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BATTERY CHARGER
AND ANALYZER
USER GUIDE
Model 3641
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[engn001 Inside Front cover]
Important Notice
Safety
All Danger, Warning and Important notes must be followed for your safety. These safety messages will be in the following
formats:
Danger:
You may risk possible loss of life
Warning:
You may risk bodily harm
Important:
You risk damage to the vehicle or the tool
Notes:
Added to provide clarity and helpful tips.
These safety messages cover situations SPX is aware of. SPX cannot know, evaluate and advise you as to all of the
possible hazards. You must be certain that any conditions or service procedures encountered do not jeopardize your
personal safety.
Copyright
No part of this user guide may be reproduced, stored in a retrieval system or transmitted, in any form or by any means,
electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of SPX.
Disclaimer
All information, illustrations, and specifications contained in this user guide are based on the latest information available at
the time of publication. The right is reserved to make changes at any time without obligation to notify any person or
organization of such revisions or changes. Further, SPX shall not be liable for errors contained herein or for incidental or
consequential damages (including lost profits) in connection with the furnishing, performance or use of this material.
© 2002 SPX Corporation. All rights reserved.
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Contents
Contents
Important Safety Instructions ..................................................... ii
Specifications ...............................................................................................................iv
Getting Started ............................................................................. 1
Battery Charger and Analyzer ...................................................................................... 1
Assembly Instructions .................................................................................................. 1
Quick Tour .................................................................................................................... 2
Operating Instructions................................................................. 2
Set the Internal Clock ................................................................................................... 2
Set Language ............................................................................................................... 2
Select the Printer .......................................................................................................... 2
Set Ethernet ................................................................................................................. 3
Self-Test .......................................................................................................................3
Battery Test .................................................................................................................. 3
Test Report ................................................................................................................... 4
Software Update........................................................................................................... 5
Maintenance Instructions ............................................................ 5
User-Serviceable Components .................................................................................... 5
Unit Relocation ............................................................................................................. 5
Warranty ....................................................................................................................... 6
Technical Service and Repair....................................................................................... 6
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Battery Charger and Analyzer User Guide
Important Safety Instructions
WARNING:
1. SAVE THESE INSTRUCTIONS – This manual contains important safety and operating instructions for the
battery charger and analyzer.
2. Do not expose the battery charger and analyzer to rain or snow.
3. Use of an attachment not recommended or sold by the battery charger and analyzer manufacturer may result in
a risk of fire, electric shock, or injury to persons.
4. To reduce risk of damage to electric plug and cord, pull by plug rather than the cord when disconnecting the
battery charger and analyzer.
5. An extension cord should not be used. Use of an extension cord could result in a risk of fire and electric shock.
6. Do not operate the battery charger and analyzer with damaged cord or plug – replace the cord or plug immediately.
7. Do not operate the battery charger and analyzer if it has received a sharp blow, been dropped, or otherwise
damaged in any way; take it to qualified service personnel.
8. Do not disassemble the battery charger and analyzer; take it to qualified service personnel when service or
repair is required. Incorrect reassembly may result in a risk of electric shock or fire.
9. To reduce risk of electric shock, unplug the battery charger and analyzer from an outlet before attempting any
maintenance or cleaning. Turning off controls will not reduce this risk.
10. WARNING – RISK OF EXPLOSIVE GASES:
a) WORKING IN VICINITY OF A LEAD-ACID BATTERY IS DANGEROUS. BATTERIES GENERATE EXPLOSIVE
GASES DURING NORMAL BATTERY OPERATION. FOR THIS REASON, IT IS OF UTMOST IMPORTANCE THAT
EACH TIME BEFORE USING YOUR BATTERY CHARGER AND ANALYZER, YOU READ THIS MANUAL AND
FOLLOW THE INSTRUCTIONS EXACTLY.
b) To reduce risk of battery explosion, follow these instructions and those published by battery manufacturer
and manufacturer of any equipment you intend to use in vicinity of a battery. Review cautionary marking on
these products and on the engine.
11. PERSONAL PRECAUTIONS:
a) Someone should be within range of your voice or close enough to come to your aid when you work near a
lead-acid battery.
b) Have plenty of fresh water and soap nearby in case battery acid contacts skin, clothing, or eyes.
c) Wear complete eye protection and clothing protection. Avoid touching eyes while working near battery.
d) If battery acid contacts skin or clothing, wash immediately with soap and water. If acid enters eye, immedi-
ately flood eye with running cold water for at least 10 minutes and get medical attention immediately.
e) NEVER smoke or allow a spark or flame in vicinity of battery or engine.
f) Be extra cautious to reduce risk of dropping a metal tool onto battery. It might spark or short-circuit battery
or other electrical part that may cause explosion.
g) Remove personal metal items such as rings, bracelets, necklaces, and watches when working with a lead-
acid battery. A lead-acid battery can produce a short-circuit current high enough to weld a ring or the like to
metal, causing a severe burn.
h) Use the battery charger and analyzer for charging a 12V LEAD-ACID, Absorbed Glass Mat (AGM) or gel-cell
battery only. It is not intended to supply power to a low voltage electrical system other than in a startermotor application. Do not use battery charger and analyzer for charging dry-cell batteries that are commonly
used with home appliances. These batteries may burst and cause injury to persons and damage to property.
i) NEVER charge a frozen battery. Allow the battery to warm up before testing.
12. PREPARING TO CHARGE
a) If necessary to remove battery from vehicle to charge, always remove grounded terminal from battery first.
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Contents
Make sure all accessories in the vehicle are off, so as not to cause an arc.
b) Be sure area around battery is well ventilated while battery is being charged. Gas can be forcefully blown
away by using a piece of cardboard or other nonmetallic material as a fan.
c) Clean battery terminals. Be careful to keep corrosion from coming in contact with eyes.
d) Study all battery manufacturer’s specific precautions such as removing or not removing cell caps while
charging and recommended rates of charge.
13. BATTERY CHARGER AND ANALYZER LOCATION
a) Locate battery charger and analyzer as far away from battery as DC cables permit.
b) Never allow battery acid to drip on battery charger and analyzer when reading gravity or filling battery.
c) Do not operate battery charger and analyzer in a closed-in area or restrict ventilation in any way.
d) Do not set a battery on top of battery charger and analyzer.
14. DC CONNECTION PRECAUTIONS
a) Connect and disconnect DC output clips only after setting any battery charger and analyzer switches to off
position and removing AC cord from electric outlet.
b) Attach clips to battery posts and twist or rock back and forth several times to make a good connection. This
tends to keep clips from slipping off terminals and helps to reduce risk of sparking.
15. DO NOT CHARGE A BATTERY INSTALLED IN VEHICLE. A SPARK NEAR BATTERY MAY CAUSE BATTERY
EXPLOSION. Damage to the vehicle computer system may occur if the battery is tested in the vehicle.
16. FOLLOW THESE STEPS WHEN BATTERY IS OUTSIDE VEHICLE. A SPARK NEAR THE BATTERY MAY CAUSE
BATTERY EXPLOSION. TO REDUCE RISK OF A SPARK NEAR BATTERY:
a) Check polarity of battery posts. POSITIVE (POS, P, +) battery post usually has a larger diameter than NEGA-
TIVE (NEG, N, –) post.
b) Connect POSITIVE (RED) battery charger and analyzer clip to POSITIVE (POS, P, +) post of battery.
c) Connect NEGATIVE (BLACK) battery charger and analyzer clip to NEGATIVE (NEG, N, –) post.
d) When disconnecting battery charger and analyzer, always do so in reverse sequence of connecting proce-
dure.
e) A marine (boat) battery must be removed and charged on shore. To charge it on board requires equipment
specially designed for marine use.
17.GROUNDING AND AC POWER CORD CONNECTION INSTRUCTIONS – battery charger and analyzer should be
grounded to reduce risk of electric shock. Battery charger and analyzer is equipped with an electric cord having
an equipment-grounding conductor and a grounding plug. The plug must be plugged into an outlet that is
properly installed and grounded in accordance with all local codes and ordinances.
DANGER – Never alter AC cord or plug provided – if it will not fit outlet, have proper outlet installed by a
qualified electrician. Improper connection can result in a risk of an electric shock. This battery charger and
analyzer is rated more than 15 amperes and is for use on a circuit having a nominal rating of 120 volts. It is
factory-equipped with a specific electric cord and plug to permit connection to an acceptable electric circuit.
Make sure that the battery charger and analyzer is connected to an outlet having the same configuration as the
plug. No adapter should be used with this battery charger and analyzer.
18.This battery charger and analyzer should be installed so that unauthorized personnel are not likely to be in
contact with it.
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Battery Charger and Analyzer User Guide
WARNING:
• The battery charger and analyzer is intended only to test and charge 12V gel-cell, Absorbed Glass Mat (AGM),
and wet cell, lead-acid automotive rechargeable batteries. Other types of batteries may burst and cause personal injury.
• Do not operate the battery charger and analyzer where flammable liquids or vapors may be present. Sparks and
electrical arcing can occur during the test procedure.
• When plugging the power cord into an electrical outlet, avoid wet floors to prevent electrical shock.
• Unplug the battery charger and analyzer from an electrical outlet before performing maintenance. Turning off
the battery charger and analyzer does not reduce the risk of electrical shock.
• Do not alter the AC cord or plug provided. Do not use an adapter to fit a two-pole receptacle. This battery
charger and analyzer is equipped with an electrical 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.
• Do not spray excessive liquids on the battery charger and analyzer case, they may enter the case and cause
permanent damage to the electrical components. Flammable liquids may cause an explosion.
• Remove metal jewelry such as rings, watches and bracelets. Contact with a battery post and ground can cause
severe burns or a spark that may cause an explosion.
• Do not operate the battery charger and analyzer if the power cord is damaged. Replace it immediately.
•Wear ANSI approved eye protection when testing or working with batteries.
• During a battery test, stand a safe distance away and place a shield around the battery to prevent direct
exposure to sulfuric acid.
• Do not remove the leads from a battery during the test. If a lead must be removed, press the “Clear” button to
stop the test.
Important:
• Do not use an extension cord to connect the battery charger and analyzer.
• Do not cut the grounding prong off the AC power cord.
• When removing the power cord from an electrical outlet, pull out by the plug to reduce damage to the power
cord.
• The battery must be removed from the vehicle before testing. Damage to the vehicle computer system may
occur if the battery is tested in the vehicle.
• Before removing the battery from the vehicle, turn Off the ignition, accessories and any other battery load.
Remove the Negative (-) battery cable first, then remove the Positive (+) battery cable. Install the battery in the
reverse order.
Specifications
• Battery Test Range: 12 volt automotive battery rated at 150-1500 Cold Cranking Amps (CCA), 200-1900 Cranking Amps
(CA, MCA).
• Amphere Hours: 26-260
• Operating Temperature Range: 0°C to 50°C / 32°F to 122°F
• Storage Temperature Range: -20°C to 70°C / 4°F to 158°F
• Humidity Range: 0 to 85%
• Power Supply Parameters: Input volts must be 120 VAC, Input amps must be 20 A . A dedicated line is required. Failure
to adhere to the power requirements can cause inaccurate test results or a break in the electrical circuit.
• Installation Requirements: Non-portable; indoor use only; 120 VAC, 60 Hz, 20 A.
• Current Draw: 16 Amps, not including 120v. printer accessory outlet.
• Commercial Charger: Intended for use on automotive batteries, not intended for use in household or industrial applications.
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Getting Started
Battery Charger and
Analyzer
The battery charger and analyzer is a non-portable testbench that incorporates the following battery test and
charge functions into a single bench-top unit:
•Test and determine if a 12 volt gel-cell, Absorbed Glass
Mat (AGM), or wet cell, lead-acid automotive rechargeable battery is good or bad.
• Charge the battery in less than one hour.
•Warn if battery leads are faulty or connected incorrectly.
• Bar code reader to identify the battery.
• Indicator lights to show the progress of the test.
• Easy-to-follow on-screen instructions for each step of the
test procedure.
•A printed report that shows the battery condition after the
test and charge.
The battery charger and analyzer is easily connected to a
Local Area Network
Battery Test reports.
(LAN) for data transfer and for printing
Assembly Instructions
The battery charger and analyzer is not intended to be a
portable unit, it is mounted in a stand where it will be
permanently located.
To complete the assembly for the battery charger and
analyzer, follow these steps:
1. Insert the battery cables into the battery cable port (item
1). Insert the sense cable into the sense cable port (item
2). See Figure: Battery charger and analyzer Ports.
3. If the optional bar code reader was purchased, insert the
bar code reader serial cable into the serial port (item 9).
Consult the bar code reader documentation to set up the
bar code reader.
4. If the optional printer was purchased, connect the printer
serial cable into the serial port (item 7). Consult the
printer documentation to locate the serial port on the
printer and to set up the printer.
Plug the printer into the power receptacle located on the
back of the battery charger and analyzer (item 5).
Turn On the printer and leave it On. The power switch for
the battery charger and analyzer will now turn the printer
On or Off when the printer is needed.
5. If connecting the battery charger and analyzer to a LAN,
connect your Ethernet cable to the Ethernet port (item
8).
6. Plug the battery charger and analyzer power cord (item
3) into a 120 volt, 60Hz, 20A grounded wall outlet.
1
5
4
3
6
7
8
Figure: Battery charger and analyzer Ports
1. Battery cable port
2. Sense cable port
3. Battery charger and analyzer Power Cord
4. 3A-125V, Type 3AG “fast-acting” fuse
5. Printer Plug-in
6. Compact Flash Card port
7. Serial port (printer)
8. Ethernet port
9. Serial port (bar code reader)
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2
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Battery Charger and Analyzer User Guide
Quick Tour
10
Analysis
Progress Good
Bad
in Progress
9
Figure: Battery charger and analyzer
Take a moment to quickly tour the battery charger and
analyzer .
8
1. Compact Flash Card port
Battery charger and analyzer Ports): Program
updates for the battery charger and analyzer
Operating Software can be furnished on a flash
card. The software is updated when the flash card is
installed into the Flash Card port.
2. On/Off (I/0) switch: Press this switch to provide
power to the battery charger and analyzer .
3. Breaker switch: Press the Breaker switch to reset
the connection if an electrical overload causes a
break in power.
4. Number keys: Enter numeric information.
5. Clear key: Press to remove information entered
onto the display, or to stop the battery testing
procedure.
6. Go key: Press to start a test program.
7. Up/Down keys: Press to scroll up or down to the
next line on the Display window or to the next
screen.
8. Menu key: Press to select the Main menu.
9. Display: Menus and input screens are shown on
the Display.
10.Status Lights: The status lights indicate that the
battery charger and analyzer is powered on
(Power); a test is in progress (Progress); a fault is
found (Bad); or the testing procedure is completed
(Good).
11. Battery Clamp Test Leads: Connect to the battery
posts to apply a load to the battery, take voltage
measurements and charge the battery.
6
7
2
5
11
(see item 6 in Figure:
3
4
Operating
Instructions
The battery charger and analyzer evaluates and charges
the battery in a single test.
Warning:
The battery charger and analyzer must be properly
assembled in accordance with the assembly instructions before it is used.
Set the Internal Clock
The internal clock can be set to display time/month/day/
year. The clock information is printed on the Battery Test
printed report.
To set the internal clock, follow these steps:
1. Press the MENU button. Press Button 2 to select
Setup> Button 1 to select Set Clock. After each “Enter”
screen press GO to advance to the next screen.
2. Press the number key to select AM or PM.
3. Enter the month, day, hour and minutes as two digits; for
example, 00 through 09 or 10 though 59.
Set the Language
Select the Language for the on-screen display.
To select the language, follow these steps:
1. Press the MENU button. Press Button 2> Setup>
Button 2 to select Set Language.
2. Press the number key to select a language, press GO.
3. Press Save Setup to save all changes.
Select the Printer
To select the printer, follow these steps:
1. Press the MENU button. Press Button 2> Setup>
Button 3 to select Select Printer.
2. Press Button 1 to select a printer connected to the
battery charger and analyzer or press Button 2 to select
a printer connected to the Ethernet network.
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Set Ethernet
To set up the Ethernet communication, follow these
steps:
1. Press the MENU button. Press Button 2> Setup>
Button 3 to select Ethernet Setup.
2. To view the net setup, press Button 1 - Display Net
Setup. To change the Net Setup, press Button 2 - Edit
Net Setup.
3. To edit the net setup, enter numbers for each segment
and press GO to advance to the next segment. Press
the down Key (▼) to advance to the next address of the
Ethernet setup.
Tool IP Address
10.72.33.106
Press ▼ for other
Battery Test
The technician performs three basic steps:
1. Visually inspect the battery,
2. Connect the battery leads to the battery,
3. Enter a brief battery description.
At the conclusion of the test, a printed report is produced
that reports battery failure or pass and the battery warranty
number.
To test a battery, follow these steps:
1. Before removing the battery from the vehicle, turn Off the
ignition, accessories and any other battery load. Remove
the Negative (-) battery cable first. Then remove the
Positive (+) battery cable.
Important:
Failure to remove the Negative (-) battery cable first can
damage the vehicle computer.
press GO to advance to each segment
Self-Test
Individual self-tests should be activated if any problems are
noted with the display, keys, status lights or audio. If a test is
failed, follow the instructions for Technical Service and
Service Repair, page 6.
To self-test individual functions, follow these steps:
Press the MENU button. Press Button 3 to select Self Test.
Press the Button number to activate a self-test.
• Display Test: Press Button 1 to select Display Test.
A series of tests will be initiated, at the successful
completion of each test press GO to answer YES or to
advance to the next test until the message “DISPLAY
TEST COMPLETED” is received.
• Keypad Test: Press Button 2 to select Keypad Test.
Press each key, the screen will verify the key pressed.
When all keys are pressed and verified the message
“Keypad Test PASSED” is displayed.
• Status Light Test: Press Button 3 to select Status
Light Test.
Each status light is illuminated in turn. The test will verify
all status lights and display “status light test completed”
at the successful completion of the test.
• Audio Test: Press Button 4 to select Audio Test.
A “tone” will sound and the message “Audio test completed” is displayed at the successful completion of the
test.
2. Place the battery on the test-bench. Connect the
Positive (+) Battery Test lead to the Positive battery post;
connect the Negative (-) Battery Test lead to the Negative battery post.
3. Lower the test stand shield over the battery.
4. Press the
charger and analyzer; The POWER status light will glow.
5. Press the GO button to begin the Test and Charge
Battery program. Press CLEAR if the test must be
stopped any time during the Battery Test.
On/Off
(I/O) button to power-up the battery
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Battery Charger and Analyzer User Guide
6. Press a number key to respond to each of the three
battery visual inspection questions:
• Case cracked?
Figure: Cracked case
• Posts/Terminals broken?
Figure: Broken post
• Battery frozen?
7. Press a number key to select one of the following
methods of battery identification:
• CCA or MCA:
1. Enter the CCA or MCA number with the number keys,
press GO.
2. Select Yes/No if Gel Cell/AGM battery, testing will
begin immediately.
• Amp Hours:
1. Enter the Amp hours with the number keys, press
GO.
2. Select Yes/No if Gel Cell/AGM battery, testing will
begin immediately.
Figure: Bar Code/CCA/Amp hours
When the Battery Load test or the battery charge process
are active, the PROGRESS status light will glow. Respond
to any messages displayed during the Battery Test. One of
two results will be displayed at the completion of testing:
• If the Battery Test detects a failure (Bad battery), the
BAD status light will glow.
• When the test is completed (Good battery), the GOOD
status light will glow.
Figure: Frozen battery
4
Test Report
The battery test results are saved into the battery charger
and analyzer memory to be printed if required.
To print the battery test report, follow these steps:
1. Press the MENU button. Press Button 1 to select Test
Results.
2. Press Button 1 to print the report.
Battery Service Checksheet
Unit ID=94-5
BATTERY CONDITION
Battery is bad
Warranty code: 15FAZ707
Store:_______________________________________
Invoice:
Page 11
Software Update
The battery charger and analyzer operating software is
easily updated with upgraded programs supplied on
Compact Flash cards.
To update battery charger and analyzer software with
the Compact Flash card, follow these steps:
1. Turn OFF the battery charger and analyzer. Insert the
Upgrade Software Compact Flash card into the Compact
Flash Card port.
• Do not spray excessive liquids on the battery
charger and analyzer case, they may enter the case
and cause permanent damage to the electrical
components. Flammable liquids may cause an
explosion.
• When plugging the power cord into an electrical
outlet, avoid wet floors to prevent electrical shock.
• Immediately replace the battery charger and analyzer
cable if it is worn or damaged.
Clean the outside of the case and the cables with a mild,
multipurpose cleaner. Do not allow excessive moisture to
seep into the case. While cleaning the cables, inspect for
damage and replace as necessary.
IMPORTANT:
Do not use solvents or harsh cleaners on the cables,
the chemicals will eventually dry them out and they will
crack.
Compact Flash Card port
Figure: Compact Flash Card port
2. Turn ON the battery charger and analyzer. Press the
MENU button. Press Button 4 to select Update S/W
(Software). Press Button 1 to begin the update.
3. Press GO, the installation will be completed in two or
three minutes.
4. When the installation is completed, turn OFF the battery
charger and analyzer and remove the Compact Flash
card from the Compact Flash Card port. Restart the
battery charger and analyzer to complete the update
process.
Maintenance
Instructions
Keep the cable clamp ends clean. Use a small wire brush if
necessary.
User-Serviceable Components
Warning:
There are no user-serviceable components located
on the inside of the tester: all servicing should be
performed by qualified service personnel.
Unit Relocation
The battery charger and analyzer is not intended to be
removed from the stand or used as a portable unit. If
relocation or replacement is necessary, a minimum of two
persons are required to lift and move the unit.
To clean the outside surface of the battery charger and
analyzer, follow these precautions and steps:
Warning:
• Unplug the battery charger and analyzer from the
electrical supply before performing maintenance.
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Battery Charger and Analyzer User Guide
SPX Corporation Limited Warranty
THIS WARRANTY IS EXPRESSLY LIMITED TO ORIGINAL RETAIL BUYERS OF SPX ELECTRONIC DIAGNOSTIC
TOOLS (“UNITS”).
SPX Units are warranted against defects in materials and workmanship for three years (36 months) from date of delivery.
This warranty does not cover any Unit that has been abused, altered, used for a purpose other than that for which it was
intended, or used in a manner inconsistent with instructions regarding use. The sole and exclusive remedy for any Unit
found to be defective is repair or replacement, at the option of SPX. In no event shall SPX be liable for any direct,
indirect, special, incidental or consequential damages (including lost profit) whether based on warranty, contract, tort or
any other legal theory. The existence of a defect shall be determined by SPX in accordance with procedures established
by SPX. No one is authorized to make any statement or representation altering the terms of this warranty.
Disclaimer
THE ABOVE WARRANTY IS IN LIEU OF ANY OTHER WARRANTY, EXPRESS OR IMPLIED, INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.
Software
Unit software is proprietary, confidential information protected under copyright law. Users have no right in or title to Unit
software other than a limited right of use revocable by SPX. Unit software may not be transferred or disclosed without the
written consent of SPX. Unit software may not be copied except in ordinary backup procedures.
Order Information
Replacement and optional parts can be ordered directly from your SPX authorized tool supplier. Your order should
include the following information:
1. Quantity
2. Part number
3. Item description
Technical Service
If you have any questions on the operation of the product, please call: (800) 533-6127
Repair Service
Send your SPX electronic product freight prepaid and include the following information:
• company name
• contact name
• telephone number
• description of the problem
• proof-of-purchase for warranty repairs
• preferred method of payment for non-warranty repairs
Payment can be made with Visa, Master Card, COD, or with approved credit terms. To receive a credit application, please
fax your request to Credit Department at 800-962-8734.
Send the unit to:
SPX Corporation, Owatonna Facility
2300 Park Drive, Owatonna, MN 55060
Attn: Repair
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1-800-533-6127
www.otctools.com
Service Solutions, a unit of SPX Corporation
655 Eisenhower Drive, Owatonna, MN 55060-0095
Phone: 507-455-7000, International Sales: 507-455-7223
© 2002 SPX CORPORATION. ALL RIGHTS RESERVED
03/21/03 Part No. 516373
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