Battery Electrical And Starting Tester

Transcription

1 OPERATOR S MANUAL Battery Electrical And Starting Tester Copyright 2005, GxT, Inc., All Rights Reserved 1

2 Test & Measurement Specifications RPM ,000 RPM RPM Type... Inductive, Plug in Field Replaceable Battery Volts to Volts External Volts (10 Megohm Impedance)... 0 to +/ Volts Inductive Amps...0 to +/- 600 Amps Type... Inductive, Plug in Field Replaceable Load Range... 0 to 600 Amps Load Type...Carbon Pile Load Configuration...Clockwise = On, Counterclockwise = Spring Loaded Battery Condition...Estimated Cold Cranking Amps Rating Amps Ripple... LCD Indicator Load On Indicator... LCD Indicator Load Hot Indicator... LCD Indicator Display Information Display Type...2 Line Backlit LCD Bargraph Segment Refresh Rate... 3 times a second or better Printer... Thermal, 40 Column Physical Dimensions Case Size x 16.5 x 9.5 in. Weight Pounds Power Requirements Volt Battery Replacement Parts Axle Cap...B Axle...G Wheel, 8...H Thermal Printer Paper, 80mm or 3 1/8...H Extension Lead for 5 Pin Din... W Spark Pickup... X High Amps Probe... X Introduction Equipped with a thermal printer, advanced computer aided system tests and a large display. This tester has the ability to the estimate cold cranking amps of the battery and detect batteries likely to fail in the near future. Large simple controls and labeling. Inductive Amp probe makes hookup easy. Welded steel with baked powder coat finish. Carbon pile loads output. Inductive amp probe measures output and indicates defective diode/stators. Checks voltage regulation. Applies up to 600 amp test current and measures voltage. Timer sounds after 15 seconds of load. Checks current draw and cable/solenoid resistance voltage drops. 1 x 3/4 opening clamps around large battery cables and wire bundles. Plug-in user replaceable probe. Control knob sets load current to a stable test amperage. Fan cooled for heavy duty service. Easily tests 1200 CCA Batteries. Side handle cable exits make hookups easier and more secure. Cables are jacketed to reduce tangles. Technical Support Questions or inquiries about service can be answered by contacting GxT, Inc., at: Toll Free (800) Fax: (231) , Toll Free (231) , or repair@gxtauto.com When sending an item to the factory address it to: GxT, Inc., 520 MM Riggs Drive., Cheboygan, MI Include a note describing the problem. 2

3 Table of Contents Test & Measurement Specifications...2 Display Information...2 Physical Dimensions...2 Replacement Parts...2 Introduction...2 Technical Support...2 Warranty...3 Keypad...4 Indicators & Messages...4 Installing Printer Paper...5 Stand Assembly...5 Battery Test (Manual)...6 Battery Test (Automatic)...7 Starter Test (Manual)...8 Voltage Drop Test...8 Starter Test (Automatic)...9 Alternator Output Test (Manual)...10 Regulator Charging Voltage Test...10 Alternator Output Test (Automatic)...11 Safety Precautions...12 Warranty FERRET BRAND LIMITED PRODUCT WARRANTY GxT, Inc. of Cheboygan Michigan, warrants to the original purchaser that FERRET brand products are free from defects in materials and workmanship for a period of two years from date of purchase. Our sole obligation for a product within the above warranties will be to repair or replace, at our option, any defective parts and return the product to the sender within the U.S.A., shipping prepaid, if it is sent to our Repair Department shipping prepaid and accompanied by proof of purchase. This Warranty does not apply to products which have been altered outside the factory; or repaired by anyone other than the factory or its authorized service centers; or which have been damaged from accidents, negligence, or abuse; or have been used differently than described in the printed instructions. Please note that wear and tear on leads and replacement of consumable items such as: NOx Sensors, Oxygen Sensors, and paper, is not covered by warranty. GxT Inc. s sole liability and buyer s exclusive remedy is limited to repair or replacement of the product as stated in the Limited Product Warranty. THERE ARE NO OTHER WARRANTIES EXPRESSED OR IMPLIED INCLUDING THOSE OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE AND GxT, INC. SHALL NOT BE LIABLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES ARISING FROM THE SALE OR USE OF THE PRODUCT. Some states do not allow limitations on the length of implied warranties nor exclusion or limitations of incidental or consequential damages, so that the above limitations and/or exclusion may not apply to you. This warranty gives you specifi c legal rights and you may also have other rights which may vary from state to state. 3

4 Keypad Amps/Ext V Pressing the Amps/Ext V button will display amperage measurements from the High Amps Probe on the upper display, and the voltage measurements from the external volts leads on the bottom display. Amps/Batt Pressing the Amps/Batt button will display amperage measurements from the High Amps Probe on the upper display, and the voltage as measured from the Battery Clamps. This test configuration is the most widely accepted measurement configuration for typical Battery Testers. RPM/Amps Pressing the RPM/Amps button will display the RPM of the engine on the upper display, and the amperage measurements from the High Amps Probe on the lower display. RPM/Batt Pressing the RPM/Amps button will display the RPM of the engine on the upper display, and the battery voltage on the lower display. RPM/Ext V Pressing the RPM/Ext V button will display the RPM of the engine on the upper display, and the voltage measurements from the external volts leads on the bottom display. Amps Zero Pressing this button will zero the amp probe. Print Press this button to print whatever is on the display. 2C/4C Press this button to configure the RPM measurement to be compatible with 2 cycle or 4 cycle engines. Batt Pressing this button will activate an automatic test of the battery. See the test details further in the manual. Start Pressing this button will activate an automatic test of the Starting System. See the test details further in the manual. Charge Pressing this button will activate an automatic test of the Charging System. See the test details further in the manual. Special Key Combinations Press the Print and 2C/4C buttons at the same time to advance the paper. Indicators & Messages LOad HOT When this message is displayed on the LCD, the carbon pile is getting too hot. Immediately turn off the load and let the fan cool the carbon pile. Then the LOad HOT message is not display, you can continue testing. Diode Symbol If the Diode symbol on the LCD is on, your alternator has an open or shorted diode or stator. This indicator is most accurate when the battery is under a load and the RPM is above 1,000 RPM. 4

5 The battery tester has a built in 40 column thermal dot matrix printer that uses paper that is 80mm or 3.18 wide. To Install the paper, remove the printer cover. The easiest pay to load the paper is to cut the paper into an arrowhead. Feel the paper into the printer as shown in the pictures. Once you see the point of the arrowhead appear, grab the tip of the paper and gently pull the paper until the full width of the paper has been fed through the printer. Tear off the paper. Install the paper into the paper holder by holding down on one or both of the pins found at the top of the printer housing. Reinstall the printer cover. You are now ready to print. Installing Printer Paper Stand Assembly 5

6 Battery Test (Manual) CAUTION Wear Safety Glasses, Do not break live circuits at the battery terminals, Avoid ac ci den tal ly shorting the insulated battery terminal to any ground metal. Never put a wrench on a live battery wire terminal. Burns may be the result. Dis con nect the battery chassis cable first. 1. Be sure the Load Knob is turned to OFF before con nect ing the analyzer cables to the battery. Take note of the safety pre cau tions on the back cover of this manual. 2. Connect the analyzer Battery Clamps to the battery ter mi nals; Red to positive, Black to negative. The cable jaw contact from each clamp must make a solid con nec tion to the battery terminal to assure good voltage mea sure ments and avoid sparks during load tests. Side terminal bat ter ies may need special adapters attached to make solid con nec tions for high current load tests. 3. Press the Amps/Volts Test Button. 4. With the Amp Probe jaws closed and not around any wires, press the Zero Amps button until the Amps Display shows Connect the Amp Probe around either analyzer load lead. Open Circuit Voltage Test Measure the open circuit (no load) stabilized voltage. A stabilized battery has no sur face charge, which means that the electrolyte has had a chance to remix and shed gas bub bles after current flow has stopped. With less than 12.4 volts, first recharge the battery. Open Ckt. Volts % of Charge Load Test 1. Determine the battery load test amperes from the battery test specification, CCA, or Ah ratings. To give consistent results a load test requires that a battery be at least 75% charged and not have been heavily used within the last 10 minutes. Cold Cranking Amperes at 0 F. (CCA) Use 1/2 the CCA for a load test. For example, 360 CCA divided by 2 equals a 180 ampere test load. Ampere Hour Rating (Ah) Multiply the Amp Hour Rating by 3 to obtain the load. For example, a 60 Ah battery times 3 equals a 180 ampere load. 2. Turn the Load Control Knob clockwise until the amps reading gradually reaches the required load. Watch the battery voltage. After 15 seconds at the test amperage, or if the voltage goes below the min i mum value, turn the load off. NOTE: The Load-on Lamp flashes and beeps once per second. After 16 seconds of load current, the beeper will sound continuously. LOAD TEST CAUTION If a battery smokes while being loaded, stop testing immediately. It is not safe. 3. Test Conclusions. If the battery voltage went below the min i mum volt age from the table during the test the battery is either dis charged or defective. Recharge and test again if necessary. At 70 F and higher a good battery will maintain an output of 9.6 volts or more during the loading period (4.8 volts for 6 volt bat ter ies). When a battery is cooler than 70 F, the output voltage re quire ment is reduced to give equivalent test con clu sions per the following table: ELECTROLYTE TEMP. MINIMUM F C LOADED VOLTS

7 Battery Test (Automatic) CAUTION Wear Safety Glasses, Do not break live circuits at the battery terminals, Avoid ac ci den tal ly shorting the insulated battery terminal to any ground metal. Never put a wrench on a live battery wire terminal. Burns may be the result. Dis con nect the battery chassis cable first. 1. Be sure the Load Knob is turned to OFF. 2. Connect the analyzer Battery Clamps to the battery ter mi nals; Red to positive, Black to negative. 3. With the Amp Probe jaws closed and not around any wires, press the Zero Amps buttons until the Amps Display shows Connect the Amp Probe around either analyzer load lead. 5. Press the BATT button. The analyzer will measure the Open circuit voltage of the battery. When the analyzer displays LOAd you should apply a load equal to 1/2 the Cold Cranking Amps rating. 6. Turn the Load Control Knob clockwise until the amps reading gradually reaches the required load. 7. When the Analyzer beeps, turn off the load. The analyzer will now measure battery recovery time and calculate the Cold Cranking Amps rating of the battery. 8. At the conclusion of the test, a report will be printed. Open Circuit Voltage Test The open circuit (no load) stabilized voltage of the Battery. An open circuit voltage of less than 12.4 volts indicates the battery should be charged before testing. * * * * * * * BATTERY TEST * * * * * * * Open Circuit Voltage Volts Load On Time 15 Seconds Load On Time The time, in seconds, that a load is being applied to a battery. Recovery Time The time it takes the battery to recover from the loaded voltage to 12.3 volts once the load is removed. Used to calculate the CCA of the battery. If it takes more than 30 seconds to recover, the battery is weak. Battery Loaded Voltage Final Load Current Recovery Time BATTERY TEMP. CCA: Over 15C/60F 697 O-15C/30-60F C/0-30F Volts 346 Amps 4 Seconds CCA Estimate The estimated Cold Cranking Amp rating of the battery. Three readings are given based on the battery temperature. Battery Data Tech Name Battery & Technicians Information Use this part of the report to write down the battery information, your name and the date the test was run. Date 7

8 Starter Test (Manual) When testing the starting system, fi rst test for battery performance. With a known good bat tery, the starter motor, cables and starter solenoid can be checked. Starter amps should not exceed the maximum specifi ed for the vehicle being tested, and the cranking RPM should be satisfactory. 1. Engine should be at normal op er at ing temperature. Make sure all lights and accessories are off and vehicle doors are closed. 2. Be sure the Load Knob is turned to OFF before connecting the analyzer cables to the battery. Take note of the safety pre cau tions on the back cover of this man u al. 3. Connect the analyzer Battery Clamps to the battery terminals; Red to positive, Black to negative. 4. With the Amp Probe jaws closed and not around any wires, press the Zero Amps button until the Amps Display shows Press the Amps/Volts button. 6. Place the Amp Probe around either of the en gines battery cables. 7. Set the Volts Selector to Battery Volts. 8. Disable the ignition or fuel system. 9. Crank engine for 15 seconds with ignition key and note the cranking amperage reading. Also, watch to see that the battery voltage stays above 9.6 V. Wait a few minutes for the starter to cool if the cranking test is repeated TYPICAL STARTER CRANKING DRAW Engine Size Cubic Inches Liters Amps Draw 100 to to to to to to to to to 300 NOTE: Higher starter amps may be encountered if engine temperatures are extremely hot or cold. 9. Test Conclusions. The system is good if the cranking speed is satisfactory and the battery voltage stayed above 9.6 volts. If Crank Speed was slow use the following chart. Voltage Drop Test Voltage Amps Likely Cause Below 9.6 High Bad Starter or a very hot or cold engine. Below 9.6 Low Bad Battery or Loose Battery Terminals. Above 9.6 Low Connections at Starter or Solenoid. The voltage drop test is a very helpful diagnostic test for de ter min ing the condition of cables and connections for the starting charging circuit. The voltage drop test can be used on any part of the circuit. In the example below, we are checking the entire circuit from the positive side of the battery to the starter. 1. Be sure the Load Knob is turned to OFF before connecting the analyzer cables to the battery. Take note of the safety pre cau tions on the back cover of this manual. 2. Connect the analyzer Battery Clamps to the battery terminals; Red to positive, Black to neg a tive. 3. Select external volts. 4. Connect the external volts leads as shown in the illustration. Connect the Red auxiliary lead to the positive side of the battery. Con nect the Black lead to the input terminal of the starter. 5. Disable ignition to prevent the engine from starting during the test. 4. Operate the Starter and read the volt me ter while cranking. 5. Test Conclusions. Good circuits drop less than 0.50 volts on a 12 volt system. Typ i cal ly you should not have more than 0.10 volts drop per connection. 8

9 When testing the starting system, fi rst test for battery performance. With a known good bat tery, the starter motor, cables and starter solenoid can be checked. Starter amps should not exceed the maximum specifi ed for the vehicle being tested, and the cranking RPM should be satisfactory. Starter Test (Automatic) 1. Be sure the Load Knob is turned to OFF. 2. Connect the analyzer Battery Clamps to the battery ter mi nals; Red to positive, Black to negative. 3. With the Amp Probe jaws closed and not around any wires, press the Zero Amps button until the Amps Display shows Connect the Amp Probe around either battery cable. 5. Connect the Red spark pickup around any spark plug wire. For ignition systems without spark plug wires, consult the operators manual. 6. Press the START button. 7. Disable the fuel or ignition system on the vehicle and crank the engine. 8. The bargraph will move indicating the measurements are being taken. When the bargraph will begin moving indicating the test is underway. When the HOLD indicator comes on the test is finished. Stop cranking. 9. At the conclusion of the test, a report will be printed. Cranking Speed The RPM of the engine while the starter is engaged trying to start the vehicle. Please note if you disable the ignition system, the RPM will be zero. Cranking Duration This is the length of time, in seconds, the starter was engaged for the test. Battery Voltage This is the battery voltage while the starter was engaged. * * * * * * * STARTING TEST * * * * * * * Cranking Speed 275 RPM Cranking Duration 15 Seconds Battery Voltage Volts Starter Draw 90 Amps Battery Data Tech Name Date Starter Draw This is the amperage draw of the starter. Battery & Technicians Information Use this part of the report to write down the battery information, your name and the date the test was run. 9

10 Alternator Output Test (Manual) Al ways compare test results with manufacturer s specifi cations before coming to conclusions regarding the performance or effi ciency of charg ing systems and their components. 1. Be sure the Load Knob is turned to OFF before connecting the analyzer cables to the battery. Take note of the safety pre cau tions on the back cover of this manual. 2. Connect the analyzer Battery Clamps to the battery terminals; Red to positive, Black to neg a tive. 3. With the Amp Probe jaws closed and not around any wires, press the Zero Amps but tons until the Amps Display shows Place the Amp Probe around the al ter na tor output wire. Try to po si tion the probe away from strong magnetism near the back shaft end of the al ter na tor to avoid mea sure ment error. 5. Press the Amps/Volts button 6. Start and run the engine at about 2000 RPM. 7. Turn the Load ON and increase until the battery voltage decreases to be between 12 and 13 volts while reading the output amperage. 8. Turn Load OFF and reduce RPM. 9. Test Conclusions If the Amps Ripple lamp stayed on during the output test replace the al ter na tor. If the amperage abruptly decreased during the test check for a loose belt. If output was less than 90% of rating use the voltage drop test to check output resistance. If output did not change, full field the alternator. If the alternator output increases, replace the regulator. Regulator Charging Voltage Test Follow the same setup and test procedure used for the alternator test, except put the Amp Probe around either battery cable. Once the charging amperage drops below 20 amps, the voltage displayed will be the regulator setting. This should be between 13.5 and 15.5 volts on a 12 volt system. 10

11 Alternator Output Test (Automatic) Al ways compare test results with manufacturer s specifi cations before coming to conclusions regarding the performance or effi ciency of charg ing systems and their components. 1. Be sure the Load Knob is turned to OFF. 2. Connect the analyzer Battery Clamps to the battery ter mi nals; Red to positive, Black to negative. 3. With the Amp Probe jaws closed and not around any wires, press the Zero Amps buttons until the Amps Display shows Place the Amp Probe around the al ter na tor output wire or positive battery cable. Try to po si tion the probe away from the back end of the al ter na tor to avoid mea sure ment error. 5. Connect the Red spark pickup around any spark plug wire. For ignition systems without spark plug wires, consult the operators manual. 6. Start and Run the Engine. 7. Press the CHARGE button. 8. Run the engine at about 1500 RPM, and apply a load until the battery voltage decreases to 12.5 volts. The bargraph will move indicating the measurements are being taken. The HOLD indicator will come on signaling the end of the test. 9. At the conclusion of the test, turn the load off and let the engine idle. A report will be printed. Engine Speed The RPM of the engine. Battery Voltage This is the battery voltage during the test. Alternator Output This is the amperage output of the Alternator. Alternator Ripple If their is excessive alternator ripple, the printout will show that the amps ripple is high, otherwise, it will print O.K. * * * * * * * CHARGING TEST * * * * * * * Engine Speed 1500 RPM Battery Voltage Volts Alternator Output 90 Amps Alternator Ripple OK Battery Data Tech Name Date Battery & Technicians Information Use this part of the report to write down the battery information, your name and the date the test was run. 11

12 SAFETY PRECAUTIONS Always wear eye protection when testing vehicles. Be extra careful near batteries and moving parts. Do not lay tools on a battery. Battery gas is highly explosive. a. If a battery explodes flush the acid away from persons skin with generous amounts of water. Follow up with a neutralizing solution of baking soda and then more water. Treat clothing, vehicle parts, and equipment similarly. Any acid traces inside equipment must be removed by generous rinsing. Dry equipment and place in a warm 50 C (120 F) oven until thoroughly dry. b. Never use a wrench on the ungrounded battery terminal until the grounded one has been disconnected. Contact between the vehicle body metal and the hot terminal can cause sparks to ignite gas or even weld tools into a battery short circuit. c. Keep the space around a battery well ventilated. d. Do not make sparks or allow flames near batteries. Before working on a vehicle set the brakes and block the wheels. Beware of automatic parking brake releases. Keep your work area well ventilated and free of exhaust. Engine exhaust contains deadly poisons. Treat Gas Detector exhaust and drain hoses the same as the vehicle tailpipe. Both give off deadly exhaust fumes. Avoid electrical shocks caused by getting close to live ignition wires or touching the coil TACH terminal. A person s reaction near a live engine can be more damaging than the shock. Keep spark producing devices at least 0.5m (18 ) above the floor to reduce the hazard of igniting gasoline vapor. Do not let test leads wind up in a moving fan or pulley. Route leads away. Remove finger rings and metal wrist bands. They can short terminals and become very hot from electric current E044-01G