36 Figure 36 4 lf the voltage drop is too great during the cranking the tested results will display as follows Figure 37 and will prompt you to check the starter system Figure 37 5 During cranking when it detects that there is no drop in voltage it will display the following screen Figure 38 _34 Figure 38 6 Pressing the Ler key at any moment will exit and return back to the previous screen Battery System Analyser ess User s Manual Version 2 80e 35 9 0 Alternator Test An alternator is the device used to produce the electricity the car needs to run and to keep the battery charged The alternator uses the principle of electromagnetic induction to produce voltage and current The four main parts of the alternator are the Rotor Stator Diode Pack Voltage Regulator and an Ammeter or Indicator Light to inform the driver of any problems All of these parts must be in good working order for the alternator to do its job Battery Warning Lamp LED Ve Output Field Curent Magnetic Field Altemator The Rotor is a coil of wire wound around an iron core The Roto
9. plates because during the recharging process it will warm and expand After recharging has been completed recheck the level Battery System Analyser T User s Manual Version 2 80e gt Reinstall the vent caps BEFORE recharging recharge ONLY in well ventilated areas and wear protective eye ware Do NOT smoke or cause sparks or flames while the battery is being recharged because batteries give off explosive gasses gt If your battery is an AGM or a sealed flooded type do NOT recharge with current ABOVE 12 of the battery s RC rating or 20 of the ampere hour rating Gel cells should be charged over a 20 hour period and never over the manufacturer s recommended level or over 14 1 VDC gt Follow the battery and charger manufacturer s procedures for connecting and disconnecting cables and other steps to minimize the possibility of an explosion or incorrectly charging the battery You should turn the charger OFF before connecting or disconnecting cables to a battery Do not wiggle the cable clamps while the battery is recharging because a spark might occur and this could cause an explosion Good ventilation or a fan is recommended to disperse the gasses created by the recharging process gt Ifa battery becomes hot over 110 F 43 3 C or violent gassing or spewing of electrolyte occurs turn the charger off temporarily or reduce the charging rate gt When charging the battery in the car with an external MANUAL c
10. repere peer 39 10 0 View Last Results 11 0 The Printer 11 1 alius 43 11 2 Printer S t Up 222222222220202sesenenesenenssnseseseesesenesesesssssssessesesesssssssesesseseses 44 11 3 Printing the reSUultS 2 2 22 2 00 cs eee peep peer 45 12 0 Warranty Information 12 1 Limited Warranty 2 220 n nnn nn nn nnn nnn n nnn n nn enn nnn nnnnnnnennnnenee 48 12 2 Limitations of Warranty 2 2 222 nnn nn nnn ne neee 49 Battery System Analyser no User s Manual Version 2 80e 1 0 Introduction 1 1 The Product Basic Set PRO Set As we all know battery plays a very important role in a vehicle by providing power to all the electrical components and also the initial power to get the engine started Once the engine runs the alternator will take over and at the same time it charges the battery In order these power systems to perform efficiently at all times they need to be checked regularly during service and maintenance of the vehicle For quick and convenient way of checking the condition of these power systems this Battery System Analyser is designed to perform the following tasks 1 Battery Test Analyses the battery condition using the latest battery testing methods without the need of fully charging it before test The unit consumes very little current during testing hence the test can be rep
11. 0 180G51L NT250 15L 1090 70D23L_ 25 60 490 540 580 195G51R NX300 51 1145 75D23R_ 500 520 580 195G51L_ NX300 51L 1145 75D23L 500 520 580 190H52R_ N200 925 1100 1300 75D26R__ F100 5 490 190H52L N200L_ 925 1100 1300 75D26L F100 5L 490 245H52R_ NX400 20 1530 1250 735 245H52L NX400 20L 1530 1250 99 Battery System Analyser User s Manual Version 2 80e aoa 6 2 DIN amp EN Standards Rating Chart Battery Amps Battery Amps Model No DIN EN _ ModelNo DIN EN 52805 180 240 55057 320 540 52815 180 240 55068 220 390 53517 175 300 55069 220 390 53520 150 240 55218 255 420 53521 150 240 55414 265 450 53522 150 240 55415 265 450 53621 175 300 55421 265 450 53624 175 300 55422 265 450 53625 175 300 55423 300 5100 53638 _ 175 300 55427 300 510 53646 175 300 55428 300 510 53653 175 300 55457 265 450 53836 _ 175 300 55529 220 360 53890 175 300 55530 255 420 54038 175 300 55531 255 420 54039 175 300 55545 255 420 54232 175 300 55548 255 420 54312 210 360 55552 255 420 54313 220 330 55559 255 420 54324 220 330 55563 255 420 54434 210 360 55564 255 420 54437 210 360 55565_ 255 420 54459 210 360 55566 265
12. 10 If the measured resistance reading is within limits then it will display as follows Fig 30 30 Figure 30 Battery System Analyser eS User s Manual Version 2 80e 11 If the measured resistance reading has gone beyond the limits then it will display the screen as follows Fig 31 Figure 31 Note The above indicates that the ground contact from the engine body to the battery is bad Check for rusted or corroded point of contacts If found dismantle it for cleaning or replace before fixing back Repeat the test again after fixing Another thing is that if you suspect that the result is in question you may conduct the test with the Black clip clamp at different locations in the engine 12 If you did not follow the right procedures during the testing it will display the results as follows Fig 32 below Figure 32 31 13 To exit the program pressing the key at any moment will exit and return back to the main menu screen Fig 24 Battery System Analyser User s Manual Version 2 80e ee 8 0 Starter Test L This test actually checks the cranking effectiveness of the battery and also can predicts when the battery will fail to crank a vehicle This Analyser is designed to address the weakness of conventional testers with its cranking power measurements Simply connect the analyzer to the battery in the vehicle and start the engine To understand the working principle of the tests
13. 9 Figure 39 2 It will run through a self test and when completed it displays the Main Menu as shown Fig 40 36 Figure 40 Battery System Analyser yess User s Manual Version 2 80e 3 After you have made your choice selecting New gt Clear Memory or Last gt Continue will proceed to the display below Fig 41 Figure 41 4 Pressing amp key to scroll down to the Alternator Test Fig 42 Figure 42 5 Press EE key to continue and the display will show Fig 43 37 Figure 43 Battery System Analyser User s Manual Version 2 80e C Start the engine and then press ED xc again and the screen will prompt you as shown below Fig 44 Rev engine up to 3 000 RPM Average volts Captured volts Voltages values Range Limit Figure 44 Make sure that all loads lights air condition etc are OFF Rev the engine up to 3000 RPM and maintain it for 3 5 seconds and then release the pedal The maximum and minimum voltages values will be captured Note While revving the engine you need not have to hold the analyser in your hand as it can capture the maximum voltage generated at 3 000 RPM in the display Just place the analyser in a safe and secure place during testing With the captured readings analysis can done by referring to the limits as indicated that MAX voltage should not exceed 14 5V max voltage at 3 000 RPM and MIN voltage should be mo
14. NT80 S6 390 95E41L_ NiooL 515 640 770 500200 310 380 480 105E41R Niooz 580 720 880 50D20L 310 380 480 105E4iL N100ZL_ 580 720 880 50D23R_ 85BR60K__ 500 105F51R_ N100Z_ 580 50D23L_ 85B60K__ 500 105F51_ N100ZL_ 580 50D26R_ 50D20R_ 370 115E41R_ NS120 650 800 960 50D26L 50D20L 370 115E41L _ NS120L 650 800 960 55B24R__ NX100 S6 435 420 500 115F51R_ N120 650 800 960 55B24L NX100 S6L 435 420 500 115F51L N120L_ 650 800 960 55B24RS_ NT80 S6S_ 430 420 500 130E41R_ NX200 10 800 55B24LS NT80 S6LS 430 420 500 130E41L NX200 10L_ 800 55D23R_ 355 480 500 130F51R 800 55D23L 355 480 500 130F51L 800 55D26L N50ZL 350 440 525 145F51R_ NS150 780 920 55D26R_ N50Z 350 440 525 145F51L_ NS150L 780 920 60D23R_ 520 145G51R_ N150 780 900 1100 60D23L 520 150F51R_ NT200 12 640 65D23R_ 420 540 580 150F51L NT200 12L_ 640 65D23L 420 540 580 165G51R_ NS200 935 980 65D26R_ NS70 415 520 625 165G51L _ NS200L 935 980 65D26R_ NS70L 415 520 625 170F51R NX250 12 1045 6sD31R N70 390 520 630 170Fs51L_ Nx250 t2L 105 65D31L NTL 390 520 630 180G51R NT250 15 1090 70D23R_ 35 60 490 540 58
15. anty only extends to the first owner and not assignable or transferable to any subsequent owner 4 Cost of delivery charges incurred for the repair of the product to and from the manufacturer will be borne by the owner si This limited warranty covers only those defects that arises as a result of normal use and does not cover those that arises as a result of e Unauthorized modifications and repair e Improper operation or misuse e Accident or neglect such as dropping the unit onto hard surfaces e Contact with water rain or extreme humidity e Contact with extreme heat e Cables that have broken bent contact pins or subject to extreme stress or wear e Physical damage to the product surface including scratches cracks or other damage to the display screen or other externally Bnk exposed parts Battery System Analyser AQ User s Manual Version 2 80e 12 2 Limitations of Warranty Other than the foregoing limited warranty the manufacturer does not make any other warranty or condition of any kind whether express or implied Any implied warranty of merchantability or fitness for use shall be limited to the duration of the foregoing limited warranty Otherwise the foregoing limited warranty is the owner s sole and exclusive remedy and is in lieu of all other warranties whether express or implied The manufacturer or any of its exclusive sales agents shall not be liable for any consequential or incidental damages or losses a
16. e voltage regulator sends current to the field terminal and allows the alternator to start charging Current will then flow into the battery and bring it up to full charge Battery System Analyser User s Manual Version 2 80e 365 lf the voltage goes above 14 5 volts the voltage regulator shuts off the current to the field terminal and keeps the battery from overcharging and cooking itself This is how the voltage regulator controls the alternator output When you first start your vehicle the alternator needs some current to start working The voltage regulator supplies this current from the battery to the field stator terminal of the alternator to get it started The state of charge of the battery controls amperage output of the alternator When the battery has a full charge the electro motive force of the voltage lowers the amperage to almost zero As the battery charge wears down the electro motive force is not enough to stop the amperage so it flows into the battery and charges it again 9 1 Start Testing This test is to check the MAX and MIN charging voltages output of the alternator at 3000 RPM without load and 2000 RPM with all loads ON With this test you can determine the alternator s condition when in reference with the vehicle s Service Manual No load testing at 3 000 RPM 1 Attach the clips onto the battery terminal posts and the analyser will power up and lights up the LCD display screen as shown Fig 3
17. eated numerous times without worry of draining the battery and its results are highly accurate Extremely safe as it does not create any sparks during clamp on and it takes less than 5 seconds to obtain the full analysed results of oO tested battery 2 Grounding Test Analyses the condition of the engine body grounding contact to the battery terminal with results display after test Battery System Analyser User s Manual Version 2 80e a ne 3 Starter Test Checks the cranking effectiveness of the battery to predict when the battery will fail to crank a vehicle basing on voltage profiles with results display 4 Alternator Test This test checks the alternator charging condition during load at 2 000 RPM and without load at 3 000 RPM with results after each test It is maintenance free and no internal batteries required It powers up when connected to the battery posts during testing The operation is fast and simple When hooked up to the battery posts the displayed instructions on the screen will lead you through and a warning tone to caution you to perform the correct steps Its result is consistent and repeatable and can be performed numerous times without heating up the unit It is very safe as it does not create any sparks when connected to the battery terminals during testing on the vehicle After the test the results will be stored in its memory and can be reviewed again later and printed if connected to a
18. esults Here it will let you review the test results of the last tested car The results stored will always depends on the tests that you had done Use E or gt keys to scroll for the pages during viewing While in this mode you can print the results by pressing PRINT key and the display will prompt you Fig 5 if the printer is connected Figure 5 Press C key will activate the printer to start printing 3 After you have made your choice selecting New gt Clear Memory or Last gt Continue will proceed to the display below Fig 6 _13 Figure 6 Battery System Analyser User s Manual Version 2 80e iS 4 Pressing key once will scroll down to the next item if there is a need to select it 5 As an example Fig 6 the selected item was on Battery Test and it is being highlighted 6 Press QD key will proceed to do the battery testing and if it has detected any surface charge on the battery it will start to remove and a message is shown Fig 7 below Figure 7 7 Ifthe surface charge is too great for the analyser to handle it will prompt you with the instructions as shown Fig 8 below Figure 8 8 Wait until the surface charge removal had completed the analyser will advise as follows Fig 9 and then press L sen J key 14 Figure 9 Battery System Analyser nn 5 User s Manual Version 2 80e 9 If there is no surface charge present then it will straight awa
19. g Disclaimer All information illustrations and specifications contained in this user manual are based on the latest information available at the time of printing The right is reserved to make any changes at any time without obligation to notify any person or organization of such revisions or changes Furthermore the manufacturer or its sales agents are not liable for errors contained herein or for incidental or consequential damages including lost profits in connection with the furnishing performance or use of this material This user manual tells how to use and perform the required procedures on vehicles Safe and effective use of this Analyser is very much dependant on the user following the normal practices and procedures outline in this manual Battery System Analyser User s Manual Version 2 80e Ea 12 0 Warranty Information Se 12 1 Limited Warranty This limited warranty cover defects in materials and workmanship for a period of twelve 12 months which begins from the date the product is purchased by the end user and is subjected to the following terms and conditions 1 Within the warranty period the manufacturer will repair or replace at their options any defective parts and return to the owner in good working condition 2 Any repaired or replaced parts will be warranted for the balance of the original warranty or three months 3 months from the date of repair whichever is longer 3 This warr
20. g require that at O F 18 C the number of amperes that the 12V battery can deliver while maintaining a voltage of at least of 8 4 Volts for 60 seconds during cranking EN European Norms Standard EN amperes rating require that at O F 18 C the number of ampere that the 12V battery can deliver while maintaining a voltage of at least 6 0 Volts for 180 seconds during cranking JIS Japanese Industrial Standard JIS amperes rating is based on Ampere Hours and is calculated using 20 hours rating In this manual it is using CCA ratings reference table list provided basing on the JIS model number See page 34 DIN Deutsches Institut fur Normung German Institute for Standardization Taking an example DIN 100 Amperes Basing on DIN 100 Amp battery the rating requires that at O F 18 C the battery is able to deliver 100 amperes while maintaining a voltage of at least of 9 0 Volts for 30 seconds and 8 0 Volts for 150 seconds during cranking Unknown If you are not sure which ratings CCA EN IEC JIS or DIN that the battery is based on then choose this setting It will show the battery s Voltage CCA and the Internal Resistance mQ only This selection can also be used to test 12V Deep Cycle Batteries An example of the results display is shown below Fig 17 20 Figure 17 Battery System Analyser eS User s Manual Version 2 80e Use Voltage should not fall below 12 6V when fully charged and
21. harger make sure that it will not damage the vehicle s electrical system or components with high voltages Even if this is a remote possibility it is best to disconnect the vehicle s battery cables from the battery BEFORE connecting the charger Battery System Analyser User s Manual Version 2 80e 4 0 The Battery System Analyser 4 1 Main Unit LCD Back light switch LCD Display Results and instructions sl Keypad Command keys to access to various functions Figure 1 4 2 Keypad Functions Figure 2 Battery System Analyser B T User s Manual Version 2 80e 11 4 3 Functions of Individual key PRINT 0 00o o Use this key to scroll up to the next item OR when itis in the keying in Battery Ratings values mode press this key once will increase the value by step of 5 units Use this key to shift the selection tab to the right item OR when itis in the keying in Battery Ratings values mode press this key once will increase the value by step of 100 units Use this key to scroll down to the next item OR when itis in the keying in Battery Ratings values mode press this key once will decrease the value by step of 5 units Use this key to shift the selection tab to the left item OR when itis in the keying in Battery Ratings values mode press this key once will decrease the value by step of 100 units Press this key will ENTER into the selected funct
22. ic acid electrolyte which is a highly corrosive poison and will produce gasses when recharged and explode if ignited This will hurt you BAD When working with batteries you need to have plenty of ventilation remove your jewelry wear protective eyewear safety glasses and clothing and exercise caution Do not allow battery electrolyte to mix with salt water Even small quantities of this combination will produce chorine gas that can KILL you Whenever possible please follow the manufacturer s instructions for testing jumping installing charging and equalising batteries n he l Timmi c ae EXPLOSIVE Si TEAC GASEScan toute 1 FLAMES SUINDNESS OF BUNOMESS ORINJURY T SMOKING T SEVERE BURKS KEEP OUT OF THE REACH OF CHILDREN OO NOT TIP KEEP TENT CAPS TIGHT AHO LEVEL gt Never disconnect a battery cable from a vehicle with the engine running because the battery acts like a filter for the electrical system Unfiltered pulsating DC electricity can damage expensive electronic components e g emissions computer radio charging system etc Turn off all electrical switches and components turn off the ignition and then disconnect the battery gt For non sealed batteries check the electrolyte level Make sure it is covering the plates and it is not frozen before starting to recharge especially during winters gt Do not add distilled water if the electrolyte is covering the top of the
23. intenance Free 10 To enter the value 630 press gt key will increase the original value of 500 Fig 13 by step of 100 units to 600 Likewise ic gt key to increase the last two digits 00 to 30 by step of 5 units for each pressing Fig 14 Figure 14 11 Once the CCA rating of the battery is confirmed press QO key will start the testing process Refer to the display below Fig 15 17 Figure 15 Battery System Analyser User s Manual Version 2 80e Zio nbs 12 For less than 5 seconds the results of the testing will be displayed on the LCD screen Fig 16 Figure 16 Interpretations of the above results 1 RESULTS Good A very straight forward display of the final results basing on the evaluation of the tested condition Good indicates the battery in good condition Replace indicates that the battery needs to be replaced If not the battery will fail anytime without any warning 2 Voltage 12 46V This indicates the tested battery voltage 12 46V It depends on the state of charge on the battery 100 fully charged 13 20V 90 charged 12 90V 75 Charged 12 45V 3 CCA Cold Cranking Amps 406 CCA CCA ratings has been used here therefore the tested result is in 406 CCA If other rating DIN or JIS or IEC or EN were selected it will base on the respective rating to calculate and show the results in that selected rating Please take Note This output value 406
24. ion To EXIT press this key once will return back to the previous screen This key will access the print command and will start printing when the ENTER key is pressed Note Printing mode can only be activated while in View Last Results menu IJ Battery System Analyser User s Manual Version 2 80e ee FSR 5 0 Battery Test R 5 1 Start Testing This Battery System Analyser can perform testing while the battery is still fixed on the vehicle Please make sure the engine is OFF 1 Attach the clips onto the battery terminal posts and the analyser will power up and lights up the LCD display screen as shown Fig 3 Figure 3 2 It will run through a self test and when completed it displays the Main Menu as shown Fig 4 Figure 4 Here it will let you select your choice from the Menu New gt Clear Memory selecting this item will allow the tester to clear the last tested results 49 stored in its memory and begin a new test Last gt Continue selecting this item will allow you to continue the last test on the same car from where you had stopped Battery System Analyser nia User s Manual Version 2 80e For example lf you had done Battery Test and later you wish to do Alternator Test or Grounding Test on the same car just select this item and it will update the results after each test in its memory so that it can be review later or to be printed out from the printer View Last R
25. l light up Check the power led on the printer whether it is lighting if not switch the power switch to ON See Fig 63 Sq AX Figures SEL Led a g SEL Button TF Button 4 To advance the paper forward the SEL LED should be OFF Switch it OFF by pressing the SEL button once Then press TF button once the paper will scroll forward Fig 65 5 To start to print SEL LED should light up Activate it by pressing the SEL button again Fig 65 11 3 Printing the Last Test Results To print the results of the test the Battery System Analyser has to be connected to the printer and powered up as described above Fig 63 amp 64 1 The wakeup screen will display as follows 45 Figure 66 Battery System Analyser User s Manual Version 2 80e e 2 It will run through a self test and when completed it displays the Main Menu as shown Fig 67 Figure 67 3 Pressing key once will scroll down to the View Last Results as shown Q Fig 68 Figure 68 4 Press amp gt key will proceed to display the last test results depending the type of test you had performed earlier Fig 69 _ 46 Figure 69 Battery System Analyser S User s Manual Version 2 80e 47 PRINT 5 While in this mode you can print the results by pressing C key and the display will prompt you Fig 70 if the printer is connected Figure 70 6 Press C key will activate the printer to start printin
26. ll down to the Grounding Test 4 Pressing Fig 24 Figure 24 5 Press QD key will proceed to the display as follows Fig 25 28 Figure 25 Battery System Analyser T User s Manual Version 2 80e 6 Press J2 key again and it will starts analyzing Fig 26 Figure 26 7 Once it has finished analysed it will prompt you with an instruction Fig 27 stating that you have should unclamp the black battery clip from the battery negative terminal and clamp it to the engine body within 15 seconds Note Before removing the black clamp from the battery terminal try look for a position that the clamp can hold securely at the engine body in order to get a good reading Figure 27 7 The moment you remove the Black clip from the battery terminal the Analyser screen display will switched OFF until you have clamp it to the engine body 2 I During the procedure your time limit is within 15 seconds to establish the contact to the engine body failing which the data obtained earlier will be lost Then you need to repeat the whole testing procedures again from steps 2 page 27 Battery System Analyser User s Manual Version 2 80e Eoo 8 Once the Black clip is clamped onto the engine body the Analyser display will light up in a blank screen no wordings Fig 28 Figure 28 9 Now you need to press QD key to proceed and the display will show as follows Figure 29 Figure 29
27. maintaining a voltage of 1 2 volts per cell 7 2 volts per battery or higher Thus the CCA test shows the minimum power requirement for the battery as rated which means a battery rated at 400 CCA must measure 7 2 volts or above for 30 seconds when a load of 400 amps is applied at 0 F 18 C The above methods also hold for DIN IEC JIS EN basing on its individual ratings 4 Int R Internal Resistance 6 72mQ In normal condition the internal resistance should fall between 2 0 mQ 15 0 mQ As a matter of fact the higher the battery CCA readings obtained the lower the internal resistance should be 5 LIFE 50 This is an indication of the battery life expectancy in percentage If the life falls below 45 the RESULT will display Replace and it is time to change to a new battery 19 Battery System Analyser User s Manual Version 2 80e Eo Explanation of the following terms used as shown on the LCD display CCA Cold Cranking Amps most commonly used Standard CCA is a rating used in the battery industry to rate a battery s ability to start an engine in cold temperatures This rating is the number of amperes that a new fully charged battery can delivery at O F 18 C for 30 seconds while maintaining a voltage of at least 7 2 Volts for a 12V battery The bigger the CCA will have the greater starting power of the battery IEC International Electrotechnical Commission Standard IEC amperes ratin
28. printer Note Printer is supplied separately depending on the models 1 2 Specifications Operating Voltage 9V 15V max Analysing Capacity Amps CCA 100 1700 EN 100 1000 IEC 100 1700 DIN 100 1000 JIS 100 1700 CCA Battery analysing time Less than 5 seconds Printer Optional Available in PRO Set only Operating Voltage 12V DC Aes Print Head Type Thermo Power Adaptor Input 110 240 AC 50Hz Output 12V DC 2A Dimensions 181x110x90 mm Battery System Analyser User s Manual Version 2 80e 2 0 Safety Measures For safety reasons read this manual thoroughly before operating the Tool Always refer to and follow the safety instructions and testing procedures provided by the car or equipment manufacturer The safety messages presented below and throughout this user s manual are reminders to the operator to exercise extreme care when using this test instrument 2 1 Safety Precautions A ADANGER When the engine is running it produces carbon monoxide a toxic and poisonous gas Always operate the vehicle in a well ventilated area Do not breathe exhaust gases they are hazardous that can lead to death ACAUTION To protect your eyes from propellant object such as caustic liquids always wear safety eye protection ADANGER Fuel and battery vapors are highly flammable DO NOT SMOKE NEAR THE VEHICLE DURING TESTING ACAUTION When engine is running many par
29. r rotates as the alternator shaft rotates and current passes through brushes The Rotor winding passes the Field current This causes the Rotor to produce a magnetic field So basically the Rotor is a rotating electro magnet The Stator is a set of three windings fixed to the case of the alternator and these windings are static i e they dont rotate As the Rotor rotates its magnetic field cuts each Stator winding in turn this induces a current in each winding The outputs from the Stator windings are 120 degrees apart and are alternating current AC But vehicles run on DC current so we need something that will convert the AC current to DC current This is the job of the diode pack A diode Is an electrical one way check valve that will let current flow in only one direction The typical diode pack uses four diodes to accomplish this AC current is feed in on one side of the diode pack and DC current comes out the other side The diode pack here will rectify the alternating 3 phases from the Stators and combine them into a single Direct Current which also works the dash ammeter or indicator light Now that we have a DC current that the vehicle can use we need a way to control that current That is the job of the voltage regulator As the name implies it regulates the voltage going to the battery It does this by turning current to the field stator terminal of the alternator on and off lf the battery voltage goes below 13 5 volts th
30. re than 13 3V min voltage during idling speed 6 Press L sen J key will show the results of the test Figure 45 38 Figure 45 Battery System Analyser T User s Manual Version 2 80e 7 If either minimum or maximum charging volts are not within the voltage range limits then it will display one of the screen as below Figures 46 amp 47 and it will prompt you to check the alternator system for the fault Figure 46 Figure 47 Testing with load at 2 000 RPM As more electrical accessories such as lights heater air condition car stereos etc were used the electro motive force decreases and this will allow more amperage from the alternator to flow into the battery to compensate for the added load This test is to check the alternator s behavior during loading 7 Continue from the previous test Fig 45 proceed to the next step by pressing key will enter to the display as follows Fig 48 s39 Figure 48 Now switch ON all loads Head Lights Air condition Heater etc and press gt enter key will display Fig 49 Battery System Analyser User s Manual Version 2 80e ey te Rev engine up to 2 000 RP Average volts Captured volts values Should above these voltages Figure 49 With all loads ON rev the engine to 2000 RPM and maintain it for 3 5 seconds and then release the pedal The MAX and MIN readings will be captured 8 Press QOD key will proceed to show
31. rising of the loss of uses of this product All warranty information product features and specifications are subjected to change without prior notice 49 Battery System Analyser
32. ser is meant for testing of 12 Volts batteries only e ts operating voltage is from 9V 15V DC and should not be tested on 24V directly It will cause damage the unit For 12V x 2 batteries in series or parallel disconnect the connections and test them individually e Battery that has just been charged by the charger contains surface charge and it should be discharged by turning ON the Head lights for 3 5 minutes before testing e Always attached the analyser clips on the lead side of the battery terminal posts during testing so that it has a good contact This will provide better and accurate results e Do not attach the analyser clips directly onto the steel bolt that tightened to the battery terminal posts this may give inaccurate readings or inconsistent results Note This also applies to all other battery testing methods e lf the battery terminal posts were oxidized or badly corroded and the connections were bad the analyser will prompt you to check the connections In this case clean the terminal posts and performs testing directly on the terminal posts it self e During testing on the battery whist it is still in the car make sure the engine is OFF e Do not store the analyser near high humidity or temperature area Exposing to extreme temperatures will cause damage to the unit Battery System Analyser User s Manual Version 2 80e 3 0 Working with Batteries 4A1CAUTION Lead acid batteries contain a sulfur
33. the Internal Resistance Int R should not more 15mQ readings to determine the condition of the tested Deep Cycle Battery Batteries that had been left idle for long periods can still be tested with this analyser To perform the test just clamp the analyser clips onto the battery terminals and it will display the screen Fig 18 as shown if its voltage falls below the normal 12 volts and a buzzing sound is heard Figure 18 Press ENTER J key to continue and the display will show Fig 19 Figure 19 Check the battery ratings and enter it as described in step 10 and 11 page 17 and the results will show as an example below Fig 20 31 Figure 20 Battery System Analyser User s Manual Version 2 80e aa You will notice that there is no indication of message Good or Replace on the RESULTS instead on LIFE it indicates Charge gt Test It means that the battery has to be fully charged and repeat the test again 13 Pressing the the previous screen key at any moment will exit and return back to 6 0 Battery Ratings Charts 6 1 Japanese Industrial Standard JIS CCA Ratings Battery Model JIS CCA Rating Battery Model JIS CCA Ratine NEW OLD WET we SMF NEW ovo wer mF SMF NEW WET SMF NEW WET SMF 26A17R 20 B 280 26A17L 200 34B19R__ NS40ZA___ 270 325 400 28A19R_ NT50 N24 250 34B19LS NS40ZALS 270 325 400 28A19L NT50 N24L 250
34. the results of the test Figure 50 9 If either minimum or maximum charging volts are not within the voltage range limits then it will display one of the screen as below Figures 51 amp 52 and it will prompt you to check the alternator system for the fault Figure 51 Figure 52 10 To exit the program pressing the L er key at any moment will exit and return back to the previous screen Battery System Analyser ST User s Manual Version 2 80e 10 0 View Last Results To view the results of the last test the Battery System Analyser has to be connected to an external power source by either clamping its clips directly to a 12Volt car battery or using a 12Volt AC DC adaptor Fig 53 12V AC DC Adapter Optional if Basic Set Figure 53 1 Once power up the wakeup screen will display as follows Figure 54 lt will run through a self test and when completed it displays the Main 2 Menu as shown Fig 55 41 Figure 55 Battery System Analyser User s Manual Version 2 80e E 3 Pressing Fig 56 below key once will scroll down to the View Last Results Figure 56 4 Press G key will proceed to display the last test results depending the type of test you had performed earlier Fig 57 Figure 57 or b key to get to the Some examples below are Figs 58 59 60 amp 61 5 To view the next page press page you want Figure 58 Figure 59 Batter
35. ts such as pulleys coolant fan belts etc turn at high speed To avoid serious injury always be alert and keep a safe distance from these parts AWARNING Before starting the engine for testing or trouble shooting always make sure the parking brakes is firmly engaged Put the transmission in Park automatic transmission and Neutral manual transmission Battery System Analyser User s Manual Version 2 80e Cabs AWARNING Always block the drive wheels Never leave vehicle unattended while testing ACAUTION Never lay tools on vehicle battery You may short the terminals together causing harm to yourself the tools or the battery ACAUTION Engine parts become very hot when engine is running To prevent severe burns avoid contact with hot engine parts AWARNING Do not wear loose clothing or jewelry while working on engine Loose clothing can get caught in fan pulleys belts etc Jewelry can conduct current and can cause severe burns if comes in contact between power source and ground ACAUTION When the engine is running be cautious when working around the ignition coil distributor cap ignition wires and spark plugs They are HIGH VOLTAGE components that can cause electrical Shock IMPORTANT Always keep a fire extinguisher readily available and easily accessible in the workshop Battery System Analyser User s Manual Version 2 80e 2 2 Other Precautions A e This battery analy
36. y System Analyser ES User s Manual Version 2 80e Figure 60 Figure 61 11 0 The Printer Available only in PRO Set eee 11 1 Functions Figure 62 43 1 Paper cover 6 Roller guide 2 Print head cover 7 LED indicating lights 3 SEL Button 8 Universal Interface jack 4 LF Button 9 Connection to Battery Analyser System 5 Paper Compartment 10 12Volts DC power Input Jack Battery System Analyser User s Manual Version 2 80e Se 11 2 Printer Set up 1 Open the paper cover 1 and put the roll of thermal printing paper into the paper compartment 5 The paper should face up with some extra length shown when closing the paper cover The roller guide 6 should be tightly press against the paper when the cover was closed 2 The input power to the printer can be powered either by a 12 Volts car Battery or through a 12 Volts output AC DC power adopter supplied with the set Connection using 12Volts Battery Power Power inlet to both analyser and printer has to be F T Me connected A Clamp the analyser N Power ON OFF clips to the battery Kk switch terminals NN T Figure 63 Connection using 12VDC Output AC DC Power Adapter OAK 12VDC AC DC Power Adapter D to be connected to 100 240V CN 50HZAC outlet ie ka K T Figure 64 Battery System Analyser AB User s Manual Version 2 80e 3 Once the power has been supplied to the units the analyser display wil
37. y enter into Select Rating menu screen as shown in Fig 10 Figure 10 10 Before selecting the ratings CCA EN IEC DIN and JIS from the menu check the battery specification value This value can be checked on the battery labels as some of the examples shown below 15 Battery System Analyser User s Manual Version 2 80e e If it is selected under JIS Japanese Industrial Standard then the display will prompt you as shown Fig 11 below Figure 11 Refer to the battery model example 80D26L or NX110 5L on the Cold Cranking Amps CCA Table list supplied separately or from this manual on page 18 amp 19 See example Fig 10 below Battery Model JIS cca Battery Model JIS CMF enl oo oer we Sey op Loe ue a lX LALA UAL 50D20R r 00200 E a e E e zmz esse po i oR ear e e 50024R Naap 390 osos TOS 620 660 850 __ s5082 NSS 390 TRER N00 55 e 77m0 500 R 50020R 30 oem no TSS Tap o Figure 12 Press cD key and the display will show Fig 13 below 16 Figure 13 Battery System Analyser S User s Manual Version 2 80e Referring to the Table list Fig 12 under 80D26L check the battery type WET MF Sealed MF or Closed MF CMF as each category has different CCA ratings For instance if the battery is a Sealed MF CMF then it is rated at 680 CCA Note WET Wet Cell Type MF Maintenance Free Type SMF Closed or Sealed Ma
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