Auto Meter XTC-160OZR Operator's Manual

The Xpress XTC-160OZR is the ultimate load tester and battery charger with fast and accurate automated testing and charging for the professional. 2650-1741-00 10/8/13 Test Equipment Auto Meter Products Inc. 413 West Elm Street Sycamore, IL 60178 Toll Free (866)-883-TEST (8378) www.autometer.com/test

Never insert an object into the fan vents. This can cause electrical and/or mechanical damage. Never cover the fan vents. Never attempt to open up or repair the tester. Repairs should only be done by an authorized repair center. Note: Doing so could void the warranty. Always be sure the tester is off and the smart clamps are removed before cleaning. SMART CLAMPS TM Both jaws of each clamp must firmly engage the battery terminal. One copper jaw connects to the smaller gauge wire that reads the voltage and the other jaw connects to the larger conducting wire that draws the load in each test. Electrical isolation between jaws is necessary for accurate readings. For side terminal battery connection, the threaded stud connects to the smaller gauge wire that reads the voltage, and the load pad ring connects to the larger conducting wire that draws the load in each test. Damaged clamps or loose wires will affect the readings. Keep clamps clean and in good repair. Use the side terminal feature on the clamp to connect battery side terminals. When testing dual post batteries always check the post to which the vehicle system is attached. CARE AND MAINTENANCE CHECK OFTEN FOR LOOSE JAWS OR DAMAGED INTERNAL PLASTIC SHOULDER INSULATORS

designed to load test a battery and automatically provide a fast charge when needed. The system is fully automated with LCD readout for menu instructions, test results, and LED lights for unattended distance viewing. If you should have any questions about this equipment or the procedures, please see the back cover for contact information. XTC-160OZR Tests .......................... 6 Volt and 12 Volt Battery Check and Load Test Load Sequence.............................Automated 160 Amp resistive ribbon Charge Sequence ......5 to 30 min. (larger discharged batteries longer) CCA Range......................................................................... 100 – 1600 LCD........................................... Backlit 1" x 2.5" 4 line x 16 characters Cooling............................................................................5" Internal Fan Battery Temperature Measurement.................................... Infrared (IR) Temperature Probe Holder....................... Mounts to Battery Enclosure Leads.....................................Load Amp/Volt – 4 ft., 6 Gauge/18 Gauge 2 conductor Smart Clamp Power Cord.....................................................................14 AWG 15 Ft. Size ......................................................................... 11.5" x 11" x 9 1/4" Weight........................................................................................43.5 lbs T#10 12V BATT. BATT. OVERHEATED 'Y' TO CONTINUE T#10 12V BATT. ERROR:ABORTED! 'Y' TO CONTINUE The battery overheated during the charge. Let the battery cool and try recharging. The charge stopped due to a hardware issue with the XTC-160. Check the clamps and AC power. Cycle the power on the XTC-160 and try a recharge. If error occurs again, call 866-883-8378 for technical assistance.

COPYRIGHT 2012 T#10 12V BATT. POSSIBLE BAD CON 'Y' TO CONTINUE T#10 12V BATT. DISCONNECTED!! 'Y' TO CONTINUE T#10 12V BATT. ABORTED!! 'Y' TO CONTINUE DEEP DISCHARGE MOVE TO SLOW CHARGER 'Y' TO CONTINUE T#10 12V BATT. POWER PROBLEM 'Y' TO CONTINUE REVIEW/PRINT SETUP USE USB DRIVE >ABOUT Press 'N' to return to the main menu. This is due to a bad connection. Check the battery connection. Clean terminals of any corrosion. Clean clamps. The clamps disconnected during charging. Check connection. Clean terminals of any corrosion. Clean clamps. Battery is so discharged it is drawing more current than the XTC-160 can safely provide. Place battery on a slow charger. There is a problem with the AC power. (Brown out, circuit breaker opened, unit accidently shut off.) Charge was aborted by the operator. Select ABOUT from the main menu. The following is displayed. Error Messages Specifications..............................................................................3 Safety..........................................................................................5 Cause of Battery Failure.............................................................. 5 Inspection and Visual Check....................................................... 6 What to Expect............................................................................7 Controls and Functions............................................................... 8 Hook-Up......................................................................................9 Battery Test and Charge Sequence......................................10-12 Charge Only Sequence........................................................13-14 Test Only Sequence.............................................................15-16 Test Results...............................................................................17 Setup.........................................................................................18 Printer Operation.......................................................................19 Review Tests.............................................................................19 Using USB Drive.......................................................................20 About Menu...............................................................................21 Care and Maintenance.............................................................. 22 Contact Information...................................................................24

using the XTC-160OZR. Wear eye protection when working around batteries. The XTC-160OZR is equipped with a power cord. Never use an extension cord that is more than 50ft and it must not be smaller than 12 gauge. Make sure the extension cord and receptacle are properly grounded. Be sure each test is completed before removing load clamps to prevent arcing and potential explosion from battery gases. Never remove load clamps while testing. Keep sparks, flames or cigarettes away from batteries. Provide adequate ventilation to remove car exhaust. In extremely cold temperatures, check for frozen electrolytic fluid before applying load. Do not attempt to Load Test or Charge a battery under 20°F. Allow the battery to warm to room temperature before testing or charging. Never connect load clamps to more than one 6 volt or one 12 volt battery at a time. Connection to 24 volts will dangerously overload the circuitry. Do not test multiple batteries or 24 volt systems using the XTC-160OZR. Warning! Never attach the XTC-160OZR to a battery that is connected to any other tester or charging unit. Damage may result. CAUSE OF BATTERY FAILURE Incorrect Application: Wrong size battery may have inadequate cold cranking Amp rating for original vehicle specifications. Incorrect Installation: Loose battery hold-downs cause excessive vibration, which can result in damage to the plates. Improper Maintenance: Low electrolytic fluid and corrosion on battery connections, can greatly reduce battery life and affect battery performance. Age of Battery: If the date code on the battery indicates it is fairly old, the failure may be due to natural causes. Overcharging: Overcharging caused by a high voltage regulator setting or incorrect battery charging can cause excessive gassing, heat and water loss. Undercharging: Undercharging caused by a faulty charging system or low voltage regulator setting can cause lead sulfate to gradually build up and crystallize on the plates greatly reducing the battery’s capacity and ability to be recharge. SAFETY USB DRIVE REVIEW PRINT SETUP >USE USB DRIVE ABOUT >SAVE TEST DATA UPGRADE UNIT 'Y' TO CONTINUE PLACE USB MEMORY DEVICE INTO USB SMART PORT 'Y' TO CONTINUE Select USB drive from the menu. The following menu appears that lets you save the units stored data in a USB memory device or upgrade the units firmware via a USB memory device. Plug USB memory device into the USB smart port. Wait a few seconds for the smart port to see the USB memory device and then press 'Y'. The XTC-160OZR will save the data in memory to the USB memory device's 'Root Directory' as XTC160.CVS. It will return to the USB menu when done. The file can then be opened by most spreadsheet or text editor programs. The XTC-160OZR will be automatically upgraded through the in store network as needed. Saving test data Upgrading Note: Power switch must be ON to communicate with POSI-160. TESTING OF HYBRID VEHICLES DO NOT test the starter, alternator and/or 12 volt starting battery. DO NOT remove, service or test the hybrid battery pack under any circumstances. WARNING!

on all the components being in good operating condition. In addition, the battery MUST have sufficient charge for testing. Carefully perform the following before attempting any electrical diagnosis. VISUAL CHECK Inspect Battery for terminal corrosion, loose or broken posts, cracks in the case, moisture, and dirt around the terminals. Important Note: A damaged battery must be replaced before proceeding. From the menu select REVIEW/PRINT using the (+up) or (-down) keys. Press the (+up) or (-down) key to select the desired test. To print results to the Printer, press 'Y' to print. Press 'N' to return to the main menu. TEST & CHARGE TEST ONLY CHARGE ONLY >REVIEW/PRINT #290 12V BATT. GOOD BATTERY 'Y' TO PRINT REVIEW / PRINT

…from your XTC-160OZR Tester/Charger The Test and Charge Sequence can indicate if a 6 or 12 Volt battery is 'Good' or 'Bad'. If the XTC-160OZR indicates that the battery needs charging it will automatically charge the battery and in some cases you will know the results within 5 minutes. Except in the case of deeply discharged batteries, 30 minutes will be sufficient to determine if the battery is ‘Good', or 'Bad'. There is no need to spend needless charging time on a bad battery. During the charge sequence the XTC-160OZR will indicate the maximum time remaining to bring the battery to a full charge. The LCD screen makes it possible to view the XTC-160OZR testing and charging status – fully unattended. The LCD provides easy menu instructions and test results for close-up operation. SETUP Scroll Down to Setup, Select setup by pressing 'Y'. Select the temp in Fahrenheit or Centigrade. Choose between English and Spanish Language. Set the LED display contrast. Settings are from 1 to 10. Press 'Y' when contrast is at an acceptable level. The tester/charger factory default settings are English, F (Temp). To change the settings, setup menu's below. >SET TEMPERATURE SCALE: F. USE +/- 'Y' TO SELECT >SET LANGUAGE ENGLISH USE +/- 'Y' TO SELECT CHARGE ONLY REVIEW/PRINT >SETUP ABOUT >SET CONTRAST CONTRAST 1 USE +/- 'Y' TO SELECT

on when AC switch is on. 2. LCD: Displays menus and test results 3. DATA PORT Used for data download to flash memory. 4. USB MINI CONNECTION Used for tethering to the POSI- 160OZR. 5. KEYS When each key is pressed a beep sounds to assure contact has been made. Y Enter Key: This key selects the main or next menu. It also selects the cursor line item and answers yes to a test progression. 6. Battery Test Sequence Indicating Testing, 'Good', or 'Bad'. 7. Battery Charge Sequence Indicating Charging or Charged. 8. Battery Temperature The battery temperature probe is mounted in the battery enclosure aimed at the battery. The XTC- 160OZR constantly monitors battery temperature. CONTROLS AND FUNCTIONS After the Test and Charge Sequence or Test Only Sequence is complete one of the following result screens will be displayed. Battery passes testing. Return to service. Charge battery and place into service. (Test Only) Battery did not have a sufficient charge for a Digital Pulse Load Test. Charge required. (Test only) Battery passes testing and is "Good, In Last Quarter of Life" Battery is currently okay, but should be tested periodically. Battery did not have sufficient remaining capacity to pass tests. Battery should be replaced immediately. #33 12V BATT. BAD BATTERY 'Y' TO PRINT RESULTS #32 12V BATT. GOOD BATTERY 'Y' TO PRINT #34 12V BATT. GOOD NEEDS CHRG. 'Y' TO PRINT #35 12V BATT. CHARGE & TEST 'Y' TO PRINT #36 12V BATT. GOOD, IN LAST QUARTER OF LIFE 'Y' TO PRINT 1 3 2 +Up Key: This key moves the cursor up in order to select a menu line item. It also increments a value. On Menu: An Up or Down arrow means there are more options than are displayed. -Down Key: This key moves the cursor down in order to select a menu line. It also decrements a value. N Esc Key: This key cancels a test or progression. It also returns to the previous menu. 4

When testing dual post batteries always check the post to which the system is attached. HOOK UP 2. Connect to only one 6-volt or 12-volt battery at a time. Red = (+) Positive and Black = (-) Negative Make sure the terminals are clean and the connection is sure then press 'Y' Enter. If the "Check Battery Connections" remains the connections are not secure. If you are sure of a solid connection replace the battery. 1. Turn on the AC switch. The LCD will indicate "XTC- 160OZR" if the unit is properly plugged into an AC outlet. For your safety, make sure the AC receptacle is properly grounded. Note: The XTC-160OZR is equipped with a power cord. Never use an extension cord smaller than 12 gauge or longer than 50ft. Make sure the extension cord and receptacle are properly grounded. Note: Due to gases and usual corrosion around the positive terminal it is important to connect the positive (+) red clamp first. Make sure the connection is certain. Then connect the negative (-) black clamp. 3. If the XTC-160OZR displays one of the following messages check your connections. Connect Black Clamp to Negative (-) Terminal Connect Red Clamp to Positive (+) Terminal REVERSED BATTERY CONNECTIONS!! CHECK BATTERY CONNECTIONS ‘Y’ TO CONTINUE Adjust the rating using the (+Up) and (-Down) keys. Press 'Y' to Enter and begin the test. If OTHER brand was selected, the battery rating type is needed. Use the (+Up) and (-Down) keys to move the cursor. Press 'Y' to select. Depending on the battery type the choices will vary. The options are CCA, CA, MCA, and AH. ENTER BATTERY RATING: 600 CCA USE +/- 'Y' TO CONTINUE BATTERY RATING >MCA CCA CA TESTING BATTERY PLEASE WAIT... S#22010 T#290 'N' TO STOP #290 12V BATTERY GOOD BATTERY 'Y' TO PRINT TEST ONLY SEQUENCE cont. The XTC-160OZR serial number and test number are displayed to help reference the test to the print out. BATT. CATEGORY? >ECONOMY EXTREME PLATINUM BATTERY TYPE? >STANDARD AGM 'Y' TO SELECT Use the (+Up) and (-Down) keys to move the cursor. This list will vary depending on the battery brand selected. Press 'Y' to select. 'N' will go back to brand screen. Economy Extreme Platinum Premium Super Start Commercial Lawn & Garden Marine Power Sport Red Yellow Blue Optima Other Marine Power Sport Starting Commercial Lawn & Garden For some battery categories the battery type is needed. Use the (+Up) and (-Down) keys to move the cursor. Press 'Y' to select. Press 'N' to go back to the Battery Category screen. For marine batteries the battery function type is needed. Use the (+Up) and (-Down) keys to move the cursor. Press 'Y' to select. Press 'N' to go back to the Battery Type screen. BATTERY TYPE? >STD. STARTING STD. DEEP CYCLE AGM STARTING

TEST ONLY SEQUENCE If the battery temperature is above 120°F the following message will appear. If the battery temperature is below 10°F the following message will appear. If no temperature probe is connected use the +(Up) and -(Down) keys to enter the current battery temp. The (Up) & (Down) keys increment & decrement in units of 10. Press ‘Y’ to begin. If temperature probe is connected, the unit will automatically measure the temperature of the battery. Then press ‘Y’ to enter. The unit will go back to main menu. THE BATTERY NEEDS TO COOL BEFORE CHARGING 'Y' TO CONTINUE THE BATTERY NEEDS TO WARM BEFORE CHARGING 'Y' TO CONTINUE BATTERY BRAND? >SUPER START OPTIMA OTHER >ENTER BATTERY TEMP. 70F USE +/- 12.56V 'Y' TO BEGIN THE BATTERY IS TOO HOT TO CHARGE SAFELY 'Y' TO CONTINUE THE BATTERY IS TOO COLD TO CHARGE SAFELY 'Y' TO CONTINUE >TEST & CHARGE TEST ONLY CHARGE ONLY REVIEW/PRINT The unit will go back to main menu. Use the +(Up) and -(Down) keys to move the cursor. The options are: Super Start, Optima, and Other. Press 'Y' to select. >ENTER BATTERY TEMP. 70F USE +/- 12.56V 'Y' TO CONTINUE The unit will go back to main menu. THE BATTERY NEEDS TO COOL BEFORE TESTING 'Y' TO CONTINUE THE BATTERY IS TOO HOT TO TEST SAFELY 'Y' TO CONTINUE If the battery temperature is above 180°F the message to the left will appear. If no temperature probe is connected use the (+Up) and (-Down) keys to enter the current battery temp. The (+Up) & (-Down) keys increment & decrement in units of 10. Press ‘Y’ to begin. If temperature probe is connected, the temperature will be taken automatically. TEST & CHARGE >TEST ONLY CHARGE ONLY REVIEW/PRINT From the menu select TEST ONLY using the +/- keys. Then press ‘Y’ Enter to enter. BATTERY BRAND? >SUPER START OPTIMA OTHER Use the (+Up) and (-Down) keys to move the cursor. The options are: Super Start, Optima, and Other. Press 'Y' to select.

Wait for results. See Automated Conditions for status. Other Conditions: if the battery has a surface charge the LCD will display "REMOVING SURFACE CHARGE" and if the load clamps become disconnected or loose "CHECK BATTERY CONNECTIONS" will appear. If 'Y' is pressed the XTC-160OZR will charge the battery in 6 volt mode. If 'N' is pressed the XTC- 160OZR will attempt to bring the battery up to a level where the normal 12V charge can be applied. TESTING BATTERY PLEASE WAIT... S#11001 T#10 'N' TO STOP >IS THIS A 6V BATTERY? CHARGING MAX TIME: 35 MIN 'N' TO STOP If the XTC-160OZR determines a low voltage it will ask if the battery is a 6 Volt. Press the "Yes" or "No" key. Depending on the starting voltage the XTC-160OZR will either test the battery and then charge or it will charge the battery and then test it. CHARGE ONLY SEQUENCE cont. ENTER BATTERY RATING: 600 CCA USE +/- 'Y' TO CONTINUE BATT. CATEGORY? >ECONOMY EXTREME PLATINUM BATTERY TYPE? >STANDARD AGM 'Y' TO SELECT BATTERY TYPE? >STD. STARTING STD. DEEP CYCLE AGM STARTING Use the (+Up) or (-Down) keys to move the cursor. This list will vary depending on the battery brand selected. Press 'Y' to select. 'N' will go back to brand screen. Economy Extreme Platinum Premium Super Start Commercial Lawn & Garden Marine Power Sport Red Yellow Blue Optima Other Marine Power Sport Starting Commercial Lawn & Garden For some battery categories the battery type is needed. Use the (+Up) or (-Down) keys move the cursor. Press 'Y' to select. Press 'N' to go back to the Battery Category screen. For marine batteries the battery function type is needed. Use the (+Up) or (-Down) keys move the cursor. Press 'Y' to select. Press 'N' to go back to the Battery Type screen. BATTERY TYPE? >STD. STARTING STD. DEEP CYCLE AGM STARTING For marine batteries the battery function type is needed. Use the (+Up) or (-Down) keys to move the cursor. Press 'Y' to select. Press 'N' to go back to the Battery Type screen. BATTERY TYPE? >STANDARD AGM 'Y' TO SELECT For some battery categories the battery type is needed. Use the (+Up) and (-Down) keys move the cursor. Press 'Y'' to select. Press 'N' to go back to the Battery Category screen. Press 'N' to stop the charge if necessary. ENTER BATTERY RATING: 600 CCA USE +/- 'Y' TO CONTINUE CHARGING PLEASE WAIT... S#11001 T#10 'N' TO STOP #290 12V BATTERY CHARGED ONLY 'Y' TO PRINT CHARGING MAX TIME: 35 MIN 'N' TO STOP If OTHER brand was selected, the battery rating type is needed. Use the (+Up) and (-Down) keys to move the cursor. Press 'Y' to select. Depending on the battery type the choices will vary. The options are CCA, CA, MCA, and AH. If OTHER brand was selected, the battery rating type is needed. Use the (+Up) and (-Down) keys to move the cursor. Press 'Y' to select. Depending on the battery type the choices will vary. The options are CCA, CA, MCA, and AH. BATTERY RATING >MCA CCA CA BATTERY RATING >MCA CCA CA Adjust the rating using the (+Up) and (-Down) keys. Press ‘Y’ to begin the charge. Adjust the rating using the (+Up) and (-Down) keys. Press 'Y' to begin the charge.

run a Load Test. The LED indicators will show the status during a fully automated Test and Charge sequence. This makes it possible to view the status and final results at a distance. Red "TESTING" light indicates battery is being tested. Red "CHARGING" light indicates battery is being charged. . Green "GOOD" light indicates battery is good. Green "GOOD" with Red "CHARGING" light indicates battery is being charged. . Green "GOOD" with Green "CHARGED" light indicates battery is good and has been charged. Yellow See Display indicates that some condition occurred that did not let the battery charge or that the battery is Good, Last Quarter of Life. See the display for details. Red "BAD" indicates the battery is too bad to charge or is considered bad after a charge is attempted. TEST and CHARGE SEQUENCE cont LCD TEST RESULTS: Include "GOOD BATTERY" "GOOD, IN LAST QUARTER OF LIFE" and "BAD BATTERY". #290 12V BATT. GOOD BATTERY 'Y' TO PRINT Press 'Y' to print results on printer. See page 17 for results. CHARGING MAX TIME: 10 MIN 'N' TO STOP If the battery temperature goes over 140°F charging will stop. If no temperature probe is connected use the (+Up) and (-Down) keys to enter the current battery temp. The (Up) & (Down) keys increment & decrement in units of 10. Press ‘Y’ to begin. If temperature probe is connected, the unit will automatically measure the temperature of the battery. CHARGE ONLY SEQUENCE From the menu select CHARGE ONLY using the +/- keys. Then press ‘Y’ Enter to enter. >ENTER BATTERY TEMP. 70F USE +/- 12.56V 'Y' TO CONTINUE The unit will go back to main menu. THE BATTERY NEEDS TO COOL BEFORE CHARGING 'Y' TO CONTINUE THE BATTERY IS TOO HOT TO CHARGE SAFELY 'Y' TO CONTINUE If the battery temperature is above 120° the following message will appear TEST & CHARGE TEST ONLY >CHARGE ONLY REVIEW/PRINT BATTERY BRAND? >SUPER START OPTIMA OTHER Use the (+Up) and (-Down) keys to move the cursor. The options are: Super Start, Optima, and Other. Press 'Y' to select. BATT. CATEGORY? >ECONOMY EXTREME PLATINUM Use the (+Up) and (-Down) keys to move the cursor. This list will vary depending on the battery brand selected. Press 'Y' to select. 'N' will go back to brand screen. Economy Extreme Platinum Premium Super Start Commercial Lawn & Garden Marine Power Sport Red Yellow Blue Optima Other Marine Power Sport Starting Commercial Lawn & Garden