ATD-5494 Battery Condition and Charging System Tester User Manual

ATD-5494 Battery Condition and Charging System Tester

INTRODUCTION

Your new Model ATD-5494 Battery Diagnostic Tester employs conductance testing to determine the condition of all types of lead acid batteries, including Flooded, AGM, and Gel Cell batteries. The patented circuit eliminates the need for time-consuming CCA input or conversions to other rating systems. When the ENTER button is pressed, the ATD-5494 will immediately display BOTH the percent available capacity of the battery and the condition of the battery. The ATD -5494 also tests 12V alternator systems and displays charging test data for Rev, Idle, and Load conditions including Ripple output. The ATD-5494 will display up to 33V output in Voltmeter Mode and can also test 24V charging systems in this mode.

FEATURES

• Displays % of available battery capacity
• Tests all 12V lead acid batteries
• Tests AGM, GEL, and sealed lead acid batteries
• 50 CCA to 1700 CCA battery size range
• Color Coded LED Bar Graph
• 4 Range Battery Size Selection
• V oltmeter Mode 5.5V to 39.9V
• Tests discharged batteries down to 5.5V
• No need to input battery CCA’s
• Patented conductance technology
• Reverse polarity protection
• Tests 12V Start/Charging Systems
• Color Graphic Display
• Alternator Rev, Load & Ripple Test
• Bad cell is detected and displayed

SPECIFICATIONS

Model ATD-5494

WARNING

• Batteries produce explosive gases and can explode
• Wear safety goggles (user and bystander)
• Wear protective clothing (user and bystander)
• Chemical burns can cause injury
• Keep flames and sparks away from batteries
• Read and follow instructions
• Battery explosion and ignited gases can cause injury

TESTING BATTERY STATE OF CHARGE

Connect the red clip to the positive battery post and the black clip to the negative post*. The ATD-5494 obtains its power from the battery under test. The battery’s State of Charge (SOC) voltage will be displayed as follows:

• 12.5V to 12.9V = “GO OD”, Bar Graph Green 12.3V to
• 12.4V = “M MARGINAL”, Bar Graph Yellow
• < 12.3V = “LO W”, Bar Graph Red

Other messages

• 13.0V to 13.9V = “SUR FACE CHARGE”, (No Bar Graph) <11.0V = “BAD CELL”, 1 Red Flashing 13.5V = “CHARGING DETECTED” (ie Engine Running)

Note:
always connect to the lead battery post with at least part of the clip on the post. For side mount batteries, use adapter po sts P/N B555 (not included- sold separately).

VOLT METER MODE

Press ENTER while displaying the SOC screen to use the ATD-5494 as a voltmeter. The ATD -5494 will automatically switch to VOLTMETER MODE when the (non-charging) voltage at the battery is >14.0V.

TESTING BATTERY CONDITION

1. Select the battery size range by pressing the TEST OPTIONS button. The ATD-5494 wil l scroll the four ranges on the display each time the TEST OPTION S button is pressed as follows:
   • AUTO: 390 to 749 cca
   • TRUCK: 750 to1700 cca
   • NON-AUTO: 50 to 199 cca
   • COMPACT AUTO: 200 to 389 cca
2. Once the correct battery siz e range is displayed, Press the ENTER button and the battery condition will be displayed as percent available capacity.
   • 80% to 100%* = GOOD, bar g raph- 1 or more green led’s
   • 70% to 79% = MARGINAL, bar graph- 1 or more yellow led’s
   • < 70% = REPLACE, bar graph- 1 or more red led’s

Notes:

1. Some batteries may display above 100%. This means that the available capacity is greater than the rated capacity.
2. Recharge and retest MARGINAL batteries that show SOC LOW voltage.
3. New Batteries: nearly all new batteries will not reach full capacity until cycled 10-30 times. A brand new battery will have a capacity of about 5-10% less than the rated capacity. Inactivity can be extremely harmful to a battery. New batteries that have been on the shelf for many months may show “marginal” or “replace” when tested, depending on the storage conditions. In that case, always charge and retest the battery before replacing.

STARTER TEST- 12V SYSTEM

Note: The battery condition must be tested to make sure it is in good condition before performing this test.

1. After testing the battery condition and while still clamped to the battery, press the TEST OPTIONS button.
2. “RUN THE STARTER TEST” will be displayed.
3. Press ENTER. “ACCESS ORY OFF, START THE ENGINE” will be displayed.
4. Crank engine until engine starts and then turn engine off. Depending on the star ter, the following test results may be displayed:
   • GOOD = ≥ 9.8V bar grap h- GREEN
   • MARGINAL = 9.7V bar gr aph YELLOW
   • CHECK STARTER or RETE ST battery = <9.7V bar graph RED
5. For 12V systems the normal cranking voltage at the battery should be equal to or greater than 9.7 volts*.

REVIEW 12V STA RTER TEST RESULTS

Once STARTER TEST is completed the starter test results appear at the bottom of the screen. The voltage readings will be displayed for t he INITIAL VOLTS and CRANK ING VOLTS.

If the cranking voltage is less than 9.7 volts*, starting system or battery has a problem. Retest battery or check wires, connections and starter and check manufacturer’s specifications for 12V systems.

STARTER TEST- VOLTMETER MODE (for 12V and 24V systems). After connecting the battery clips to the battery posts and displaying the battery SOC, press ENTER. In this VOLTMETER MODE the real-time voltage at the battery will be displayed. For 12V systems the normal cranking voltage at the battery should be equal to or greater than 9.7V and equal to or greater than 19.4V for 24V systems. Note: Press ENTER again to return to the SOC screen.

CHARGING SYSTEM TEST TIP

Note:
After running the STARTER TEST, the CHARGING SYSTEM TEST can be run next without testing the battery condition. Otherwise, the battery condition must be tested first to make sure it is in good condition before performing this test.

NOTE:
Start this test with the Engine and Accessories (Lights, A/C, Heater Radio etc) OFF. The ATD-5494 will auto-detect engine started and begin recording the test voltages automatically. For this reason, it is not necessary to view the display on the tester during the revving and idle sequences. Once the engine is started, wait 5 seconds and begin REVVING the engine for 15 seconds. While continuing to revv, turn on the lights and for another 15 seconds. Then idle for 15 seconds before turning engine off.

12V CHARGING SYSTEM TEST

Note: First check for a loose, worn or broken alternator belt. If okay, proceed to #1. If monitoring the display, the following messages will be displayed:

1. With engine off after testing the battery condition or Starter Test and while still clamped to the battery, press the TEST OPTIONS button until “RUN THE CHARGER TEST” is displayed.
2. Press ENTER. The display will show: “ACCESSORY OFF-START ENGINE”. IDLE ENGINE.
3. Start engine. The display will auto detect engine started after displaying “ENGINE RUNNING ACCESSORIES OFF-IDLE ENGINE” for approximately 5 seconds.
4. The display will then show “REVV ENGINE”. Revv engine to 2500 to 3000 RPM for 15 seconds. The tester will auto detect engine revving and then display “ACCESSORIES ON” (while continuing to for another 15 seconds).
5. The display will show “IDLE ENGINE” for the final 15 seconds with accessories on.
6. Press ENTER to review the test results as follows:
   • CHARGER NORMAL, GREEN ARROW (PASS)
   • NO CHARGING DETECTED, RED (FAIL)
   • BAD DIODE REPLACE ALTERNATOR, RED (>.250mv Ripple) (FAIL) REPLACE REGULATOR, RED (charging >15V (FAIL)
   • CHECK CONNECTIONS, RED (FAIL)

CHARGING TEST- VOLTMETER MODE (for 12V and 24V systems).
12V and 24V Charging systems can be tested in VOLTMETER MODE. After connecting the battery clips to battery posts and displaying the battery SOC, press ENTER. In this VOLTMETER MODE, the real-time voltage at the battery is displayed. Note: Press ENTER again to return to the SOC screen.

1. With the engine running and lights on, the real-time alternator output voltage will be displayed. The reading should display between 13V and 15V for 12V charging systems and 26.0V to 30V for 24V charging systems.
2. Low charging voltage: Check belts for slippage. Check connections from the alternator to the battery. If no problems are found, replace the alternator.
3. High charging voltage: Check for loose connections including the ground connection. If OK, replace the voltage regulator. Newer alternators house the regulator inside. In this case, replacing the alternator is necessary.

REVIEW 12V CHARGING TEST RESULTS

Once the CHARGING TEST is completed, press ENTER to review the charging test results. The following messages will display for each charging condition and the bar graph will display the corresponding voltage measured.

Press TEST OPTIONS to scroll the following test results for each of the charging conditions displayed below:

• UNLOAD IDLE
• UNLOAD REVVING
• LOAD REVVING
• LOAD IDLE
• NOTE: RIPPLE readings appear in the bottom right corner

For each of these charging conditions, the Voltage will be displayed.

CHARGING VOLTAGES

• NORMAL (GREEN) ≥ 13.5V
• MARGINAL (YELLOW) 13.0-13.4V
• NO CHARGING DETECTED Volts = SOC
• CHECK CONNECTIONS <13.5V
• REPLACE REGULATOR (RED) >15V

RIPPLE VOLTAGES

• GOOD (GREEN) <200mV
• MARGINAL (YELLOW) 200mV – 300mV
• BAD DIODES REPLACE ALTERNATOR (RED) >300mV

Low charging voltage:
Check belts for slippage. Check connections from the alternator to the battery. If no problems are found, replace the alternator.

High charging voltage:
Check for loose connections including the ground connection. If OK, replace the voltage regulator. Newer alternators house the regulator inside. In this case replacing the alternator is necessary.

CONVERTING % CAPACITY TO CCA CAPACITY

If required, the available CCA can easily be determined by multiplying the percent displayed times the battery’s original rating. For example, a 600 CCA battery with 80% capacity available would have 480 CCA (.80 x 600) available.

RETURN FOR REPAIR POLICY

Every effort has been made to provide reliable, superior quality products. However, in the event your instrument requires repair, forward the unit to Service Center freight prepaid to the address below with the return address, phone number and/or email address.

SERVICE CENTER
2651 W 81st Street Hialeah, FL 33016

WARRANTY POLICY

The ATD-5494 Battery Diagnostic Tester is warranted to be free of defects in materials and workmanship for a period of two years from the date of purchase. This warranty applies to all repairable instruments that have not been tampered with or damaged through improper use including the unauthorized opening of the unit. Please ship warranty units that require repair freight prepaid to the Service Center along with proof of purchase, return address, phone number, and/or email address.

References

• Automotive Tools and Equipment | ATD Tools, Inc.

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