Midtronics DCA-8000 User Manual

July 2018

167-000837EN-A

DCA-8000

Controlled Charger

Users Guide

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DCA-8000

Contents

General Safety Precautions	6
General Safety Precautions	6
Personal Precautions	7
Preparing To Charge The Battery	7
Grounding & Power Cord Connections	8
Charger Location	9
DC Connection Precautions	10
Installing The Battery	10
Removing the Battery	10
Maintenance & Storage	11
Locking Power Cord	11
Wireless Safety	11
Product Specifications	12
1 – Introduction & Overview	13
Safety Reminder	13
Safety Precautions	13
Manual Conventions	13
Front View	14
Rear View	14
Connections	15
Charging Cables	15
Locking Power Cord	15
Scanner Cable	15
Main Menu	16
Additional Screens	16
Main Menu Icons	17
Inspecting the Battery	17
Charging Out-of-Vehicle (Battery Test)	18
Connecting To The Battery	18
Initial Setup	18
2 – In Vehicle Charge	21
Battery Test	21
Battery Test Results	22
System Test	24
System Test Results-Summary	24
3 – Out Of Vehicle Charge	25
Battery Test Results	25
4 – Battery Diagnostics	26
Battery Test	26
Battery Test Results	27
New Battery Install	27
System Test	28
System Test Results-Summary	28
5 – Jump Start	29
Jump Start Summary	30

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	DCA-8000
6 – History	31
Tool History	31
Totals By Test Decision	31
Totals By Charge Decision	31
Totals By Test Type	32
Totals By Date And Location	32
Vehicle History	32
Vehicle Select Option	32
User History	33
Totals By Test Decision	33
Totals By Charge Decision	33
Totals By Test Type	33
Totals By Date And Location	33
7 – Messages	34
Accessing Messages	34
Message Types	34
8 – Manual Charge	35
9 – Settings	36
WiFi	36
Adding A Network	36
Deleting A Network	36
Printer Settings	37
Adding A WiFi Printer (Admin Only)	37
Adding A Bluetooth Printer (Admin Only)	37
Deleting A Printer (Admin Only)	37
Email	38
Add Address (Admin Only)	38
Edit Address (Admin Only)	38
Deleting An Address (Admin Only)	38
Server Settings	38
User Settings (Admin Only)	39
User Management (Admin Only)	39
Language Settings	39
System Language	39
Test Result Language	39
Email Language	39
Print Language	39
Display Settings	40
Brightness	40
Auto Brightness	40
Sleep Time	40
Dim Time	40
BMIS Login (Admin Only)	40
Shop Information (Admin Only)	41
Shop Information	41
Test Settings	42
Device List	43
Add CVG Device	43
Version Information	44
Factory Preset	44
Legal Information	44
Check for Updates	44

4	Midtronics Inc. 7000 Monroe Street Willowbrook, IL 60527

DCA-8000

10 – Reflash	45
11 – After New Battery Install	46
Battery Test	46
Battery Test Results	47
Reset Electronics	47
System Test Results-Summary	47
Appendix A: Recommended Scanning Procedure	48
VIN Scanning	48
Scanning Tips	48
Appendix B: Battery Information Definitions	49
Appendix C: Test Results Decision Tables	50
Battery Test Results	50
Starter Test Results	51
Alternator Test Results	52
Diode Test Results	52

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General Safety Precautions	DCA-8000

General Safety Precautions

IMPORTANT SAFETY INSTRUCTIONS. WORKING IN THE VICINITY OF A LEAD-ACID BATTERY IS DANGEROUS. BATTERIES GENERATE EXPLOSIVE GASES DURING NORMAL BATTERY OPERATION. FOR THIS REASON, IT IS OF THE UTMOST IMPORTANCE THAT THESE INSTRUCTIONS ARE FOLLOWED EACH TME THE CHARGER IS USED.

For safe, efficient, and accurate charging and testing, review the safety and operating instructions in this manual before using the analyzer. In addition, follow all manufacturers’ instructions and BCI (Battery Council International) safety recommendations.

1 General Safety Precautions

Charging a non-rechargeable battery may cause the battery to burst.

To reduce the risk of injury, only charge rechargeable lead-acid type batteries including maintenance-free, low-maintenance, or deep-cycle batteries.

Risk of explosive gases.

Batteries generate explosive gases during normal operation, and when discharged or charged.

1.1To reduce risk of 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 marking on these products and on the engine, and on the vehicle or equipment containing the battery.

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.

1.2Use 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.

1.3To reduce risk of damage to the electric plug and cord, pull by the plug rather than by the cord when disconnecting the charger.

1.4Position the AC and DC leads to avoid tripping over them and to prevent damage from moving engine parts; protect from heat, oil, and sharp edges.

1.5Do 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.

1.6Do not disassemble charger; take it to a qualified service center when repair is required. Incorrect reassembly may result in a risk of electric shock or fire.

1.7To reduce 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.

1.8Connect and disconnect the battery leads only when the AC supply cord is disconnected.

1.9Do not overcharge the battery.

1.10Charge the battery in a dry, well-ventilated area.

1.11Never place articles on or around the charger, or locate the charger in a way that will restrict the flow of cooling air through the cabinet.

1.12An extension cord should not be used unless absolutely necessary. (See paragraph 4.2)

1.13Have a damaged cord or plug replaced immediately.

1.14Do not expose the charger to rain or snow.

6	Midtronics Inc. 7000 Monroe Street Willowbrook, IL 60527

DCA-8000	General Safety Precautions

2 Personal Precautions

2.1This charger is not to be used by people with reduced physical, sensory or mental capabilities, or lack of experience and knowledge, unless they have been given supervision or instruction.

2.2Children should be supervised to ensure they do not play with the appliance

2.3Always have someone within range of your voice, or close enough to come to your aid, when working around lead acid batteries.

2.4Have plenty of fresh water and soap nearby in case battery acid contacts skin, clothing or eyes.

2.5Wear complete eye protection, clothing protection, and wear rubber soled shoes. Place damp cloth over battery to protect against acid spray. When ground is very wet or covered with snow, wear rubber boots. Avoid touching eyes while working near battery.

2.6If battery acid contacts skin or clothing, wash immediately with soap and water. If acid enters the eye, immediately flush with cold running water for at least 10 minutes, and seek medical attention.

2.7NEVER smoke or allow a spark or flame in vicinity of a battery or engine.

2.8Be extra cautious to reduce 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.

2.9Before 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.

To avoid electrical shock or burn, never alter the charger’s original AC cord and plug. Disconnect plug from outlet when charger is idle.

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 battery charger for charging dry-cell batteries commonly used with home appliances. These batteries may burst and cause personal injury and property damage.

2.10 NEVER charge a frozen battery; thaw it out first.

3 Preparing To Charge The Battery

3.1If it is necessary to remove the battery from vehicle to charge it, always remove the grounded terminal from the battery first. Make sure all accessories in the vehicle are off, so as not to cause an arc.

3.2Be sure the area around the battery is well ventilated while the battery is being charged. Gas can be forcefully blown away by using a piece of cardboard or other non-metallic material as a fan.

3.3Clean the battery terminals. Be careful to keep corrosion from coming into contact with your eyes.

3.4Add 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

3.5Study all battery manufacturer’s specific precautions such as removing or not removing cell caps while charging and recommended rates of charge.

3.6Determine the voltage of the battery by referring to the car owner’s manual and make sure that the output voltage selector switch is set at the correct voltage. If the charger has an adjustable

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General Safety Precautions	DCA-8000

charge rate, charge the battery initially at lowest rate. If the charger has only one voltage, verify that the battery voltage matches the voltage of charger.

For a charger not having an output voltage selector switch, determine the voltage of the battery by referring to car owner’s manual and make sure it matches the output rating of the battery charger.

4 Grounding & Power Cord Connections

4.1The charger must be grounded to reduce 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.

Hazardous voltage.

An improper connection can result in electric shock.

To avoid electrical shock or burn, never alter the charger’s original AC cord and plug. Disconnect plug from outlet when charger is idle.

IMPORTANT: If the plug does not fit the outlet, have a proper outlest installed by

aqualified electrician.

4.2This 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.

Hazardous voltage.

An improper connection can result in electric shock.

Before using an adapter be certain the center screw of the outlet plate is grounded. The 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 screw that secures the adapter ear or lug to the cover plate and make the ground connection to the grounded outlet.

IMPORTANT: Use of an adapter is not allowed in Canada. If a grounding-type receptacle is not available, do not use this appliance until the proper outlet is installed by a qualified electrican.

8	Midtronics Inc. 7000 Monroe Street Willowbrook, IL 60527

DCA-8000	General Safety Precautions

4.3An 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:

a.that the pins on plugs of the extension cord are the same number, size, and shape as those of the plug on the charger;

b.that the extension cord is properly wired and in good electrical condition;

c.that the wire size is large enough for the AC ampere rating of charger as specified in the following table.

Recommended minimum AWG* size for extension cords for battery chargers

AC input rating Amps				AWG* size of cord
Equal or greater	But less		Length of cord, feet (m)
than:	than:	25 (7.6)		50 (15.2)	100 (30.5)	150 (45.6)
8	10	18		14	12	10
10	12	16		14	10	8
12	14	16		12	10	8
14	16	16		12	10	8
16	18	14		12	8	8

*American Wire Gauge

5 Charger Location

Not for permanent installation: Modifying this charger for permanent installation in a vehicle or installing this charger in a vehicle for permanent use is not recommended.

In the event of fail device may generate and emit sparks.

Only charge rechargeable flooded maintenancefree, low-maintenance or deep-cycle batteries.

This charger is NOT designed outside use or for wet location mounting. The charger must always be protected from direct contact with water.

5.1The charger must be located in an area with sufficient air space to allow unrestricted airflow in and around the charger.

5.2Locate the charger as far away from the battery as the charger cables permit.

5.3Never place the charger directly above the battery being charged; gases from the battery will corrode and damage the charger.

5.4Never allow battery acid to drip on the charger when taking gravity readings or filling a flooded cell battery.

5.5Operate the charger only in a well-ventilated area that is free of dangerous vapors.

5.6Store the charger in safe, dry location and maintain it in perfect condition.

5.7Do not set the battery on top of the charger or where its acid might drip onto the charger.

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General Safety Precautions	DCA-8000

6 DC Connection Precautions

6.1Connect and disconnect the charger clamps only after the charger has been turned off and the AC supply cord is disconnected from the electric outlet.

6.2Never allow the charger clamps to touch each other.

6.3When 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. The clamps should be kept clean.

Hazardous voltage.

Can cause death or serious personal injury.

Setting the switches to“OFF”does not always disconnect the charger electrical circuit from the AC power cord or the DC charger clamps.

7 Installing The Battery

Risk of explosive gases.

A spark near the battery may cause a battery explosion. Follow these steps when the battery is installed in the vehicle to reduce the risk of explosion.

7.1Locate 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 moving engine parts.

7.2Turn OFF all vehicle loads, including door lights, and correct any defects in the vehicle’s electrical system that may have caused low battery.

7.3First connect the POSITIVE (RED) clamp from the charger to the POSITIVE (POS., P, +) ungrounded post of the battery. Then connect the NEGATIVE (BLACK) clamp to the NEGATIVE (NEG., N,–) post of the battery. Do not connect the clamp to the carburetor, fuel lines, or sheetmetal body parts.

8 Removing the Battery

8.1If it is necessary to remove the battery from the vehicle or equipment, always remove the grounded terminal from the battery first.

Risk of explosive gases.

A spark near the battery may cause a battery explosion. Follow these steps when the battery is installed in the vehicle to reduce the risk of explosion.

Risk of explosive gases.

Make sure all vehicle loads are OFF to prevent a possible arc.

8.2Check the polarity of battery posts.

8.3Connect the POSITIVE (RED) charger clamp to the POSITIVE (POS., P, +) post of battery.

8.4Position yourself and the free end of cable as far away from the battery as possible—do not face the battery when making the final connection—then connect the NEGATIVE (BLACK) charger clamp to the free end of the cable.

10	Midtronics Inc. 7000 Monroe Street Willowbrook, IL 60527

DCA-8000	General Safety Precautions

8.5When disconnecting the charger, always do so in the reverse sequence of the connecting procedure; break the first connection while staying as far away from the battery as practical.

9 Maintenance & Storage

Follow these guidelines to protect the charger and test cables from damage and premature wear:

9.1The grease, dirt, and sulfation that build up on battery terminals are highly corrosive and can damage the clamps over time. Before connecting the clamps, ensure accurate test readings and protect the clamps by cleaning the battery case and terminals using a wire brush and a mixture of water and baking soda.

9.2Periodically clean the clamps using a mixture of baking soda and water, or a mild hand-soap, and a small bristle brush.

9.3Clean the battery terminals. If stud adapters are required, fasten them with the proper tool. Do not use the battery clamps to tighten adapters.

9.4Never remove the clamps from a battery to abort an active charging session. Always press the red STOP button before removing the clamps.

9.5Do not leave the clamps laying in battery acid.

Locking Power Cord

Always pull back on the red tab on the side of the power cord connector to release/remove it from the charger’s power socket.

Release

Storage

Always store the charger in safe, dry location and maintain it in perfect condition.

10 Wireless Safety

The operation of this equipment is subject to the following two conditions.

1.This equipment or device may not cause harmful interference.

2.This equipment or device must accept any interference. Including interference that may cause undesired operation.

SAVE THESE INSTRUCTIONS

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Product Specifications	DCA-8000

Product Specifications

Power

Input:	100 – 240 , 50/60 Hz; 12A max.
Output:	12 V , 70A

Charge Cables

•3m

•5m

Power Cord

Accepts C19 locking connector for region-specific power cables:

•United States: EMA 5-15 termination, rated at

15A/125V UL CSA

Applications
•	Automotive				•	Marine
•	Heavy-Duty				•	Group 31
•	Power Sports				•	Commercial
						4D/8D
Battery Chemistries
•	Lead acid				•	EFB
•	AGM				•	Lithium ion
Rating System
•			•					•
	CCA			JIS					IEC
•	CA		•	DIN				•	EN
•	MCA		•	SAE

Operating Parameters

•Input Voltage:

100 – 240 , 50/60 Hz; 12A max.

•Output:

15VDC; 70A maximum

Humidity

•15% to 85% R.H., non-condensing

Dimensions

(without handle or base)

•Weight:34 lbs (15.45 kg)

Temperature

•Operating temperature range: 0°C to +60°C (32°F to +140°F)

•Storage temperature range: -10°C to + 85°C (14°F to 185°F)

Certifications
•	CUL	•	RoHS
•	ETL	•	VL

•FCC

Connectivity

Wi-Fi

•802.11 b/g/n 2.4GHz

•Security – WEP, WP, WPA-2 Enterprise

Bluetooth

•2.0

•USB 2.0 connection

CAN bus interface

Protection Features
•	Reverse polarity	•	Battery voltage
•		•	too low (< 5.5 V)
	Non-12V battery		Clamp high
	connection		temperature
			detection

•Clamp connection

BMIS-Enabled

•Remote “over the air” software updates

•Remote diagnostics

•Enterprise asset management

•Reporting and analytic tools

•Communication with next generation Midtronics

platforms and tools

User Interface

•Advanced navigation and charge applications

•Remote notifications

(Wi-Fi- or Bluetooth-enabled)

•Intuitive charge cycle feedback

•5”Touch Screen

12	Midtronics Inc. 7000 Monroe Street Willowbrook, IL 60527

DCA-8000	1 – Introduction & Overview

1 – Introduction & Overview

Safety Reminder

For safe, efficient, and accurate charging and testing, review the safety and operating instructions in this manual before using the analyzer. In addition, follow all manufacturer instructions and BCI (Battery Council International) safety recommendations.

Safety Precautions

Inspect the battery for damages and check the electrolyte level. If the electrolyte level is too low, replenish it and fully charge the battery. Always use the necessary safety precautions when working with batteries to prevent severe injury or death. Follow all manufacturers’ instructions and BCI (Battery Council International) safety recommendations, which include the following precautions:

Risk of explosive gases.

Never smoke or allow a spark or flame in the vicinity of a battery.

Batteries can produce a highly explosive mix of hydrogen gas and oxygen, even when the battery is not in operation. Always work in a well-ventilated area.

Wash hands after handling.

REQUIRED BY CALIFORNIA PROP. 65: Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the state of California to cause cancer and birth defects or other reproductive harm.

9Battery acid is highly corrosive. If acid enters your eyes, immediately flush them thoroughly with cold running water for at least 15 minutes and seek medical attention. If battery acid gets on your skin or clothing, wash immediately with a mixture of water and baking soda.

9Always wear proper safety glasses or face shield when working with or around batteries.

9Keep hair, hands, and clothing as well as the analyzer cords and cables away from moving engine parts.

9Remove any jewelry or watches before you start servicing the battery.

9Use caution when working with metallic tools to prevent sparks or short circuits.

9Never lean over a battery when testing, charging, or jump starting.

9Never charge a frozen battery. Gases may form, cracking the case, and spray out battery acid.

Manual Conventions

This manual uses these symbols and typographical conventions:

Symbol	Description
	The safety symbol indicates instructions for avoiding
	hazardous conditions and personal injury.
	The safety symbol with the words CAUTION, WARNING,
	or DANGER indicates instructions for avoiding hazardous
	conditions and personal injury.
	The wrench symbol indicates procedural notes and helpful
	information.
	These symbols indicate which arrow keys on the keypad to
	press for a given function.
Bold Letters	The text for screen options are in Bold letters.

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1 – Introduction & Overview	DCA-8000

Front View







			
	Thermal Printer		Charger Power Button
	Touch Screen Display		USB Port

Rear View













	Communication Cable		Circuit Breaker Reset
	Connection
	Charge Cable Connections		Power Cord Socket
	VIN Scanner Connection (DB-9)		For Charger Cart Mounting Bolts

14	Midtronics Inc. 7000 Monroe Street Willowbrook, IL 60527

DCA-8000	1 – Introduction & Overview

Connections

Charging Cables

1.Insert the communication cable.

2.Insert and rotate the charge cable quick connectors clockwise 180° to lock them onto the Quick Connector Locking Post on the charger.

3.The connection process is complete when all three cables are connected to the charger.

Locking Power Cord

Pull back on the red tab on the side of the connector to release/remove the power cord from the charger’s power socket.

Pull Back To

Release

Scanner Cable

Use the screws on the connector to secure the cable to the charger.

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1 – Introduction & Overview	DCA-8000

Main Menu

Log Out	DCA-8000
In Vehicle	Out of Vehicle	Battery	Jump Start
Charge	Charge	Diagnostics
		
History	Messages	Manual Charge	Settings

Menu Bar

Log Out	Log out current user		Bluetooth connectivity
	Measured battery voltage		status
	WiFi signal strength

Main Menu Selection Area

Additional Screens

The dots at the bottom or side of a menu or results screen indicate additional screens are available. Use your finger to swipe horizontally left, right, up or down across the Controller screen to view all of the results.

 Screen 1		Screen 1
 Screen 2	
	
 Screen 3		Screen 2
Swipe		Swipe
Horizontally		Vertically

16	Midtronics Inc. 7000 Monroe Street Willowbrook, IL 60527

DCA-8000	1 – Introduction & Overview

Main Menu Icons

Icon

In Vehicle

Charge

Out of Vehicle

Charge

Battery

Diagnostics

Jump Start

History

Messages

Description

Automates battery testing for quickly testing vehicles using the fewest steps.

For testing out-of-vehicle customer batteries for possible return.

Performs full battery diagnostics but will not charge the battery.

Makes high output current available to boost charge an in-vehicle battery and assist in starting the engine.

Access archived test histories or search test history by VIN or by technician.

Displays alerts and notifications for upcoming tests and activities including scheduled tests, tool software updates and maintenance opportunities.

Icon

Manual

Charge

Settings

Reflash

After New

Battery

Install

Support

Description

Provides a timed charge that ranges from 5 to 120 minutes or a continuous charge that ends when STOP is pressed.

Setup/adjust: WiFi, printer setup, email settings, user information, default language, display/sound settings, BMIS, shop info, connected devices, tool software version information.

Evaluates and maintains battery voltage at 13.5 volts to provide uninterrupted reprogramming and retention of a vehicle’s system settings.

Access the analyzer Self-Test and a digitized version of the Instruction Manual that was shipped with the analyzer.

Access the analyzer Self-Test and a digitized version of the Instruction Manual that was shipped with the analyzer.

Inspecting the Battery

Before starting the test visually inspect the battery for:

•Cracked, buckled, or leaking case. If you see any of these defects, replace the battery.

•Corroded, loose, or damaged cables and connections. Repair or replace them as needed.

•Corrosion on the battery terminals, and dirt or acid on the case top. Clean the case and terminals using a wire brush and a mixture of water and baking soda.

•Low electrolyte level. If the electrolyte level is low, add distilled water to fill up to ½ above the top of the plates and fully charge the battery. Do not overfill.

•Corroded or loose battery tray and hold-down fixture. Tighten or replace as needed.

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