November 2008
168-822C
GR8 1100
INSTRUCTION ManuAl
INNOVATION |
TECHNOLOGY |
QUALITY |
WORLDWIDE |
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GR8 1100 |
Contents |
Contents
Contents
Safety Guidlines |
5 |
General Safety Precautions |
5 |
Personal Precautions |
5 |
Preparing To Charge The Battery |
6 |
Grounding And AC Power Cord Connections |
6 |
Charger Location |
7 |
DC Connection Precautions |
7 |
Installing The Battery |
7 |
Chapter 1: Before You Begin |
9 |
Safety Reminder |
9 |
Safety Precautions |
9 |
Registering Your GR8 |
10 |
Assembling the GR8 |
10 |
Attaching the Control Module |
10 |
Attaching the Charger Cables |
11 |
Chapter 2: Overview |
12 |
Front of GR8 |
12 |
Back of GR8 |
13 |
Display and Keypad |
14 |
Data Entry Methods |
15 |
Menu icons |
15 |
Option Buttons |
15 |
Scrolling Lists |
15 |
Alphanumeric Entry |
16 |
Value Boxes |
16 |
Menu Structure |
16 |
Main Menu |
16 |
Charging Menu |
17 |
Info Menu |
17 |
Setup Menu |
18 |
Chapter 3: Getting Started |
19 |
Logging In for the First Time |
19 |
Bootup |
19 |
Initial User Login |
19 |
Chapter 4: Setup Menu |
20 |
Clock |
21 |
Time |
21 |
Mode |
21 |
Date |
21 |
Users |
21 |
Entering a New User ID |
21 |
Deleting a User ID |
22 |
Edit (Editing a User ID) |
22 |
Shop |
23 |
Display |
23 |
Contrast Level |
23 |
Coupon |
24 |
Edit Coupon |
24 |
Temp |
24 |
Language |
25 |
Format Disk |
25 |
Update |
25 |
Admin |
25 |
Options |
25 |
Change Admin PIN |
25 |
Clear Test Totals |
25 |
Reset Defaults |
26 |
Buzzer |
26 |
Chapter 5: Preparing to Charge |
27 |
Inspecting the Battery |
27 |
Connecting the Clamps |
27 |
Connecting to AC Power |
27 |
Setting User Preferences |
27 |
Help Menu and Soft Keys |
27 |
www.midtronics.com |
• 3 • |
Midtronics Inc. 7000 Monroe Street Willowbrook, IL 60527 |
Contents |
GR8 1100 |
Chapter 6: Charging Menu |
28 |
Diagnostic Charging Modes |
28 |
Selecting the Charging Parameters |
28 |
Initial Analysis |
29 |
Deep Scan Test |
29 |
Diagnostic Charging |
29 |
Recovery Mode |
30 |
Aborting a Charge Session |
30 |
Completing a Charge Session |
30 |
Top-Off Mode |
30 |
Diagnostic Charge Results |
31 |
State-of-Health (SOH) |
31 |
Manual Charging |
32 |
Jump Start |
33 |
Chapter 7: Battery Test |
34 |
Deep Scan Test |
34 |
Battery Results |
35 |
State-of-Health (SOH) |
35 |
Chapter 8: Power Supply Mode |
36 |
Chapter 9: Info Menu |
37 |
Print/View |
37 |
Totals |
37 |
Transfer |
37 |
Version |
37 |
Chapter 10: Test Messages |
38 |
Chapter 11: Replacement Printer Paper |
39 |
Replacing the Paper Roll |
39 |
Chapter 12: Test Cable Maintenance |
40 |
Midtronics Inc. 7000 Monroe Street Willowbrook, IL 60527 |
• 4 • |
www.midtronics.com |
GR8 1100 |
Safety Instructions |
! Safety Guidlines
1 General Safety Precautions
1.IMPORTANT SAFETY INSTRUCTIONS. IT IS OF UTMOST
IMPORTANCE THAT BEFORE USING YOUR CHARGER, YOU READ THIS MANUAL AND FOLLOW THE SAFETY AND OPERATING INSTRUCTIONS EXACTLY. SAVE THESE INSTRUCTIONS.
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.
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 deepcycle batteries.
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 by hood, doors, or 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.
Remove marine “boat” batteries and charge them on shore.
Charging marine batteries on-board requires specially designed equipment for marine use.
1.8Connect and disconnect the battery leads only when the AC supply cord is disconnected.
1.9Do not overcharge the battery. (See sections 3 and 10 in the safety instructions)
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 4.3.)
1.13Have a damaged cord or plug replaced immediately.
1.14Do not expose the charger to rain or snow.
2 Personal Precautions
2.1Always have someone within range of your voice, or close enough to come to your aid, when working around lead acid batteries.
2.2Have plenty of fresh water and soap nearby in case battery acid contacts skin, clothing or eyes.
2.3Wear 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.
2.4If 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.
2.5NEVER smoke or allow a spark or flame in vicinity of a battery or engine.
2.6Be 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.
2.7Before 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.
www.midtronics.com |
• 5 • |
Midtronics Inc. 7000 Monroe Street Willowbrook, IL 60527 |
Safety Instructions |
GR8 1100 |
Non-rechargeable batteries may burst when charging causing personal injury and damage.
Only charge rechargeable lead-acid maintenance-free, low-maintenance or deepcycle batteries.
The charger is not intended to supply power to a lowvoltage 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.
2.9 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 nonmetallic 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 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 And AC Power Cord Connection Instructions
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.
IFTHEPLUGDOESNOTFITTHEOUTLET,HAVEAPROPER OUTLET INSTALLED BY A QUALIFIED 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.
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 ELECTRICIAN.
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.
Midtronics Inc. 7000 Monroe Street Willowbrook, IL 60527 |
• 6 • |
www.midtronics.com |
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GR8 1100 |
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Safety Instructions |
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Recommended minimum AWG* size for extension cords for battery chargers |
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AC input rating amperes |
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AWG* size of cord |
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Equal or greater than: |
But less than: |
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Length of cord, feet (m) |
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25 |
50 |
100 |
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150 |
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(7.6) |
(15.2) |
(30.5) |
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(45.6) |
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8 |
10 |
18 |
14 |
12 |
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10 |
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10 |
12 |
16 |
14 |
10 |
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8 |
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12 |
14 |
16 |
12 |
10 |
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8 |
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14 |
16 |
16 |
12 |
10 |
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8 |
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16 |
18 |
14 |
12 |
8 |
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8 |
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*American Wire Gauge |
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5. Charger Location |
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7. Installing The Battery |
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5.1Locate the charger as far away from the battery as the charger cables permit.
5.2Never place the charger directly above the battery being charged; gases from the battery will corrode and damage the charger.
5.3Never allow battery acid to drip on the charger when taking gravity readings or filling a battery.
5.4Operate the charger only in a well-ventilated area that is free of dangerous vapors.
5.5Store the charger in safe, dry location and maintain it in perfect condition.
5.6Do not set the battery on top of the charger or where its acid might drip onto the charger.
6. DC Connection Precautions
6.1All switches should be set in the OFF position and AC cord should be DISCONNECTED from electrical outlet before you connect and disconnect the charger clamps. Never allow the clamps to touch each other.
6.2When 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.
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.
7.1Before working on the vehicle, firmly apply the emergency brake and place the gear shift to NEUTRAL—shift an automatic transmission to PARK.
7.2Locate 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 hood, doors, or moving engine parts.
7.3Stay clear of fan blades, belts, pulleys, and any other parts that can cause physical injury.
7.4Turn OFF all vehicle loads, including door lights, and correct any defects in the vehicle’s electrical system that may have caused low battery.
7.5Check the polarity of the battery posts. The POSITIVE (POS., P, +) post usually has a larger diameter than the
NEGATIVE (NEG., N,–) post.
7.6Determine which post of the battery is grounded (connected) to the 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.
7.7For a negative-grounded vehicle, first 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 sheet-metal body parts. When disconnecting the charger, turn all switches to OFF, disconnect the AC cord, remove the clamp from the NEGATIVE battery terminal, and then remove the clamp from the POSITIVE battery terminal.
www.midtronics.com |
• 7 • |
Midtronics Inc. 7000 Monroe Street Willowbrook, IL 60527 |
Safety Instructions |
GR8 1100 |
7.8For positive-grounded vehicle, connect the NEGATIVE (BLACK) clamp from the charger to the NEGATIVE (NEG., N, –) ungrounded post of battery. Then connect the POSITIVE (RED) clamp to the POSITIVE (POS., P, +) post of the battery. Do not connect clamp to carburetor, fuel lines, or sheet-metal body parts.
When disconnecting the charger, turn the switches to OFF, disconnect the AC cord, remove the clamp from the POSITIVE battery terminal, and then remove the clamp from the NEGATIVE battery terminal.
CAUTION: WHEN POSITIVE (+) POST OF VEHICLE BATTERY IS GROUNDED, DOUBLE CHECK POLARITY.
8.If 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.
WARNING: Make sure all vehicle loads are OFF to prevent a possible arc.
8.1Check the polarity of battery posts. POSITIVE (POS., P, +) post usually has larger diameter than NEGATIVE (NEG., N, –) post.
8.2Attach at least a 60 cm (24-inch), 6-gauge insulated battery cable to the negative (–) battery terminal.
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.
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.
8.6MARINE “BOAT” BATTERIES MUST BE REMOVED AND CHARGED ON SHORE. TO SAFELY CHARGE THEM ON BOARD REQUIRES EQUIPMENT ESPECIALLY DESIGNED FOR MARINE USE.
Midtronics Inc. 7000 Monroe Street Willowbrook, IL 60527 |
• 8 • |
www.midtronics.com |
GR8 1100 |
Chapter 1: Before You Begin |
Chapter 1: Before You Begin
!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 manufacturers’ instructions and BCI (Battery Council International) safety recommendations.
We also recommend that you register the GR8 to activate your warranty. See “Registering Your GR8” on the next page.
Battery 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.
Always wear proper safety glasses or face shield when working with or around batteries.
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Keep hair, hands, and clothing as well as the analyzer cords |
! |
and cables away from moving engine parts. |
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:
DANGER—RISK OF EXPLOSIVE GASES: 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. Never smoke or allow a spark or flame in the vicinity of a battery.
WARNING—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. Wash hands after handling.
Remove any jewelry or watches before you start servicing the battery.
Use caution when working with metallic tools to prevent sparks or short circuits.
Never lean over a battery when testing, charging, or jump starting.
Never charge a frozen battery. Gases may form, cracking the case, and spray out battery acid.
www.midtronics.com |
• 9 • |
Midtronics Inc. 7000 Monroe Street Willowbrook, IL 60527 |
Chapter 1: Before You Begin |
GR8 1100 |
Conventions Used in This Manual
To help you learn how to use your GR8, the manual uses these symbols and typographical conventions:
Convention |
Description |
!The safety symbol indicates instructions for avoiding hazardous conditions and personal injury.
CAUTION |
The word CAUTION indicates instructions for avoiding equipment damage. |
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The wrench symbol indicates procedural notes and helpful information. |
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UP ARROW |
The text for keypad buttons are in bold capital letters. |
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CAPITAL LETTERS |
The text for screen options are in regular capital letters. |
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BACK |
The text for soft keys are in Arial Black capital letters. |
Registering Your GR8
Before using the GR8, we recommend that you register it online to activate your warranty. Registration will also make it faster and easier for you to obtain technical support and service. The GR8 has two serial numbers: one for the control module and another for the charger engine. For their locations, see the illustration on page 14.
To register, log on at www.midtronics.com/warranty.html and have your serial numbers ready. If your charger needs repair, call Midtronics Customer Service 1.800.776.1995. Servicing the charger yourself may void your warranty. Refer to the appendix on what is covered by the warranty.
Assembling the GR8
The GR8 is shipped with the control module, mounting bracket, and charger cables packed separately. For easy assembly, follow these steps:
Attaching the Control Module
1.The hardware to attach the control module’s mounting bracket to the GR8 is installed on the top of the charger. There are three bolts with one flat washer, one lock washer, and one hex nut per bolt. Remove the washers and hex nuts, and set them aside.
2.Center the three holes in mounting bracket over the bolts, and lower the bracket onto the charger. Reinstall the hardware in this order: the flat washer first, the lock washer next, and the hex nut last. Tighten the nuts securely.
One of three |
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preinstalled |
One of four preinstalled bolts |
bolts for the |
on the bracket for mounting the |
control module |
control module. |
mounting |
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bracket. |
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Midtronics Inc. 7000 Monroe Street Willowbrook, IL 60527 |
• 10 • |
www.midtronics.com |
GR8 1100 |
Chapter 1: Before You Begin |
3.Center the holes on the bottom of the control module with the bolts, and lower the module onto the top of the barcket. Firmly pull the module down at an angle until the bolts are inserted securely into the slots extending from the module’s holes.
2.Slide the cover (C) down the cables until it seats against the sheetmetal.
C
3. Insert the screws through the holes in the cover and sheetmetal. Tighten the screws securely with a small screwdriver. (To remove the cables, use the attachment instructions in reverse.)
4.Connect the serial cable between the charger and tighten the screws on each connector.
Attaching the Charger Cables
The two connectors for the charger cables are located on the back of the GR8. Three screws are included to secure the cables. To attach the cables:
1.Plug in the large connector (A), then plug in the small connector (B).
A B
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• 11 • |
Midtronics Inc. 7000 Monroe Street Willowbrook, IL 60527 |
Chapter 2: Overview |
GR8 1100 |
Chapter 2: Overview
Front of GR8
The controls to the GR8 are accessible on the front of the charger: the control module (user interface) and the ON/OFF switch.
Control module
Backlit graphical display and keypad for data entry.
ON/OFF switch
Turns power on and off to the GR8.
SD card slot
For future upgrades via an SD card. The slot contains a plastic filler card for protection.
STATUS light
Lights in conjunction with beeping alarm to indicate transitions and warnings.
Midtronics Inc. 7000 Monroe Street Willowbrook, IL 60527 |
• 12 • |
www.midtronics.com |
GR8 1100 |
Chapter 2: Overview |
Back of GR8
In addition to containing the outlets for the charger cables and power cord, the back of the GR8 is the location for the serial numbers for the charger engine and the control module. Both numbers are necessary for warranty registration.
Serial number label
(for control module)
Cable wrap
For storing cables when not in use.
Storage shelf
Charger cable connectors
Serial number label
(for charger engine)
AC power cord
Connection to grounded nominal 120 V outlet.
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• 13 • |
Midtronics Inc. 7000 Monroe Street Willowbrook, IL 60527 |
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