EXP-1000 Heavy Duty
For testing 12-volt Truck- and automotive
batteries and 12- and 24-volt charging systems
INSTRUCTION MANUAL
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EXP-1000 HD
Contents
Chapter 1: Before You Begin 4
Starting the tester for the rst time 4
Safety 4
General Precautions 4
Chapter 2: Description 5
Connections and Data Ports 5
Removing and Inserting the Data Card 5
Connecting the Battery Test Cable 5
Display and Keypad 6
Data Entry Methods 7
Menu icons 7
Option Buttons 7
Scrolling Lists 7
Alphanumeric Entries 7
Menu Structure 8
Main Menu 8
Info Menu 8
Print/View Menu 8
Utility Menu 8
Chapter 3: Test Preparation 9
Inspecting the Battery 9
Testing Out-of-Vehicle 9
Testing In-Vehicle 9
Connecting the Battery Test Cable 9
Initial Setup 9
Chapter 7: Generate Pair 17
Chapter 8: QC test 18
Stock control 18
Compound test 18
Chapter 9: Utility Menu 19
Cong tester 19
Time 19
Mode 19
Date 19
Format 19
Temp. units 19
Write fail 19
Display 20
Contrast Level 20
Backlight Time 20
Cong Printer 20
Shop Info 20
Coupon 20
Edit Coupon 20
Language 21
Format Card 21
Update 21
Totals 22
Transfer Data 22
Version Info 22
Chapter 4: Battery Test 10
Additional Test Requirements 11
System Noise 11
Unstable Battery Detected 11
Surface Charge 11
Deep Scan Test 11
Battery Test Results 12
Battery Test 13
Starter Test 13
Starter System Test Results 13
Chapter 5: System Test 13
5 Minute Discharged Battery Test 14
Alternator Test 14
Alternator Test Results 14
Chapter 6: PDI Test 16
Procedure 16
Test Results 16
Test results 17
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Chapter 10: Info Menu 22
Chapter 11: Print/View 23
View Test 23
View QC Test 23
Chapter 12: Troubleshooting 24
The Display Does Not Turn On 24
The STATUS LED Flashes (Midtronics Printer) 24
Data Will Not Print 24
Chapter 13: Tester Internal Batteries 25
Battery Power Indicator 25
Replacing the Tester Batteries 25
Midtronics B.V. Hoofdveste 6 - 8 Houten NL
Chapter 1: Before You Begin
Starting the tester for the rst time
When the tester is rst used the operator is asked to enter a
couple of items such as language, date and time. Changes
can be made afterwards by going in to the Utility Menu and
selecting CONFIG TESTER.
Safety
Because of the possibility of personal injury, always use
extreme caution when working with batteries. Follow
all manufacturers’ instructions and BCI (Battery Council
International) safety recommendations.
General Precautions
Battery acid is highly corrosive. If acid enters your
eyes, immediately ush them thoroughly with running cold water for at least 15 minutes and seek
medical attention. If battery acid gets on your skin or
clothing, wash immediately with water and baking
soda.
Always wear proper safety glasses or face shield
when working with or around batteries.
Keep hair, hands, and clothing as well as the analyzer
cords and cables away from moving engine parts.
EXP-1000 HDChapter 1: Before You Begin
Risk of explosive gases.
Never smoke or allow a spark or
ame 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.
The tester is manufactured in line with the latest state of the
art and according to recognised safety standards. If used
incorrectly or misused, however, it can cause
- injury or death to the user or a third party,
- damage to the tester and other material assets
belonging to the operator,
- inecient operation of the tester.
Remove any jewelry or watches before you start
servicing the battery.
Use caution when working with metallic tools to pre-
vent sparks or short circuits.
Never lean over a battery when testing, charging or
jump starting it.
All persons involved in commissioning, operating, maintaining
and servicing the tester must
- be suitably qualied,
- have knowledge of and experience in dealing with
testers and batteries and
- read and follow these operating instructions carefully.
Conventions Used in This Manual
To help you learn how to use your analyzer, the manual uses these symbols and typographical conventions:
Convention
The safety symbol followed by the word WARNING or CAUTION indicates instructions for avoiding
!
CAUTION
UP ARROW
CAPITAL LETTERS The text for screen options are in regular capital letters.
hazardous conditions and personal injury.
The word CAUTION indicates instructions for avoiding equipment damage.
The wrench symbol indicates procedural notes and helpful information.
The text for keypad buttons and soft-key functions are in bold capital letters.
Description
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EXP-1000 HD Chapter 2: Description
Chapter 2: Description
Connections and Data Ports
Data transmitter: sends test results to a PC
using an optional hardware and software kit.
Infrared temperature sensor with a range of
-28 °C to +93 °C
6-pin connector for the battery test cable.
Input for accessories. (optional)
Spring-loaded data card slot for test data
storage and software upgrades.
DB-9 connector for future expandability.
Removing and Inserting the Data Card
The analyzer ships with a storage card slot to protect it from
dust and debris. To remove the data card, push briey on its
edge to release it and pull it from the slot. When inserting a
card, push it into the slot until it locks. The card is correctly
inserted when it is not protruding from the slot. To protect the
card slot and enable the analyzer to read and write to the card,
leave the card in the slot.
Connecting the Battery Test Cable
CAUTION: To prevent damage to the analyzer’s circuitry,
do not connect the analyzer to a voltage source greater than
30 Vdc.
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Midtronics B.V. Hoofdveste 6 - 8 Houten NL
EXP-1000 HDChapter 2: Description
Display and Keypad
The keypad and display work together to help you quickly nd and use the right tools at the right time. The display also keeps
you on track with on-screen navigation aids, directions and messages.
POWER Key
Press the POWER button to turn the analyzer on and
o. The analyzer also turns on automatically when you
connect its test leads to a battery.
Title Bar
The title bar shows you the name of the current menu,
test tool, utility, or function.
Selection Area
The selection area below the Title Bar contains selectable
items or dialog boxes that display information or require
a response.
Internal Batteries Status Indicator
This indicator appears in the screen’s top left corner, lets
you know the status and charge level of the analyzer’s six
1.5-volt batteries. The X in the top left corner of the screen
shows that the analyzer is powered by the battery you’re
testing to conserve the analyzer’s internal batteries.
Voltmeter
When you rst connect the analyzer to a battery it functions
as a voltmeter. The voltage reading appears above the left
soft key until you move to other menus or functions.
Soft Keys
Press the two Soft Keys linked to the bottom of the screen
to perform the functions displayed above them. The
functions change depending on the menu or test process.
So it may be helpful to think of the words appearing above
them as part of the keys. Some of the more common softkey functions are SELECT, BACK, and END.
Menu Screen Arrows
When displayed in menu screens, the menu screen
arrows show you which ARROW key on the keypad to
press to display other icons or screens. The Up and Down
Menu Screen Arrows, for example, indicate when to
press the UP ( ) and DOWN ( ) ARROW keys to display
the screens above and below the current screen.
he Left and Right Menu Screen Arrows tell you when to
T
use the LEFT
( )
or RIGHT
( )
ARROW keys to select an
icon.
When displayed under a list of options, the menu screen
arrows show you which keypad arrow to press to
highlight a character or item in a list.
Scroll Bar
Another navigational aid is the scroll bar on the right
side of the screen. The position of its scroll box shows
you whether the screen is the top (or only screen),
middle, or last in a series.
ARROW keys
Press the UP ARROW key to move up to the next
selectable item or row. When entering text, use the UP
ARROW key to move to the previous character.
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EXP-1000 HD Chapter 2: Description
Data Entry Methods
To perform a particular test or function, the tester will ask for
di erent types of information. This means that the methods
you use to enter information will change depending on
the type of information requested. The four types of entry
methods are described below.
Typically, the soft key below the right half of the screen
con rms your choice, although the word above it may vary. In
a similar fashion, the soft key below the left half of the screen
cancels your choice or returns you to the previous screen,
although the word above it may also vary.
Menu icons
A menu icon is a graphical representation of a function you
can select. To select an icon, use the LEFT or RIGHT ARROW
key to highlight it. Highlighting changes the icon to a white
picture on a black background. To con rm your selection,
press the appropriate soft key.
Option Buttons
Some lists have option buttons before each item.
To select an item, use the UP/DOWN ARROW keys to
move the dot into the button next to the item you want. You
can also use the alphanumeric keypad to enter the number
preceding the option button. To con rm your selection, press
the appropriate soft key.
Scrolling Lists
Scrolling lists contain items that extend above and below
the screen or the selection box that contains them.
To indicate that there are more items, the symbols appear
to the right of the rst visible or highlighted item on the list.
To select from this type of list, use the UP/DOWN ARROW
keys to scroll to the item, or use the keypad to enter your
choice, and press the appropriate soft key.
Alphanumeric Entries
Even though the tester does not use an alphanumeric keypad
it is possible to enter alphanumeric values. When applicable
the alphanumeric values appear on the display. Use the UP/
DOWN or LEFT/RIGHT ARROW keys to scroll and con rm
this with the > key. To return one or more steps use the < key.
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EXP-1000 HDChapter 2: Description
Menu Structure
This section will help you get to your destination while letting
you know what test leads you may need when you arrive.
The test leads are represented by symbols for their connectors.
Main Menu
The Main Menu is the starting point for all tools and utilities,
which are depicted as icons. Some icons lead directly to the
function they represent, while others are menu icons that lead
to two or more functions. Menu icons are marked here with an
asterisk (*) and are mapped on the following pages.
Icon Description
The BATTERY TEST tests a battery
using the battery information you
select in a series of screens.
The SYSTEM TEST tests a battery,
and the starting and charging system.
Optional
Performs a Pre Delivery Inspection
test.
GENERATE PAIR allows you to
check whether two batteries can be
used together.
QC TEST is used for testing stock or
compound batteries.
INFO contains a test counter, data
*
transfer utility, and the tester software
version and serial number.
PRINT/VIEW enables you to view
*
your stored test results and print
them to an optional IR printer.
UTILITY includes functionality to
*
setup the tester.
Info Menu
Icon Description
TOTALS displays the total battery tests
performed since the tester was rst used, the
totals by decision, or allows you to clear the
counters.
An optional IR software and hardware
package enables you to transfer test data to
a PC.
Displays the software version, total tests from
rst use, and serial number.
Print/View Menu
The tester stores the last test results in its memory until you
perform another test. To review or print results before you
retest, select a test type in the Print/View Menu.
Icon Description
VIEW TEST displays the last Battery and
System Test results. Sends the results to an
optional IR printer..
VIEW QC TEST displays the last QC Test
result. Sends the result to an optional IR
printer..
Utility Menu
The Utility Menu lets you customize your analyzer for your
needs.
Icon Description
The CONFIG TESTER menu allows you to
set the following parameters:
TIME, MODE, DATE, FORMAT,
TEMPERATURE UNITS, and WRITE FAIL.
Settings to adjust the contrast level and
backlight time.
Enables you to congure the printer to IrDA.
Create your own address details for printouts
with the SHOP INFO icon.
If you have created a coupon in the EDIT
COUPON utility, use COUPON to enable or
disable.
EDIT COUPON allows you to create and
store up to three separate coupons to be
printed on test results.
With the LANGUAGE menu you can select
one of the 24 available languages.
With FORMAT CARD you erase all
information on the data card.
With UPDATE you can install new software
on the tester.
Add or delete battery information
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EXP-1000 HD Chapter 3: Test Preparation
Chapter 3: Test Preparation
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. Re-
pair 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 too low, add
distilled water to ll up to 1/2 above the top of the plates
and fully charge the battery. Do not overll.
• Corroded or loose battery tray and hold-down xture.
Tighten or replace as needed.
Testing Out-of-Vehicle
The preferred battery test location is in the vehicle. However, if
you plan to test out of the vehicle:
• Always disconnect the negative cable from the battery
rst and reconnect it last.
To make sure both sides of the clamps are gripping the
terminals, rock the each clamp back and forth. A poor
connection will prevent testing, and the tester will display
the message CHECK CONNECTION. If the message reappears
after you have correctly reconnected the clamps, clean the
terminals and reconnect.
Initial Setup
When starting the EXP for the rst time you are asked to enter
a number of settings so you can already adapt the analyzer
to your personal settings. Among these settings are the
language and date and time. This only needs to be done once,
it can be changed afterwards in the UTILITY MENU (CONFIG
TESTER).
• Always use a carry tool or strap to lift and transport the
battery.
Testing In-Vehicle
The preferred test position is at the battery posts. If you must
test at a remote-post location, it should have both a positive
and negative post.
At the start of the test, make sure all vehicle accessory loads
are o, the key is not in the ignition, and the doors are closed.
Connecting the Battery Test Cable
CAUTION: Do not connect the tester to a voltage source
greater than 30 Vdc.
Connect the battery test cable to the tester by rst aligning
the cable connector’s 6 pins with the holes on top of the tester.
Firmly insert the connector and tighten the locking ring.
Connect the clamps to the battery: the red clamp to the
positive (+) terminal and the black clamp to the negative (–)
terminal.
If you connect the clamps in the wrong polarity (positive to
negative or negative to positive), the tester displays CLAMPS
REVERSED! Reconnect the clamps correctly.
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Chapter 4: Battery Test
EXP-1000 HDChapter 4: Battery Test
The tester guides you through the steps of selecting your
battery test parameters and interpreting the results. Before
you start the test, review the instructions in Chapter 3: Test
Preparation.
1. Select the BATTERY LOCATION.
1 OUT OF VEHICLE
2 IN VEHICLE
Press the NEXT soft key to continue.
2. Select the VEHICLE TYPE.
1 TRUCK
2 CAR / VAN
Press the NEXT soft key to continue.
3. In case of IN-VEHICLE please select the NUMBER OF BATTERIES.
1 1
2 2
4. Select the BATTERY TYPE.
1 REGULAR
2 AGM
3 SPIRAL
4 GEL
Press the NEXT soft key to continue.
5. Select the battery’s capacity rating standard. The standard, and the rating units required are printed on the battery label. If the information is unreadable, contact the
battery manufacturer.
Battery Standards
Rating
System
CCA Cold Cranking Amps (specied
by SAE): The amount of
current a battery can provide at
0 ºF (–17.8 ºC).
JIS Japanese Industrial Standard:
(shown on a battery as a
combination of numbers and
letters.
DIN (A) Deutsche Industrie-Norm 100 to 1000
SAE (A) European labeling of CCA 100 to 1700
IEC (A) International Electrotechnical
Commission
EN (A) European Norm 100 to 1700
Description Range
100 to 1700
73 numbers
from 26A17
to 245H52
100 to 1000
If you select JIS, the analyzer asks for the JIS part number.
Scroll to the part number. To increase your scrolling
speed, hold the UP () or DOWN () ARROW key, or use
the LEFT () or RIGHT () ARROW key to move up or
down four part numbers at a time.
Press the NEXT soft key to continue.
6. Press an UP () or DOWN () ARROW key or use the
numeric keys to select the BATTERY RATING, or in the case
of JIS, the part number. To increase your scrolling speed,
hold down the UP or DOWN ARROW key.
500 CCA
Press the NEXT soft key to continue.
7. Select the TEMPERATURE.
1 CCA
2 JIS
3 DIN
4 SAE
5 IEC
6 EN
Midtronics B.V. Hoofdveste 6 - 8 Houten NL
Aim the tester 5 cm from the sides or top of the battery
case. As soon as the temperature reading is stable the
operator can press NEXT.
The tester will now test the battery.
For the next few seconds the tester will display the word
TESTING and a stopwatch while it evaluates the battery.
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EXP-1000 HD Chapter 4: Battery Test
Additional Test Requirements
For a more decisive result the tester may ask for additional
information or probe deeper into the battery’s condition. The
following messages and instructions may appear before the
analyzer displays the results of your test.
System Noise
To perform a correct measurement the tester requires
the vehicle to be in rest. After the car has been driven
some vehicle specic systems might still be active in the
background. The tester will detect this and displays the
message SYSTEM NOISE. When this message appears switch
o all consumers(radio, airconditioning) and remove the key
from the ignition. As soon as there is no more activity in the
vehicle the tester will continue testing and display the test
result.
Unstable Battery Detected
A battery that is weak or that has just been charged may retain
enough electrical activity to be detected by the analyzer
and will adversely aect the test results. A fully charged
battery should stabilize quickly, after which the analyzer
will automatically retest. Weak batteries should be charged
and retested. If the battery is fully charged, check the clamp
connections.
Surface Charge
The battery can hold a surface charge if the engine has been
running or after the battery has been charged. The tester may
prompt you to remove the surface charge before it displays a
test result.
1. Follow the instructions indicating when to turn the headlights on and o (IN-VEHICLE)
2. The tester will resume testing after it detects that the surface charge is removed.
Deep Scan Test
In some cases the tester may need to further analyze the
battery to determine whether the battery should be replaced
or it has a signicant chance to be recovered. It will then
conduct a Deep Scan Test of the battery for a few seconds.
This test will typically be performed on batteries that are in a
low state of charge.
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EXP-1000 HDChapter 4: Battery Test
Battery Test Results
After the test the tester will display one of five battery
decisions with the complete results in a series of screens as
shown below. Use the UP/DOWN ARROW keys to scroll
through each result. To send the results to an IR printer, press
Battery decision
Temperature indication
General health of the battery
and its ability to deliver
its specied performance
compared with a new battery
the PRINT soft key. To return to the Main Menu, press the END
soft key, or to continue testing if you’ve selected the system
text, press the NEXT soft key. You’ll have the opportunity to
print all the results at the end of the system test.
Measured voltage
Measured capacity
rating units
Rating units you
selected for the test
Battery’s state of charge
Good Battery Result
Battery Decisions and Recommendations
Decision Recommended Action
GOOD BATTERY Return the battery to service.
GOOD–RECHARGE Fully charge the battery and return it to service.
CHARGE & RETEST Fully charge the battery and retest. Failure to fully charge the battery before retesting
may cause false readings. If CHARGE & RETEST appears again after you fully charge the
battery, replace the battery.
REPLACE BATTERY Replace the battery and retest. A REPLACE BATTERY result may also mean a poor
connection between the battery cables and the battery. After disconnecting the battery
cables, retest the battery using the out-of-vehicle test before replacing it.
BAD CELL–REPLACE Replace the battery and retest.
FROZEN BATTERY Thaw the battery and retest. Do NOT charge the battery!.
All battery, starting and Charging test results are
stored on the SD Card. This data can be copied from
the card and used to verify / compare results.
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EXP-1000 HD Chapter 5: System Test
Chapter 5: System Test
Before starting the test, inspect the alternator drive belt. A belt
that is glazed or worn, or lacks the proper tension, will prevent
the engine from achieving the rpm levels needed for the test.
The System Test includes 3 tests that provide a complete
diagnosis of the vehicle’s electrical system:
• BATTERY TEST
• STARTER TEST
• ALTERNATOR TEST
Battery Test
The System Test includes a test of the battery to eliminate it as
the cause of starting or charging problems. See Chapter 4 for
the Battery Test procedure.
Starter Test
1. Have your amp clamp ready and select the AMP CLAMP
availability.
1 INTEGRATED
2 OTHER
3 NONE
Press the NEXT soft key to continue.
2. Attached the Amp clamp to the tester, do not connect it
around any wire.
Press the NEXT soft key to continue.
Starter System Test Results
The results include the battery analysis. Use the UP () or
DOWN () ARROW key to scroll to each screen. See the Starter
System Decision table for an explanation of the starter system
decisions. To continue testing, press the NEXT soft key.
Average
Starter
decision
Starter System Test Decisions
Decision Action
CRANKING
NORMAL
LOW VOLTAGE The starter voltage is low and the
CHARGE
BATTERY
REPLACE Replace the battery and retest before
LOW CRANKING
AMPS
NO START The engine did not start and the test
CRANKING
SKIPPED
The starter voltage is normal and the
battery is fully charged.
battery is fully charged.
The starter voltage is low and the
battery is discharged. Fully charge the
battery and retest the starter system.
testing the alternator test..
The starter voltage is high, but the
cranking amps are low.
was aborted.
The tester did not detect the vehicle’s
starting prole and skipped the Starter
Test.
cranking
voltage
Cranking
time in mil-
liseconds
3. Tester will zero out the Amp clamp.
4. Place Amp clamp around negative cable.
Press the NEXT soft key to continue.
5. Start the vehicle’s engine when prompted. If after the vehicle started and the results do not appear after approximately 25 seconds, press the NO START soft key.
6. The analyzer displays one of the decisions and the results
in a series of screens.
NOTE: In some cases, the tester may not detect the
vehicle’s starting prole. It will display the soft key
options STARTED and NO START. If you select
STARTED, the analyzer skips to the Alternator
Test. If you select NO START, the test process ends.
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EXP-1000 HDChapter 5: System Test
5 Minute Discharged Battery Test
In some cases, when dealing with a discharged battery, the
dynamic response test will be prompted. Usually it is hard to
determine the condition of a discharged battery, but in this
way we can base the condition on how the battery resonds
to this test.
1. The tester starts checking for alternator output.
NOTE: If necessary the analyzer will ask if you are
testing a diesel engine. It will resume testing after
you make your selection.
2. Depending on whether you are working with an integrated Amp clamp, you will be either prompted to TURN OFF
LOADS AND ENGINE or asked to CHECK IF CLAMP POINTS
AWAY FROM THE NEGATIVE BATTERY POST.
In case of the former, turn o vehicle loads (blowers,
interior light, radio, etc.) and the engine. Press the NEXT
soft key to continue.
3. TURN ALL VEHICLE LOADS OFF, IDLE ENGINE: Turn o vehicle loads (blowers, interior light, radio, etc.) and idle the
engine. Press the NEXT soft key to continue.
4. Enter the charge current taken by the battery using the
UP () and DOWN () ARROW keys. Press the NEXT soft
key to continue.
After a few minutes this is asked again to determine the
battery’s condition.
5. Enter the charge current taken by the battery using the
UP () and DOWN () ARROW keys. Press the NEXT soft
key to continue.
4. TESTING ALTERNATOR AT IDLE, LOADS OFF: The analyzer
will next test the engine at idle for comparison to other
readings, and then test the diode ripple. Excessive ripple
usually means one or more diodes have failed in the alternator or there is stator damage.
5. TURN HIGH BEAMS AND BLOWER MOTOR ON, IDLE
ENGINE: After a few seconds, the tester will ask you to turn
on the accessory loads. It will determine if the charging
system is able to provide enough current for the demands
of the electrical system.
IMPORTANT:
Turn on the high-beam headlights,
the blower to high and the rear defogger. Do not
use cyclical loads such as air conditioning or windshield wipers.
6. TESTING ALTERNATOR AT IDLE, LOADS ON: The analyzer
will determine if the charging system is able to provide
sucient current for the demands of the vehicle’s electrical system.
7. ANALYZING CHARGING SYSTEM DATA: The tester is completing its nal analysis of the charging system data.
8. TURN OFF LOADS AND ENGINE: Press the NEXT soft key to
display the results.
In case you are using an Amp clamp
9. DRAIN TEST or DRAIN CURRENT: This will be asked ONLY
when the Amp clamp is in use. Depending on whether or
not using the integrated clamp, press NEXT to proceed
drain test or ll in the current as displayed on the Amp
clamp.
Alternator Test
1. The tester starts checking for alternator output.
NOTE: If necessary the analyzer will ask if you are
testing a diesel engine. It will resume testing after
you make your selection.
2. Depending on whether you are working with an integrated Amp clamp, you will be either prompted to TURN OFF
LOADS AND ENGINE or asked to CHECK IF CLAMP POINTS
AWAY FROM THE NEGATIVE BATTERY POST.
In case of the former, turn o vehicle loads (blowers,
interior light, radio, etc.) and the engine. Press the NEXT
soft key to continue.
3. ACQUIRING DATA....HOLD ENGINE RPM: Continue to hold
the rpm while the tester takes system measurements.
Alternator Test Results
Loads-off
DC voltage
at rev
Normal DC
voltage
range
Peak-topeak AC
voltage
Alternator
decision
Loads-on
DC voltage
at rev
Bar graph
showing
DC voltage
within
normal
range with
loads on and
off
Graph
of diode
waveform
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EXP-1000 HD Chapter 5: System Test
Alternator Decisions and Recommendations
Decision Action
NO PROBLEMS The system is showing normal output from the alternator. No problem detected.
NO VOLTAGE The alternator is not providing charging current to the battery.
√ Check the belts to ensure the alternator is rotating with the engine running. Replace broken or slipping
belts and retest.
√ Check all connections to and from the alternator, especially the connection to the battery. If the
connection is loose or heavily corroded, clean or replace the cable and retest.
√ If the belts and connections are in good working condition, replace the alternator. (Older vehicles use
external voltage regulators, which may require only replacement of the voltage regulator.)
LOW VOLTAGE The alternator is not providing enough current to power the system’s electrical loads and charge the
battery.
√ Check the belts to ensure the alternator is rotating with the engine running. Replace broken or slipping
belts and retest.
√ Check the connections from the alternator to the battery. If the connection is loose or heavily corroded,
clean or replace the cable and retest.
HIGH VOLTAGE The voltage output from the alternator to the battery exceeds the normal limits of a functioning regulator.
√ Check to ensure there are no loose connections and that the ground connection is normal. If there are
no connection problems, replace the regulator. (Most alternators have a built-in regulator requiring you
to replace the alternator. In older vehicles that use external voltage regulators, you may need to replace
only the voltage regulator.)
Diode Decisions and Recommendations
Decision Action
EXCESSIVE RIPPLE One or more diodes in the alternator aren’t functioning or there’s stator damage, which is shown by an
excessive amount of AC ripple current supplied to the battery.
√ Make sure the alternator mounting is sturdy and that the belts are in good shape and functioning
properly. If the mounting and belts are good, replace the alternator.
PHASE OPEN The Tester has detected an open phase within the alternator. Replace the alternator.
DIODE OPEN The Tester has detected a open diode within the alternator. Replace the alternator.
DIODE SHORT The Tester has detected an shorted diode within the alternator. Replace the alternator.
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Midtronics B.V. Hoofdveste 6 - 8 Houten NL
Chapter 6: PDI Test
The PDI Test is run on new batteries before delivery to the
customer. The test results are presented as text and as
encrypted test codes.
NOTE: If the battery is dry charged, it must be lled
with acid, fully charged and then left resting for 48
hours before the PDI is run. This is so that the chemical process is completed.
Procedure
Connect the battery analyser to the battery terminals. Note:
Connect one battery at a time when running this battery test.
NOTE: Parallel connected batteries should be dis-
connected prior to a battery test.
Select the PDI test and enter the information about the
battery. The PDI test will now be run and the test results
displayed.
It is NOT possible to run the test if the battery analyser is
connected to two batteries connected in series.
EXP-1000 HDChapter 6: PDI Test
Test Results
The test results from a PDI test are displayed as text and with
test codes.
Midtronics B.V. Hoofdveste 6 - 8 Houten NL
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EXP-1000 HD Chapter 7: Generate Pair
Chapter 7: Generate Pair
This function checks whether two batteries can be used
together and is always considered to be performed outside
the vehicle. The batteries are NOT connected in the vehicle.
1. Select the BATTERY TYPE.
1 REGULAR
2 AGM
3 SPIRAL
4 GEL
Press the NEXT soft key to continue.
2. Select the battery’s capacity rating standard. The standard, and the rating units required are printed on the battery label. If the information is unreadable, contact the
battery manufacturer.
1 CCA
2 JIS
3 DIN
4 SAE
5 IEC
6 EN
Battery Standards
Rating
System
CCA Cold Cranking Amps (specied
by SAE): The amount of
current a battery can provide at
0 ºF (–17.8 ºC).
JIS Japanese Industrial Standard:
(shown on a battery as a
combination of numbers and
letters.
DIN (A) Deutsche Industrie-Norm 100 to 1000
SAE (A) European labeling of CCA 100 to 1700
IEC (A) International Electrotechnical
Commission
EN (A) European Norm 100 to 1700
Description Range
100 to 1700
73 numbers
from 26A17
to 245H52
100 to 1000
If you select JIS, the analyzer asks for the JIS part number.
Scroll to the part number. To increase your scrolling
speed, hold the UP () or DOWN () ARROW key, or
use the LEFT () or RIGHT () ARROW key to move up
or down four part numbers at a time. Press the NEXT soft
key to continue.
3. Press an UP () or DOWN () ARROW key or use the
numeric keys to select the BATTERY RATING, or in the case
of JIS, the part number. To increase your scrolling speed,
hold down the UP or DOWN ARROW key.
500 CCA
Press the NEXT soft key to start the test.
4. Select the TEMPERATURE.
Aim the tester 5 cm from the sides or top of the battery
case. As soon as the temperature reading is stable the
operator can press NEXT.
For the next few seconds the tester will display the word
TESTING and a stopwatch while it evaluates the battery.
5. Connect to another battery.
For the next few seconds the tester will display the word
TESTING and a stopwatch while it evaluates the battery.
Battery Decisions and Recommendations
Decision Recommended Action
IN BALANCE The batteries are working correctly and are balanced.
OUT OF BALANCE The batteries are not balanced with each other and should not be used together.
CHARGE Charge the battery pair and retest. Failure to fully charge the battery before retesting may cause
false readings. If CHARGE appears again after you fully charge the battery, replace the battery.
REPLACE Replace the battery and retest. A REPLACE result may also mean a poor connection between the
battery cables and the battery. After disconnecting the battery cables, retest the battery using the out-ofvehicle test before replacing it.
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Midtronics B.V. Hoofdveste 6 - 8 Houten NL
Chapter 8: QC test
EXP-1000 HDChapter 8: QC test
The tester has the ability to test multiple batteries one after
the other without having to input the battery rating / settings.
There are two types of QC tests: the STOCK CONTROL or
COMPOUND TEST.
STOCK CONTROL is meant for batteries standing in a
warehouse or on a pallet where as COMPOUND TESTING is
done when the battery is in the vehicle.
1. Select the QC MODE
1 STOCK CONTROL
2 COMPOUND TEST
Press the NEXT soft key to continue. The BACK soft key
returns you to the Main Menu at the start of the test and
to the previous screen as you progress.
Stock control
2. The rst screen shows you the amount of tests performed.
Once you press both the arrow keys you reset the test
counter. Press NEXT if you want to continue without clearing the tests.
3. Select the BATTERY TYPE
1 REGULAR
2 AGM
3 SPIRAL
6. Enter the MINIMUM VOLTAGE.
7. Select the TEMPERATURE.
Aim the tester 5 cm from the sides or top of the battery
case. As soon as the temperature reading is stable the
operator can press NEXT.
The tester will now test the battery.
Compound test
2. The rst screen shows you the amount of tests performed.
Once you press both the arrow keys you reset the test
counter. Press NEXT if you want to continue without clearing the tests.
COMPOUND TEST
3. Select the BATTERY MENU.
1 MANUAL
2 PRE-SELECTION
MANUAL input is selecting the dierent battery parameters
that can be found on the battery. The PRE-SELECTION is what
is entered in the tester memory. This is initially empty but can
be lled in from the UTILITY menu.
Press the NEXT soft key to continue. The BACK soft key returns
you to the previous screen.
For selection of the MANUAL input see the previous
explanations and screens.
4 GEL
Press the NEXT soft key to continue.
4. Select the RATING UNITS
1 CCA
2 JIS
3 DIN
4 SAE
5 IEC
6 EN
Press the NEXT soft key to continue.
5. Select the BATTERY RATING
Press the UP ( ) and DOWN ( ) ARROW keys to select
the rating. In case of a JIS battery type the part number.
Midtronics B.V. Hoofdveste 6 - 8 Houten NL
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EXP-1000 HD Chapter 9: Utility Menu
Chapter 9: Utility Menu
The Utility Menu allows you to easily set up your analyzer:
Cong tester
TIME : 9:07
MODE : 24 HOUR
DATE : 01/01/2017
FORMAT : /MM/DD/YYYY
TEMP. UNITS : °C
WRITE FAIL : ASK
Time
1. Use the LEFT/RIGHT ARROW keys to highlight the hour
or minutes. To rapidly scroll, hold down an ARROW key.
9 : 07 AM
2. Press the SAVE soft key to save your setting or BACK to
return to the ADJUST screen.
Mode
Use the LEFT/RIGHT ARROWS to select the option of your
choice.
1. Select the 24-hour or AM/PM mode
Write fail
After each measurement the test results are stored on the data
card. In case the data cannot be stored on to the card you can
select the way this is notied to the operator.
ASK (operator is asked if it is ok to continue even when
results are not stored)
FORCE (measurements can only continue when data card
is entered)
IGNORE (measurement is not stored and operator not no-
tied)
2. Press the OK soft key to save your setting
Date
Date cannot be changed.
Format
Use the UP/DOWN ARROWS to select the desired option.
1. MM/DD/YYYY (month/day/year) or DD/MM/YYYY (day/
month/year)
2. Press the OK soft key to save your setting.
Temp. units
Use the LEFT/RIGHT ARROWS to select either Celsius or
Fahrenheit as temperature indication.
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Midtronics B.V. Hoofdveste 6 - 8 Houten NL
EXP-1000 HDChapter 9: Utility Menu
Display
The LCD OPTIONS utility enables you to adjust the contrast of
the text on the display and the backlight time.
Contrast Level
The contrast level is 0 (lightest) to 10 (darkest). To change it:
1. Press the UP or DOWN ARROW to highlight the option.
CONTRAST LEVEL 10
BACKLIGHT TIME 60
2. Press the LEFT/RIGHT ARROW key to display the option’s numerical scroll box.
10
3. Press the UP/DOWN ARROW keys to select your preference.
4. Press the SAVE soft key to save your setting or the BACK
soft key to return to the CONTRAST LEVEL screen without
saving the changes.
Backlight Time
Backlight time is from 0 to 60 seconds. To change it:
1. Press the UP or DOWN ARROW to highlight the option.
(1-10)
CONTRAST LEVEL 10
BACKLIGHT TIME 60
Screen 1
1–YOUR SHOP NAME
—
2–1000 ANY STREET
3–YOUR TOWN, STATE
4–YOUR POSTAL CODE
Screen 2
5–YOUR COUNTRY
—
6–YOUR PHONE NUMBER
7–WWW.WEBSITE.COM
8–YOUR SHOP ID NUMBER
To create or overwrite a header:
1. Press the UP or DOWN ARROW to highlight the line you
want to change.
2. Press SELECT to activate the line for editing, move the
cursor backward to erase a character, press the LEFT AR-
ROW key; to move the cursor forward, press the RIGHT
ARROW key.
3. Insert a character by pressing the key associated with the
character as many times as needed.
4. You can center text by selecting blank spaces before and
after lines of text or insert spaces between words.
5. Press the SAVE soft key to save your setting or the BACK
soft key to return to the SHOP INFO screen without saving
the changes.
2. Press the LEFT/RIGHT ARROW key to display the op-
tion’s numerical scroll box.
60
3. Press the UP/DOWN ARROW keys to select your prefer-
ence.
4. Press the SAVE soft key to save your setting or the BACK
soft key to return to the BACKLIGHT screen without saving
the changes.
SEC
Cong Printer
When using this option it allows you to switch our printer from
HP protocol to IrDA protocol.
Shop Info
The SHOP INFO utility enables you to create a header for
your printed test results showing your business location
information. Its two information screens contain eight lines of
text with up to 16 characters on each line.
Coupon
The COUPON utility enables and disables the printing of the
custom coupon you have created in the EDIT COUPON utility.
1. Use the UP/DOWN ARROWS to move the dot to the option button of your choice.
2. Press the NEXT soft key to save your setting or the BACK
soft key to return to the UTILITY menu without saving the
changes.
Edit Coupon
The EDIT COUPON utility enables you to create a promotional
coupon for your customers that prints at the bottom of every
test result. Its two information screens contain eight lines
of text with up to 16 characters each. The editing process is
the same as when you create a header for your test results
printouts. See the SHOP utility for more information.
Midtronics B.V. Hoofdveste 6 - 8 Houten NL
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EXP-1000 HD Chapter 9: Utility Menu
Language
The LANGUAGE utility enables you to select a language for the
display and printouts. To set your preference:
1. Use the UP/DOWN ARROWS to move the dot to the
option button of your choice. There is a selection of 24
languages.
2. Press the NEXT soft key to save your setting.
Format Card
Select this utility to format a data card to receive data or erase
all data on the card. The Tester will warn you before formatting
the card and ask you if you want to continue. When a new
blank data card is used you always have to use this function
before the tester can write to the card.
Update
As software updates become available you’ll be able to use
this utility to update the Tester software using les on an SD
card. The use of a special formatted card is required for this
action.
FIRMWARE (use this option when new software becomes
available from Midtronics)
SAVE CONFIG (the tester will store the workshop address
to the data card, le name is CONFIG.CSV)
LOAD CONFIG (after new software is uploaded you can
reload the workshop details to the tester)
1. Connect the tester to a 12V battery to ensure the tester
does not switch o during the proces
2. Insert the disc in the tester
3. Select one of the options and follow the instructions on
the screen
4. When nished the tester will prompt you to remove the
card and reboot the tester
QC Mode
Use this option to congure your way of quality control
measurements. Select either the Compound mode or Stock
Control mode.
1. Use the UP/DOWN ARROWS to move the dot to the option button of your choice.
2. Press the NEXT soft key to save your setting or the BACK
soft key to return to the UTILITY menu without saving the
changes.
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Midtronics B.V. Hoofdveste 6 - 8 Houten NL
Chapter 10: Info Menu
The Info Menu has 3 utilities to help you manage your test
data and track the usage and history of your analyzer.
Totals
The TOTALS report displays the total number of battery tests
performed since the Tester was rst used. Press the LEFT and
RIGHT ARROW keys simultaneously to clear the total and
reset the starting date.
Transfer Data
The TRANSFER utility lets you transfer test data to a PC using
an optional IR receiver/software package.
Version Info
EXP-1000 HDChapter 10: Info Menu
Version info displays the software versions and serial number
of the analyzer.
Midtronics B.V. Hoofdveste 6 - 8 Houten NL
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EXP-1000 HD Chapter 11: Print/View
Chapter 11: Print/View
The Print/View Menu enables you to view and print the results
of the Battery and or System Tests before you perform another
test and overwrite the results in memory.
View Test
VIEW TEST gives you the option of viewing and printing the
results of the Battery and System Tests. To print the results,
align the analyzer’s IR transmitter with the printer’s receiver,
and select the PRINT soft key. To return to the Main Menu,
press the END key.
View QC Test
VIEW QC TEST gives you the option of viewing and
printing all results of the Quality Control Test. To print
the results, align the analyzer’s IR transmitter with
the printer’s receiver, and select the PRINT soft key.
To return to the Main Menu, press the END key.
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Midtronics B.V. Hoofdveste 6 - 8 Houten NL
Chapter 12: Troubleshooting
EXP-1000 HDChapter 12: Troubleshooting
If you have problems with the display or the Midtronics
printer, try these troubleshooting suggestions:
The Display Does Not Turn On
• Check the connection to the vehicle battery.
• Press the POWER button.
• The vehicle’s battery may be too low to power the ana-
lyzer (below 1 volt). Fully charge the battery and retest.
• The analyzer’s 6 AA batteries may need to be replaced.
Follow the directions in Chapter 14: EXP Internal Batteries
and replace the batteries (alkaline recommended).
• If troubleshooting does not solve the problem, contact
Midtronics at 1-800-776-1995 to obtain service. See “Patents, Limited Warranty, Service” for more information.
The STATUS LED Flashes (Midtronics Printer)
When a printer fault occurs, the STATUS LED ashes. You can
identify the fault by the number of sequential ashes:
Printer STATUS LED
Sequence Condition Solution
* * * No paper Insert new paper
** ** ** Thermal head too hot Allow head to cool
Data Will Not Print
• If the IR transmitter and receiver are not aligned, all the
data may not print. The infrared ports on the top of the
analyzer and on the printer below the MODE button
should be pointed directly at each other. The maximum
distance for reliable transmission between the ports is 17
in (45 cm).
To realign, press the END button to cancel the print
job. Verify alignment between the analyzer and printer;
then try to print the test results again.
• Make sure the printer is on. The printer shuts o af-
ter 2 minutes of inactivity to conserve the batteries.
To turn the printer on, briey press the MODE button.
The green STATUS light should turn on. Make sure you
are using the Midtronics printer. Other printers may not
be compatible.
• Direct sunlight interferes with infrared data transmission
and receiving. If the printer is not receiving data, remove
the printer and EXP from direct sunlight. If the printed
characters are not clear or are partially missing, recharge
the battery and reprint.
• If you are unable to print after ensuring the analyz-
er is functioning, the printer is on, the batteries are
good, and the IR transmitter and receiver are aligned,
check the printer manual for further instructions or call
Midtronics at 800-776-1995 for assistance. (See “Patents,
Limited Warranty, Service” for more information.)
*** *** *** Batteries weak Recharge printer
batteries for 16 hours
Midtronics B.V. Hoofdveste 6 - 8 Houten NL
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EXP-1000 HD Chapter 13: Tester Internal Batteries
Chapter 13: Tester Internal Batteries
The tester uses 6 AA, 1.5-volt batteries (alkaline recommended)
to allow testing of batteries down to 1 volt and supply power
while the menu is active. The analyzer can test batteries down
to 5.5 volts when the internal batteries are not functioning.
Battery Power Indicator
The square in the upper left corner of the display indicates
the charge level of the battery pack. The square is black when
the battery pack is fully charged. It gradually changes to white
as the charge level declines. The tester will display a warning
message when the batteries need replacing.
Full Powered by
Power Level Indicator for AA Batteries
Decreasing Low
test battery
Replacing the Tester Batteries
1. Turn the tester face down.
2. Press gently on the ridges above the arrow on the battery compartment cover.
3. Slide the cover in the direction of the arrow and remove
the cover.
4. Remove the discharged batteries.
5. Insert new batteries as shown in the gure on the right
side. Make sure the positive and negative terminals are
positioned correctly.
6. Insert the door’s tabs into the slots on the analyzer and
slide the door closed, making sure the latch locks.
Latch Press here Slide in
this direction
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Battery Replacement
Midtronics B.V. Hoofdveste 6 - 8 Houten NL
PATENTS
The EXP series is made by Midtronics, Inc., and is protected by one or more U.S. and foreign patents. For specic patent
information, contact Midtronics, Inc. at +1 630 323-2800.
LIMITED WARRANTY
This analyzer is warranted to be free of defects in materials and workmanship for a period of two years from date of purchase.
Midtronics will, at our option, repair or replace the unit with a remanufactured unit. This limited warranty applies only to the
analyzer, and does not cover any other equipment, static damage, water damage, overvoltage damage, dropping the unit, or
damage resulting from extraneous causes including owner misuse. Midtronics is not liable for any incidental or consequential
damages for breach of this warranty. The warranty is void if owner attempts to disassemble the unit or to modify the cable
assembly.
Corporate Headquarters
Willowbrook, IL USA
Phone: 1.630.323.2800
Canadian Inquiries
Toll Free: 1.866.592.8052
167-090EN-B 9/16 ©2016 Midtronics B.V.
www.midtronics.com
Midtronics B.V.
European Headquarters
Houten, The Netherlands
Serving Europe and Africa
Phone: +31 30 68 68 150
Midtronics China Oce
China Operations
Shenzhen, China
Phone: +86 755 23741010
Midtronics India
Mumbai, India
Phone: +91 22 27564103/1513
Asia/Pacic (excluding China)
Contact Corporate Headquarters
Phone: +1 630 323 2800
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