1. Testing Batteries, Starters and Charging systems using the D-TAC

2. What is a D-TAC machine
The D-TAC machine is a combination of a hand held battery tester and a battery charger
The tester and charger are electronically linked.
This allows the tester to analyze current flow during charging which helps determine the true battery condition

3. Conductance testing The D-TAC is a ‘conductance’ type battery tester
The tester sends a small A/C current through the battery
The difference between the A/C signal applied to the battery and that same signal exiting the battery is directly related to the ability of the battery plates to produce electric current
Signal sent into the battery
Signal coming out of the battery

4. Load testing vs. conductance testing
A load test places a very high current load on a battery which puts the battery under extreme stress and can cause damage to the battery
The D-TAC tester is able to test the battery condition using low current, which puts less strain on the battery and allows the tester to be lightweight and easily portable
Load testing machine [VAT]

5. Load testing machines
A load testing machine [VAT] draws several hundred amps from the battery while the technician monitors the voltage level between the terminals.
Normally a load test is run for 15 seconds

6. D-TAC / charger interface
LEDs indicate charger status
The D-TAC can also interface with a battery charger. This provides the D-TAC with data on the rate at which the battery plates can recharge. When the D-TAC is used with the battery charger a much more accurate picture of battery condition is available.

7. Digital testing
The D-TAC uses digital technology to analyze the condition of the battery. It may perform several different types of test in a fraction of a second.

8. D-TAC can test a partially charged battery
A dead or partially charged battery must be fast charged for 15 to 20 minutes before load testing with a VAT
The D-TAC can test partially charged batteries
This saves you the wasted time setting up a battery charger only to find out that the battery is no good.

9. Basic battery test using the D-TACT
The basic battery test can be done with or without the D-TAC being connected to the charger unit.
Connect the low current battery clamps to the battery terminals.

10. Socket for adapter cables
D-TAC controls
Low current battery test cable
Socket for adapter cables
Printer
Display screen
Activity LED array
Menu control buttons
Select button
On / Off button
Infrared temperature sensor

11. Select battery test from the menu
Measured voltage at battery clamps
D-TAC internal AA batteries SOC
Scroll up or down the main menu to find the battery test
Press the ‘S’ select button to proceed

12. Diagnostic charge testing
If the SOC of the battery is low it is best to select “Diagnostic Charge’ from the main menu
This will require connecting the hand held D-TAC unit to the charging unit.
Since you need to charge the battery anyway why not do an advanced battery test that will insure the battery can be returned to service

13. Identify the test vehicle - optional
If you plan to save the data from the test you will need to enter the repair order number , customer name or vehicle make and year

14. Is battery in or out of vehicle
There may be more line ‘noise’ if the battery is connected to the vehicles electrical system

15. Top post or side post
There is generally less resistance between the battery clamps and the terminals on a side post battery

16. Application Marine Lawn and garden Group 31 Commercial 4D/8D
Marine batteries may be deep cycle type batteries that have slightly different conductance properties
Lawn and garden
Usually deep cycle
Group 31
One of the largest automotive batteries group size – often deep cycle
Commercial 4D/8D
Very large battery used in golf carts and marine applications – deep cycle type

17. Battery type
AGM [Absorbed Glass Mat] batteries have slightly different conductance properties from conventional liquid electrolyte type batteries
Spiral wound batteries have a larger plate area than flat plate batteries

18. AGM battery for hybrids
AGM batteries are found in Toyota hybrids and motorcycles
AGM battery for hybrids
Positive terminal has a plastic cover
The function of the 12 volt battery in Toyota hybrids is to provide current for the computer systems, lighting system and accessories
It does not provide current to start the engine when the ignition is off

19. Battery type
AGM Spiral are aftermarket batteries that look like a 6 pack of soda cans wrapped in shrink wrap

20. Other European countries
Ratting units
Japan
Germany
Other European countries
The D-TAC can use other types of battery ratings but the CCA rating is the most common type found on batteries sold in the USA

21. CCA Rating
The CCA rating is usually found on the battery information placard on the top of the battery

22. Enter the CCA rating
Use the up and down arrows to change the CCA rating

23. Measure battery temperature
The temperature of the battery has a major effect on it’s conductance
Battery temperature must be entered to achieve accurate test results

24. Measure battery temperature
Hold the D-TAC in a vertical position directly over the battery case
Bring the D-TAC to about 2 inches above the battery and press the right arrow button to record the temperature

25. Battery test results The battery test takes just a few seconds
If the battery passes the test the test result can be printed out or saved to a PC

26. Printout
The internal printer uses thermal printing paper – no ink is required

27. Battery needs to be recharged
This battery was essentially dead.
The test indicates that the battery is safe to be recharged
The battery should be recharged in diagnostic mode using the D-TAC and D-TAC charger

28. Recharging required
In some cases the low SOC of the battery will require recharging before diagnosis can be completed

29. Warning message
If the D-TAC is detached from the charging unit you will receive this warning message

30. Mount the D-TAC to the charger unit
The D-TAC unit must be mounted to the charging unit.

31. Connect the high current battery clamps
The charger unit has a set of high current battery clamps that need to be connected to the battery for advances diagnostic testing
The D-TAC low current clamps are not needed during the charging test
Low current clamps
High current clamps

32. Charger on / off switch
The charger unit has an on/off switch located on the rear panel of the charger
When the charger is plugged in and the switch is turned on the bottom green LED on top of the charger unit will be illuminated

33. Connect charger clamps to the battery
Low current clamps do not need to be connected
The high current battery clamps should be attached to battery terminal
The D-TAC will measure battery voltage through the charger clamps during diagnostic mode charging

34. Out of car charging
Charging can be done with the battery in or out of the car.
The low current battery clamps do not need to be connected to the battery

35. Remove cell covers The cell covers should be removed during charging
Any hydrogen gas that is generated during charging must be allowed to dissipate

36. Charger unit LEDs There are four LEDs on the top of the charger unit:
Power
Charging
Fault
Communication
The ‘Fault’ led illuminates if a shorted battery cell is detected
The ‘Comm’ light flashes when data is being transferred between the D-TAC and charger unit

37. Select ‘Diagnostic Charge’ from the menu
If your starting from scratch you will need to select the diagnostic test from the main menu

38. Select Diagnostic charging test
Select ‘diagnostic charge’
Follow the menu prompts to identify the vehicle and battery parameters

39. Diagnostic charging
Number of charging hours multiplied by charging current
Estimated time to complete charge
During diagnostic charging the charging voltage is varied by the D-TAC while the charging current is monitored
Initial charging may be done at a relative high voltage level to see how easily the battery accepts a charge

40. Diagnostic charging
As charging continues the charging voltage will be reduced with a corresponding reduction of charging current
If an AGM type battery was specified the charging voltage would be limited to 14.4 volts

41. Battery fault detected
‘Fault’ indicator
If a shorted cell is detected the charging test will abort and the fault indicator LED will illuminate

42. Battery failed charging diagnostic test
A heavily sulfated battery will not accept a charge
The D-TAC measures how many amps pass through the battery at different charging voltage and the increase in voltage after charging for a short time. If the rates are too low the test will return a failure message

43. Diagnostic charge test report
The report shows the SOC voltage and measured CCA after the recharge process was completed.
Additional information on charge time and the number of amp/hours accepted

44. Battery, Starting and Charging system test
The ‘Complete System Test’ exams the battery, starting system and charging system in one test.

45. For this series of tests you will need to connect the inductive ‘Amp’ clamp to the accessory socket on the left side of the D-TAC
Inductive Amp clamp
AMP clamp

46. Inductive clamp orientation arrow
The arrow on the inductive clamp normally faces in the direction of current flow
The inductive clamps measures the strength of the magnetic field surrounding a conductor
It is important that the clamp jaws are in firm contact with each other

47. Setup for system test
The inductive clamps is installed surrounding the battery negative cable
The D-TAC will measure the current flowing between battery and starter motor during the cranking test and between the battery and alternator during the charging system test
Inductive amp clamp

48. System test – main menu
Begin the system test by scrolling down using the arrow buttons

49. Zero inductive clamp before installing
Do not connect the amps clamp to the ground cable before the D-TAC completes calibration [zeroing]
Also, make sure the amp clamp is completely closed – so the ends of the clamp are in firm contact
As soon as you begin the system test the zeroing procedure will run

50. Install inductive clamp
After this screen is displayed you can install the inductive clamp around the ground cable
The clamp should surround the cable and the ends should snap tightly together

51. Inductive clamp installed on neg cable
The low current battery clamps are installed on the battery terminals
The inductive clamp is installed around the ground cable

52. Inductive clamp orientation
The arrow on the inductive clamp normally points in the direction of current flow
Since the test will measure charging and starting current it doesn't make any difference which way the arrow faces

53. Enter battery specifications
Identifying the vehicle and entering battery parameters is done the same ways as for basic battery testing

54. Jump start post
One difference in the battery parameters is that for the system test they add a selection for a ‘jump start’ post

55. On some vehicles the battery is located in the trunk or under the rear seat.
To facilitate jump starting a terminal is located under the hood – usually next to the fuse box – that connects directly to the battery positive post
The negative cable is connected to a good engine ground
Jump start post

56. Negative cable
Note: Battery charger cables – not D-TAC cables
Any clean, unpainted surface on the engine block, cylinder head or transmission can be used to connect the D-TAC to battery negative.

57. Battery test
After inputting the basic battery parameters a regular battery test will run
If battery SOC is low the D-TAC will request a diagnostic charge test
After the battery test the starting system test

58. Starting system test
After the battery test the starting system test is run
Unlike starter testing using a VAT the D-TAC does not require that the ignition of fuel system be disabled

59. Results of Starter test
The D-DAC can measure the amount of current drawn by the starter in a few milliseconds
The test here took less than one second

60. Starter current graph
The starter draw can also be displayed as a graph
The graph here shows the voltage level while the engine was cranked by the starter

61. Charging system test
The charging system is tested next

62. Baseline voltage and current
The D-TAC starts by measuring charging voltage and current at idle with no loads turned on

63. Increase engine speed to about 1500 rpm
Once the D-TAC reads the voltage and current it wants to see what happens when the rpm is near cruise speed rpm

64. Open the throttle
If the throttle is mechanically controlled you can increase the engine rpm by manually operating the throttle linkage
If the throttle is electronically controlled you will need to operate the gas pedal from inside the car

65. Testing at idle with loads turned on
Now the D-TAC wants to see how much current the alternator can produce at idle with about 30 amps of loads turned on

66. Increase engine speed again
Rev the engine to about 1500 rpm for a second time to allow the D-TAC to record alternator voltage and current output at cruise speed with accessory loads turned on

67. Return engine to idle
The D-TAC does a final measurement of voltage and current at idle before test is finished

68. Final analysis
Once all the system measurements are made the D-TAC records all the data for uploading and printing

69. Turn off engine
The engine can now be shut down while the D-TAC finalizes the data

70. Printout
The printout shows the data for all three test

71. Ripple current
Ripple is the small amount of AC current produced by the alternator that doesn’t get converted to DC
The D-TAC uses this current to determine engine rpm increase/decrease
Excess ripple current indicates a defective diode or stator winding in the alternator

72. Advanced D-TAC tests
See the ‘Advanced D-TAC testing’ presentation for information on:
Voltage drop testing
Multimeter functions
Inductive ammeter functions
Lab Scope functions
Temperature probe [contact and immersion] temperature measurement
Infrared temperature measurement