Battery Management Innovation DIAGNOSTIC CONDUCTANCE CHARGER. For testing and charging 12-volt automotive batteries INSTRUCTION MANUAL

Transcription

1 Battery Management Innovation DIAGNOSTIC CONDUCTANCE CHARGER For testing and charging 12-volt automotive batteries INSTRUCTION MANUAL

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3 Contents Safety instructions... 3 Installing the handle... 9 Operation Front panel Back panel Charging modes Diagnostic fast charge Connect the charger to the battery Connect to AC power Select charging mode Select charge type Select battery location Select battery type Enter battery rating Diagnostic testing Diagnostic charging Automatic charging Charge completion Top-off charging Top-off charge completion Test code generation Recovery mode Recovery mode charge completion Manual charge Connect the charger to the battery Connect to AC power Select charging mode Select battery type Select charge current Enter battery rating Enter charging time Timed charging Timed charge completion Continuous charging Continuous charge completion

4 Contents Jump start vehicle Connect the charger to the battery Connect to AC power Select charging mode Options menu View test codes View last test data Print last test data Select language Troubleshooting Error messages Charger operation Maintenance Patents, Service

5 ! SAFETY INSTRUCTIONS DANGER Safety Instructions CAUTION: Because of the possibility of personal injury, always use the following precautions when working around batteries. Never smoke or cause a spark or flame in the vicinity of the battery or engine. Always wear complete eye protection: Explosive gases can cause blindness or injury Lead-acid batteries contain sulfuric acid that can cause blindness or severe burns Required by California Proposition 65 WARNING: 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. IMPORTANT: READ AND SAVE THIS SAFETY AND INSTRUCTION MANUAL. KEEP IT WITH OR NEAR THE CHARGER AT ALL TIMES. 1. IMPORTANT SAFETY INSTRUCTIONS WARNING: RISK OF EXPLOSIVE GASES 1.1 WORKING IN THE VICINITY OF A LEAD-ACID BATTERY IS DANGEROUS. BATTERIES GENERATE EXPLOSIVE GASES DURING NORMAL BATTERY OPERATION AND WHEN DISCHARGED OR CHARGED. FOR THIS REASON IT IS OF UTMOST IMPORTANCE THAT EACH TIME BEFORE USING YOUR CHARGER, YOU RE-READ THIS MANUAL AND MAKE CERTAIN YOU FULLY UNDERSTAND IT AND FOLLOW THE SAFETY AND OPERATING INSTRUCTIONS EXACTLY. 1.2 To reduce the risk of a battery explosion, follow these safety instructions and those published by the battery manufacturer and the manufacturer of any equipment you intend to use in the vicinity of a battery. Review cautionary markings on these products and on the vehicle engine and on the vehicle or equipment containing the battery. 1.3 CAUTION: To reduce the risk of injury, charge only rechargeable LEAD-ACID TYPE batteries which may include MAINTENANCE-FREE, LOW-MAINTENANCE OR DEEP CYCLE batteries. Other types of batteries may burst causing personal injury and damage. If you are uncertain as to the type of battery you are attempting to charge or the correct procedure for checking the battery s state of charge, contact the seller or battery manufacturer. 3

6 1.4 The use of an attachment not recommended or sold by the battery charger manufacturer may result in a risk of fire, electric shock, or injury to persons. 1.5 To reduce risk of damage to the electric plug and cord, pull by the plug rather than the cord when disconnecting the charger. Have a damaged cord or plug replaced immediately. 1.6 Position the AC and DC leads to avoid tripping over them and to prevent damage by the vehicle hood, doors, or moving engine parts; protect the leads from heat, oil, and sharp edges. 1.7 Do not operate the charger if it has received a sharp blow, been dropped or otherwise damaged in any way; take it to a qualified service center. 1.8 Do not disassemble the charger; take it to a qualified service center when repair is required. Incorrect reassembly may result in a risk of electric shock or fire. 1.9 If the charger is in need of service, call Midtronics at or To reduce the risk of electric shock, unplug the charger from the AC outlet before attempting any maintenance or cleaning. Turning off the controls will not reduce this risk BOAT BATTERIES MUST BE REMOVED AND CHARGED ON SHORE. TO SAFELY CHARGE THEM ON BOARD REQUIRES EQUIPMENT SPECIALLY DESIGNED AND UL LISTED FOR MARINE USE Do not overcharge the battery. See 3. Preparing to Charge the Battery When charging a battery, place it in a dry, well-ventilated area Never place articles on or around the charger or position the charger in a way that will restrict the flow of cooling air through the cabinet An extension cord should not be used unless absolutely necessary. See Safety Instructions (4.3) Do not expose the charger to rain or snow. Safety Instructions 2. PERSONAL PRECAUTIONS 2.1 Always have someone within range of your voice or close enough to come to your aid when working around lead-acid batteries. 2.2 Have plenty of fresh water and soap nearby in case battery acid contacts skin, clothing, or eyes. 2.3 Wear complete eye protection, clothing protection, and wear rubber soled shoes. When the ground is very wet or covered with snow, wear rubber boots. Avoid touching eyes while working near the battery. 2.4 If battery acid contacts skin or clothing, wash immediately with soap and water. If acid enters the eyes, immediately flush them with running cold water for at least 10 minutes and get a doctor s attention. 4

7 2.5 NEVER smoke or allow a spark or flame in the vicinity of the battery or engine. Safety Instructions 2.6 Be extra cautious to reduce the risk of dropping a metal tool onto the battery. It might spark or short circuit the battery or other electrical part that may cause an explosion. 2.7 Before working with a lead acid battery, remove personal metal items such as rings, bracelets, necklaces, watches, etc. A lead acid battery can produce a short-circuit current high enough to weld such items causing a severe burn. 2.8 Use the charger for charging LEAD-ACID batteries only. The charger is not intended to supply power to a low-voltage electrical system other than applications using rechargeable, lead-acid type batteries. Do not use the charger for charging dry-cell batteries commonly used with home appliances. These batteries may burst and cause personal injury and property damage. 2.9 NEVER charge a frozen battery; thaw it out first. 3. PREPARING TO CHARGE THE BATTERY 3.1 If necessary to remove the battery from the vehicle to charge, always first remove the grounded terminal from the battery. Make sure all accessories in the vehicle are off to prevent an arc. 3.2 Be sure the area around battery is well ventilated while the battery is being charged. Gas can be forcefully blown away by using a piece of cardboard or other nonmetallic material as a fan. 3.3 Clean the battery terminals. Be careful to keep corrosion from coming into contact with your eyes. 3.4 Add distilled water in each cell until the battery acid reaches the level specified by the manufacturer. This helps purge excessive gas from the cells. Do not overfill. For a battery without caps, carefully follow the manufacturer s recharging instructions. 3.5 Study all the battery manufacturer s specific precautions such as removing or not removing cell caps while charging and the recommended rates of charge. 3.6 Determine the voltage of battery by referring to the vehicle owner s manual and make sure that the output voltage menu selection is set at the correct voltage. The charger has adjustable charge rates, so charge the battery initially at lowest rate. If the charger has only one voltage, verify that the battery voltage matches the voltage of charger. 4. AC POWER CORD CONNECTION INSTRUCTIONS 4.1 The charger must be grounded to reduce the risk of electric shock. The charger is equipped with an electric cord having an equipment grounding conductor and a grounding plug. The plug must be plugged into an outlet that is properly installed and grounded in accordance with all local codes and ordinances. DANGER: NEVER ALTER THE AC CORD OR PLUG PROVIDED. IF IT WILL NOT FIT OUTLET, HAVE A PROPER OUTLET INSTALLED BY A QUALIFIED ELECTRICIAN. AN IMPROPER CONNECTION CAN RESULT IN THE RISK OF AN ELECTRIC SHOCK. 5

8 Safety Instructions 4.2 This battery charger is for use on a nominal 120-volt circuit and has a grounding plug that looks like the plug illustrated in Figure A. A temporary adapter, which looks like the adapter illustrated in Figures B and C, may be used to connect this plug to a two-pole receptacle as shown in Figure B if a properly grounded outlet is not available. The temporary adapter should be used only until a properly grounded outlet can be installed by a qualified electrician. DANGER: BEFORE USING AN ADAPTER AS ILLUSTRATED, BE CERTAIN THAT THE CENTER SCREW OF THE OUTLET PLATE IS GROUNDED. THE GREEN-COLORED RIGID EAR OR LUG EXTENDING FROM THE ADAPTER MUST BE CONNECTED TO A PROPERLY GROUNDED OUTLET MAKE CERTAIN IT IS GROUNDED. IF NECESSARY, REPLACE THE ORIGINAL OUTLET COVER PLATE SCREW WITH A LONGER SCREW THAT WILL SECURE THE ADAPTER EAR OR LUG TO THE COVER PLATE AND MAKE THE GROUND CONNECTION TO THE GROUNDED OUTLET. 4.3 An extension cord should not be used unless absolutely necessary. Use of an improper extension cord could result in a risk of fire and electric shock. If an extension cord must be used, make sure that: a) The pins on plugs of the extension cord are the same number, size, and shape as those of the plug on the charger; b) The extension cord is properly wired and in good electrical condition; and c) The wire size is large enough for the AC ampere rating of the charger as specified in the following table: 6

9 5. CHARGER LOCATION Safety Instructions 5.1 Locate the charger as far away from the battery as the charger cables permit. 5.2 Never place the charger directly above the battery being charged; gases from the battery will corrode and damage the charger. 5.3 Never allow battery acid to drip on the charger when taking gravity readings or filling a battery. 5.4 Operate the charger only in a well ventilated area, free of dangerous vapors. 5.5 Store the charger in a safe, dry location. 5.6 Do not set the battery on top of the charger or where its acid might drip onto charger. 6. DC CONNECTION PRECAUTIONS 6.1 Turn the power switch to the OFF position and disconnect the AC cord from the electrical outlet before you connect and disconnect charger clamps. Never allow the clamps to touch each other. 6.2 When attaching the charger clamps, be certain to make the best possible mechanical as well as electrical connection. This will tend to prevent the clamps from slipping off the connections, avoid dangerous sparking, and assure safer and more efficient charging. Clamps should be kept clean. CAUTION: Setting the power switch to OFF does not always eliminate an electrical charge in the charger s circuitry or clamps. 7. CHARGER CONNECTION FOR A BATTERY IN THE VEHICLE 7.1 Before working on the vehicle, firmly apply the emergency brake and place the manual transmission gear shift to NEUTRAL or shift the automatic transmission to PARK. 7.2 Locate the charger as far away from the battery as the charger cords permit and position the AC and DC cords to avoid stepping on or tripping over them and to prevent damage by the hood, doors, or moving engine parts. 7.3 Stay clear of fan blades, belts, pulleys, and any other parts the can cause physical injury. 7.4 Turn OFF all vehicle loads, including the door lights. 7.5 Check the polarity of the battery posts. The POSITIVE (POS., P, +) post usually has a larger diameter than the NEGATIVE (NEG., N, ) post. 7.6 Determine which post of battery is grounded (connected) to chassis. If the negative post is grounded (as in most vehicles), see paragraph 7.7. If the positive post is grounded, see paragraph 7.8 or call Midtronics at or

10 Safety Instructions 7.7 For a negative-grounded vehicle, first connect the POSITIVE (RED) charger clamp to the POSITIVE (POS., P, +) ungrounded post of the battery. Then connect the NEGATIVE (black) clamp from the charger to the NEGATIVE (NEG., N, ) post. Do not connect the clamp to the carburetor, fuel lines, or sheet-metal body parts. When disconnecting the charger, turn all switches to OFF, disconnect AC cord, and remove the NEGATIVE clamp and then the POSITIVE clamp. 7.8 For a positive-grounded vehicle, connect the NEGATIVE (BLACK) charger clamp to the NEGATIVE (NEG., N, ) ungrounded post of battery. Then connect the POSITIVE (RED) clamp from the charger to the POSITIVE (POS., P, +) post. Do not connect the clamp to the carburetor, fuel lines, or sheet-metal body parts. When disconnecting the charger, turn all switches to OFF, disconnect AC cord, and remove the POSITIVE clamp and then the NEGATIVE clamp. CAUTION: WHEN THE POSITIVE (+) POST OF THE VEHICLE BATTERY IS GROUNDED, DOUBLE CHECK THE POLARITY. 8. CHARGER CONNECTION FOR A BATTERY NOT IN THE VEHICLE If necessary to remove the battery from the vehicle or equipment, always first remove the grounded terminal from the battery. WARNING: To prevent a possible arc, make sure all vehicle loads are OFF. FOLLOW THESE STEPS WHEN THE BATTERY IS OUTSIDE OF THE VEHICLE. A SPARK NEAR THE BATTERY MAY CAUSE AN EXPLOSION. TO REDUCE RISK: 8.1 Check the polarity of the battery posts. The POSITIVE (POS., P, +) post usually has a larger diameter than the NEGATIVE (NEG., N, ) post. 8.2 Connect the POSITIVE (RED) charger clamp to the POSITIVE (POS., P, +) post of the battery. Then connect the NEGATIVE (BLACK) charger clamp to the NEGATIVE (NEG., N, ) post of the battery. 8

11 INSTALLING THE HANDLE Installing the Handle CAUTION: The charger must be fully assembled before operating. 1. Locate the handle and hardware provided. 2. Position the handle so that the angle faces away from the back of the charger and all mounting holes line up. Refer to the drawing. 3. Use all 4 screws to attach the handle to the back of the charger. Clamp holder bar Screws (4) for attaching the handle 9

12 OPERATION Charging Modes: Diagnostic Fast Charge Before using the GR1-120 Diagnostic Conductance Charger, visually inspect the battery. If there are any signs of a leaking or cracked case, discard the battery. Do not attempt to charge a battery that is in this condition. Front panel Under the GR1-120 display there are 5 push-buttons and an ON/OFF switch. The DOWN/UP ARROW buttons are used for scrolling to selections on the display and to increase/decrease displayed values. The ENTER button is used to accept the displayed selection and to continue to the next step. The INFO button is used to display the options menu, which accesses the Test Codes, Last Test Data, Language setup (English, French, or Spanish), and the printer (optional). The STOP button is used to abort any charging cycle. During menu selections, it can be used to go back to the previous step. Back panel The back panel houses the outlets for the positive and negative charging cables, the AC power cord, and a 9-pin connector. The handle, which attaches to the back panel, includes a clamp-holder bar. When used consistently, this feature adds safety, convenience and longer operating life to the clamps, cables, and charger. 10

13 Charging Modes Charging Modes: Diagnostic Fast Charge Important: Clean the battery terminals. If stud adapters are required, fasten them with the proper tool. Do not use the battery clamps to tighten adapters. Never remove the clamps from a battery to abort an active charging session. Always press the red STOP button before removing the clamps. Do not leave the clamps laying in battery acid. Hang the clamps to the clamp-holder bar when the charger is not in use. Charger handle Clamp-holder bar Clean up any acid spills immediately with baking soda and water. The clamps should be kept clean. Improper use of the 9-pin connector may cause permanent damage to the charger. 1. DIAGNOSTIC FAST CHARGE 1.1 CONNECT THE CHARGER TO THE BATTERY Important: Before connecting the clamps to the battery, turn the power switch to the OFF position and disconnect the AC power cord from the electrical outlet Connect the charging clamps to the battery in accordance with all precautions and safety instructions Do not connect either clamp to the vehicle chassis. 1.2 CONNECT TO AC POWER Plug the charger into a dedicated, grounded 15-amp AC outlet. Press the power switch to the ON position. If the clamps are not making good contact to the battery posts, the charger will ask you to check the connection. Make sure that both jaws of the charging clamp come in good contact with the connection point. Check Clamp Connections will remain on the display as long as half of one clamp is not making good contact. If you accidentally reverse the clamp connections, the charger will sound an alarm and display Charger Clamps Reversed. Press the power switch to the OFF position and reconnect the clamps. GR-1 Fast Charger X4.2 (c) Midtronics, Inc Check Clamp Connections Charger Clamps Reversed 11

14 1.3 SELECT CHARGING MODE Use the DOWN/UP! "#buttons to select Diagnostic Fast Charge. Press the ENTER button to continue. Charging Modes: Diagnostic Fast Charge Mode Diagnostic Fast Charge 1.4 SELECT CHARGE TYPE Use the DOWN/UP! "#buttons to select the battery charge type: Dealer Inventory or In Service. Press the ENTER button to continue. Select Charge Type Dealer Inventory 1.5 SELECT BATTERY LOCATION Use the DOWN/UP! " buttons to select the location of the battery: In Vehicle or Out of Vehicle. Press the ENTER button to continue. Battery Location In Vehicle 1.6 SELECT BATTERY TYPE Use the DOWN/UP! " buttons to select the battery type: Lead Acid or AGM/Spiral. Press the ENTER button to continue. Select Battery Type Lead Acid 1.7 ENTER BATTERY RATING Use the DOWN/UP! " buttons to enter the battery rating from 100 to 1500 CCA. Press the ENTER button to continue. The Diagnostic Fast Charge cycle will begin automatically. Enter Rating 500 CCA The charger will control the entire charging session including the initial diagnostic testing and charging, data analysis, charging duration, charging level, charging rate, top-off charging (when appropriate), and final diagnostic testing. DIAGNOSTIC TESTING The charger will quickly perform a number of tests to analyze the battery. During some initial diagnostic tests it will display a moving status bar. If the analysis finds a battery to be bad, the charger stops and displays Replace Battery or Replace-Bad Cell.... Analyzing Battery V 345CCA 0:00:00 Replace Battery AH: 0.0 If the analysis finds a good battery with a sufficient state of charge, the charger stops and displays the results V 0:00:00 Good Battery AH:

15 The display will alternate between the result and a message to press ENTER for the test code (see Test Code Generation. Charging Modes: Diagnostic Fast Charge DIAGNOSTIC CHARGING If the analysis finds a battery with insufficient state of charge, the charger begins the diagnostic charging mode. This mode greatly enhances the charger s ability to judge hard-to-diagnose batteries. 15.5V 42.5A 0:02:34 Diagnostic Mode AH: 1.7 The length of time required for diagnostic charging varies depending on the battery type. During this diagnostic mode, which does not exceed 5 minutes, the charger keeps you informed by displaying the charging voltage, charging current, remaining time to charge, charging mode, and the amount of charge put back into the battery in amp-hours. As in diagnostic testing, during some parts of diagnostic charging the display will show a moving status bar. If a decision is not made during Diagnostic Mode, the charger will proceed to Automatic Charging Mode. The charger alerts you of this transition with a message and an alarm. AUTOMATIC CHARGING The charger controls the charging voltage and charging current based on its analysis of the diagnostic testing and charging data, and the battery information that you selected. The charger continuously monitors the battery and analyzes the charging progress during the entire automatic charging session. In some cases the charger may find a battery to be bad before the end of the estimated time to charge. In other cases the charger may detect that the battery has charged more quickly than estimated. In either case the charger will alert you with an alarm and the appropriate message. For batteries that are weak or hard to charge the display may show Recovery Mode. In this mode the charging algorithm is optimized to try to recover the battery. 13

16 During charging, the charger displays the charging voltage, charging current, remaining time to charge, the charging mode, and the amount of charge put back into the battery in amp-hours. Charging Modes: Diagnostic Fast Charge 14.5V 35.5A Tmax=0:32:27 Automatic Charge AH: 4.6 Note: If you need to stop (abort) the charging session, press the STOP button. However, you will not be able to obtain a test code after an aborted charge V 246CCA 0:00:20 Charging Aborted AH: 0.0 CHARGE COMPLETION The automatic charge session is complete when the proper amount of charge is put back into the battery or the remaining time to charge goes to zero. The charger will then perform its final diagnostic tests on the battery. When the analysis is complete, the charger will alert you with an alarm and display the battery voltage, available starting current in CCA, total charging time, battery condition, and the final amount of charge put back into the battery in amp-hours. The display will alternate between the results and a message to press ENTER for the test code. (See Test Code Generation. ) The alarm will sound every 30 seconds until you press the STOP button or disconnect the charger clamps from the battery.... Analyzing Battery V 645CCA 0:40:36 Good Battery AH: 27.1 Press Enter For Code TOP-OFF CHARGING When the result is Good Battery, the charger will go into Top-Off Mode. You have the option of stopping Top-Off Mode by pressing the STOP button or the charger will stop automatically when the charging current drops below 2 amps. The charger alerts you of the transition with a message and an alarm. During Top-Off Mode, the charger sounds an alarm every minute and displays the charging voltage, charging current, Top-Off Mode message, and the amount of charge put back into the battery in amp-hours. 14

17 Charging Modes: Diagnostic Fast Charge 13.3V 9.4A Top-Off Good Battery AH: 23.1 Cycled messages inform you that the battery is ready to be put back into service: Good Battery / Top-Off Charging / Hit STOP To End. 13.3V 9.4A Top-Off Top-Off Charging AH: V 9.4A Top-Off Hit STOP To End AH: 23.1 TOP-OFF CHARGE COMPLETION When Top-Off Mode is complete, the charger will alert you with an alarm and display the battery voltage, battery condition, and the amount of charge put back into the battery in amp-hours. The display will alternate between the final results and a message to press ENTER for the test code. (See Test Code Generation. ) 12.74V 0:45:16 Good Battery AH: 28.2 The alarm will sound every 30 seconds, until the you press the STOP button or disconnect the charger clamps from the battery. TEST CODE GENERATION Before the charge session is finished the display will alternate between the final results and a prompt to press the ENTER button to generate the test code. Press the INFO ( i ) button to print the test codes and the final results. To return to the Mode selection screen and start a new charge session, press the STOP button. Test Code A1B2C 3D4E5 F6 15

18 Charging Modes: Diagnostic Fast Charge RECOVERY MODE Under certain conditions the charger will switch from Automatic Charge to Recovery Mode to fully charge the battery. The maximum charge time in Recovery Mode is 5 hours; however, most batteries will finish charging sooner. During Recovery Mode the charger will continuously analyze the battery to make a decision as quickly as possible RECOVERY MODE CHARGE COMPLETION When Recovery Mode ends, the charger will display the battery voltage, available starting current in CCA, battery condition and the final amount of charge put back into the battery in amp-hours. This display will alternate between the final results and a message to press ENTER for the test code. (See Test Code Generation. ) If the decision was Good Battery, the charger will proceed to Top-Off Mode V 365CCA 1:45:16 Replace Battery AH: V 9.4A Top-Off Good Battery AH: 23.1 The alarm will sound every 30 seconds until you press the STOP button again or disconnect the charger clamps from the battery. 16

19 2. MANUAL CHARGE Note: Manual Charge does not generate test codes. Charging Modes: Manual Charge 2.1 CONNECT THE CHARGER TO THE BATTERY Important: Before connecting the clamps to the battery, turn the power switch to the OFF position and disconnect the AC power cord from the electrical outlet Connect the charging clamps to the battery in accordance with all precautions and safety instructions Do not connect either clamp to the vehicle chassis. 2.2 CONNECT TO AC POWER Plug the charger into a dedicated, grounded 15-amp AC outlet. Press the power switch to the ON position. If the clamps are not making good contact to the battery posts, the charger will ask you to check the connection. Make sure that both jaws of the charging clamp come in good contact with the battery post. Check Clamp Connections will remain on the display as long as half of one clamp is not making good contact. If you accidentally reverse the clamp connections, the charger will sound an alarm and display Charger Clamps Reversed. Press the power switch to the OFF position and reconnect the clamps. GR-1 Fast Charger X4.2 (c) Midtronics, Inc Check Clamp Connections Charger Clamps Reversed 2.3. SELECT CHARGING MODE Use the DOWN/UP! "#buttons to select Manual Charge. Press the ENTER button to continue. Mode Manual Charge 2.4 SELECT BATTERY TYPE Use the DOWN/UP! " buttons to select the battery type: Lead Acid or AGM/Spiral. Press the ENTER button to continue. Select Battery Type Lead Acid 2.5. SELECT CHARGE CURRENT Use the DOWN/UP! " buttons to select the output current: 10 Amp Mode, 30 Amp Mode, or 60 Amp Mode. Press the ENTER button to continue. Select Charge Current 10 Amp Mode Notes: When in doubt, start with the lowest charging rate. If you select 60 Amp Mode, the charger will automatically switch to 30 Amp Mode after one hour of timed or continuous charging. 17

20 2.6 ENTER BATTERY RATING Use the DOWN/UP! " to enter a battery rating from 100 to 1500 CCA. Press the ENTER button to continue. Charging Modes: Manual Charge Enter Rating 500 CCA 2.7 ENTER CHARGING TIME Use the DOWN/UP! " buttons to select the charging time from 5 to 120 minutes. Press the ENTER button to begin the timed charge. Enter Charging Time 120 Minutes Using the UP " button to scroll past 120 minutes will select the Continuous Charge mode. Press the ENTER button to begin the continuous charge. (The STOP button is used to turn off continuous charging.) Important: During Manual Mode, the GR1-120 charges the battery based on the voltage, current, and charge duration that you select. Because the charger does not monitor the charging progress to optimize charging levels or reduce charging, you should monitor the battery s state of charge and temperature. Any charging after the battery is fully charged will result in excessive battery temperature and gassing, which can shorten battery life. Enter Charging Time Continuous Charge TIMED CHARGING If you have selected a charging time (between 5 and 120 minutes), the charger will analyze the battery, briefly display the measured voltage and available starting current in CCA, and begin charging at the selected levels. During charging the charger keeps you informed by displaying the charging voltage, charging current, remaining time to charge, charging mode, and the amount of charge put back into the battery in amp-hours. TIMED CHARGE COMPLETION The manual charge session is complete when the selected time to charge goes to zero. The charger will alert you with an alarm and display the ending charge voltage, total charging time, charging mode, and the final amount of charge put back into the battery in amp-hours.... Analyzing Battery V 12CCA Battery Test Information 14.5V 35.5A 1:02:34 Manual Charge AH: V 1:20:00 Manual Charge AH: 57.2 The alarm will sound every 30 seconds until you press the STOP button or disconnect the charger clamps from the battery. 18

21 CONTINUOUS CHARGING If Continuous Charge is selected, the charger will analyze the battery, briefly display the measured voltage and available starting current in CCA, and begin charging at the selected levels. During charging, the charger keeps you informed by displaying the charging voltage, charging current, charging mode (Manual Charge), and the amount of charge put back into the battery in amp-hours. To stop the charging session, press the STOP button. Charging Modes: Manual Charge... Analyzing Battery V 12CCA Battery Test Information 12.7V 9.8A - :- - :- - Manual Charge AH: 11.4 CONTINUOUS CHARGE COMPLETION The Continuous Charge session is complete when you press the STOP button. When finished, the charger will sound an alarm and display the ending charge voltage, charging mode, and the final amount of charge put back into the battery in amp-hours V - :- - :- - Manual Charge AH: 57.2 The alarm will sound every 30 seconds until you press the STOP button or disconnect the charger clamps from the battery. 19

22 3. JUMP START VEHICLE Charging Modes: Jump Start Vehicle 3.1 CONNECT THE CHARGER TO THE BATTERY Important: Before connecting the clamps to the battery, turn the power switch to the OFF position and disconnect the AC power cord from the electrical outlet Connect the charging clamps to the battery in accordance with all precautions and safety instructions Do not connect either clamp to the vehicle chassis. 3.2 CONNECT TO AC POWER Plug the charger into a dedicated, grounded 15-amp AC outlet. Press the power switch to the ON position. If the clamps are not making good contact to the battery posts, the charger will ask you to check the connection. Make sure that both jaws of the charging clamp come in good contact with the connection point. Check Clamp Connections will remain on the display as long as half of one clamp is not making good contact. If you accidentally reverse the clamp connections, the charger will sound an alarm and display Charger Clamps Reversed. Press the power switch to the OFF position and reconnect the clamps. GR-1 Fast Charger X4.2 (c) Midtronics, Inc Check Clamp Connections Charger Clamps Reversed 3.3 SELECT CHARGING MODE Use the DOWN/UP! "#buttons to select Jump Start Vehicle. Press the ENTER button to continue. This charging mode makes high output current available to boost charge an in-vehicle battery as well as assist in starting the engine. Mode Jump Start Vehicle Analyzing Battery The charger will analyze the battery and then prompt you to begin boost charging. Boost charging will improve the battery s ability to start the engine in the next step. The charger will inform you that the battery is being boost charged. Charging will take less than a minute. When the charger determines the optimal time to crank the engine, it will inform you. You can crank the engine for up to 5 seconds. Press ( ) to begin boost charge Boost charging battery, wait for beep to crank.. *** Crank Engine Now *** The charger will inform you when the jump start function is complete. 20

23 OPTIONS MENU Options Menu The following options are available when you press the INFO ( i ) button while in the Charging Mode menu. To exit the test codes display and to access the other options, press the INFO ( i ) button again. 1. VIEW TEST CODES Test codes can be viewed at the end of the charging session and anytime before the next charging session. New test codes automatically overwrite the old test codes. Press the INFO ( i ) button. Use the DOWN/UP! " buttons to select View Test Codes. Options View Test Codes Press the ENTER button to display the test codes for the most recently completed charge session in automatic or recovery mode. If the charge session is aborted or a manual charge is performed, no code is generated. Test Code A1B2C 3D4E5 F6 Test Codes No Valid Codes Available Press the INFO ( i ) button to return to the Options menu. Press it again to return to the Charging Mode menu. 2. VIEW LAST TEST DATA Press the INFO ( i ) button. Use the DOWN/UP! " buttons to select View Last Test Data. Press the ENTER button to display the results for the most recently completed charge session. The charger saves the final test data, which includes the battery voltage, available starting current in CCA, total charging time, battery condition, and the final amount of charge put back into the battery in amp-hours. Options View Last Test Data 12.15V 365CCA 1:40:36 Replace Battery AH:

24 Press the INFO ( i ) button to return to the Options menu. Press it again to return to the Charging Mode menu. Options Menu 3. PRINT LAST TEST DATA Press the INFO ( i ) button. Use the DOWN/UP! " buttons to select Print Last Test Data. Press the ENTER button to start printing. The charger prints out the final battery state of charge (SOC), final measured capacity for Replace decisions, rated capacity, battery decision, charging mode, amphours put back into the battery, and charging time. Options Print Last Test Data Printing 4. SELECT LANGUAGE Press the INFO ( i ) button. Use the DOWN/UP! " buttons to select Language. Press the ENTER button to continue. Use the DOWN/UP! " buttons to select a language: English, Español/Spanish, or Français/French. Press the ENTER button to save the new language selection, and to return to the Options menu. Press the INFO ( i ) button again to return to the Charging Mode menu. Options Language/Idioma/Langue Select Language English 22

25 Error messages TROUBLESHOOTING Troubleshooting 1. The Incorrect Voltage Error message means that you have made an incorrect menu selection (for example, selected 12 V, but connected to 24 V) or that the charger was connected across a battery voltage for which the charger is not rated. 2. The Overcurrent Error! message means that a battery or vehicle electrical system has tried to draw too much current from the charger. Observe all ratings, limits, precautions and warnings. Check all connections and charger menu selections. 3. The Hardware Check Connect message means that there is a poor connection between the battery and the charger. For this error, disconnect the clamps and reconnect them to try and improve the connection. 4. The Internal Memory Error message means that an internal error has occurred in the charger and it should be sent back for service. See back page for details. 5. The Tool Diagnostic Failure! message means that the charger has failed a hardware diagnostic test on the chargers internal components. If this condition occurs repeatedly, the charger should be sent back to Midtronics for service. Incorrect Voltage Error Disconnect Clamps Overcurrent Error! Hardware Check Connect Press ( ) to continue Internal Memory Error Return Tool for Service Tool Diagnostic Failure! Error Code 10 Charger operation 1. The ON/OFF switch is toggled to the on position but the charger does not power up. a. Make sure the AC power cord is completely inserted into the AC outlet. b. Make sure the AC outlet is live (check fuse or circuit breaker). c. Check the AC power cord for damage. 2. The charger is on, the clamps are properly connected, but the display still shows Check Clamp Connections. a. Make sure that both jaws of the charging clamp come in good contact with the battery post. Check Clamp Connections will remain on the display as long as half of one clamp is not making good contact. 3. The charger is displaying messages in the wrong language. a. See 4. Select Language in Options Menu. 23

26 Take proper care of your GR1-120: MAINTENANCE Maintenance Clean the display with a standard window cleaning solution. Never allow the clamps or cables to lay in battery acid Clean up any acid spills immediately with baking soda and water. To ensure proper operation, keep the charger clamps clean. Liberally apply baking soda and water with a clean cloth and rub thoroughly on the jaw and spring. Rinse with water and let dry. Use a soft wire brush to remove corrosion buildup. 24

27 PATENTS This charger is made in the U.S.A. by Midtronics, Inc. and is protected by one or more of the following U.S. Patents: 6,445,158; 6,441,585; 6,424,158; 6,392,414; 6,363,303; 6,359,441; 6,351,102; 6,329,793; 6,313,608; 6,304,067; 6,259,254; 6,163,156; 6,104,167; 6,091,245; 6,081,098; 6,051,976; 6,037,751; 5,831,435; 5,821,756; 5,757,192; 5,656,920; 5,592,093; 5,589,757; 5,585,728; 5,583,416; 5,572,136; 5,469,043; 4,912,416; 4,881,038; 4,825,170; 4,816,768; Canadian patents: 1,295,680; 1,280,164; United Kingdom patents: 0,672,248; 0,417,173; German patents: P ; ; P ; European patent: C ; Japanese patents: C ; ; Australian patent: C ; New Zealand patents: ; C ; and other U.S. and Foreign patents issued and pending. This product may utilize technology exclusively licensed to Midtronics, Inc., by Johnson Controls, Inc., and/or Motorola, Inc. SERVICE To obtain service, purchaser should contact Midtronics for a Return Authorization number, attach a copy of proof of purchase, and return the unit to Midtronics, Attention: Service Department / RA #, 7000 Monroe Street, Willowbrook, IL If Midtronics determines that the failure was caused by misuse, alteration, accident, or abnormal condition of operation or handling, you will be contacted for approval to be billed for repair of the product at current service repair rates. It will be returned freight prepaid. Battery chargers beyond the warranty period are also subject to the current service repair rates plus shipping and handling charges. Optional remanufacturing service is available with a six month warranty. Ask your customer service representative for information and RA#,

28 P/N A 4/ Midtronics, Inc.