Battery Management Innovation

TM

Model INC-940
Diagnostic
Conductance
Charging Station
For analyzing and
charging 12-volt
automotive batteries

INSTRUCTION MANUAL
• English ...................................p. 1
• Français .................................p. 21
• Español ..................................p. 45

TABLE OF CONTENTS
SAFETY INSTRUCTIONS ......................................................................................................................... 3
OPERATION .............................................................................................................................................. 7
OVERVIEW ........................................................................................................................................ 7
FRONT PANEL ................................................................................................................................... 7
INITIAL SETUP ................................................................................................................................... 8
Dealer Number ............................................................................................................................. 8
Date and Time ............................................................................................................................. 8
OPTIONS MENU ................................................................................................................................ 8
Set Time....................................................................................................................................... 8
Printer Type ................................................................................................................................. 9
Dealer Number ............................................................................................................................. 9
Language ..................................................................................................................................... 9
PRE-ANALYSIS BATTERY INSPECTION ......................................................................................... 9
BATTERY ANALYSIS / CHARGING SETUP ................................................................................... 10
BATTERY ANALYSIS RESULTS ..................................................................................................... 12
TEMPERATURE ............................................................................................................................... 12
CHARGE COMPLETION AND AND FINAL ANALYSIS ................................................................... 12
INFORMATION MENU ..................................................................................................................... 12
Generate Test Code .................................................................................................................. 13
Print Last Test Results ............................................................................................................... 13
View Last Test Results .............................................................................................................. 14
MAINTENANCE ....................................................................................................................................... 14
CABLE SET REPLACEMENT .......................................................................................................... 14
TROUBLESHOOTING............................................................................................................................. 15
ERROR MESSAGES ........................................................................................................................ 15
DISPLAY PROBLEMS ...................................................................................................................... 16
TEST CODE PROBLEMS ................................................................................................................ 17
PRINTING PROBLEMS .................................................................................................................... 17
SPECIFICATIONS ................................................................................................................................... 18
PATENTS, LIMITED WARRANTY, SERVICE ......................................................................................... 19

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SAFETY INSTRUCTIONS

!

IMPORTANT SAFETY INSTRUCTIONS: READ AND SAVE
THIS SAFETY AND INSTRUCTION MANUAL. KEEP IT WITH
OR NEAR CHARGER AT ALL TIMES.

1.

WARNING: RISK OF EXPLOSIVE GASES

1.1

WORKING IN THE VICINITY OF A LEAD-ACID BATTERY IS DANGEROUS. BATTERIES
GENERATE EXPLOSIVE GASES DURING NORMAL BATTERY OPERATION, AND WHEN
DISCHARGED OR CHARGED. FOR THIS REASON, IT IS OF UTMOST IMPORTANCE
THAT EACH TIME BEFORE USING YOUR CHARGER, YOU RE-READ THIS MANUAL AND
MAKE CERTAIN YOU FULLY UNDERSTAND IT AND FOLLOW THE SAFETY AND
OPERATING INSTRUCTIONS EXACTLY.

1.2

To 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 engine, and on
vehicle or equipment containing the battery.

1.3

CAUTION: To reduce the risk of injury, charge only rechargeable LEAD-ACID TYPE
batteries which may include MAINTENANCE-FREE, LOW-MAINTENANCE OR DEEP
CYCLE batteries. Other types of batteries may burst causing personal injury and damage.
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.

1.4

Use 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.

1.5

To reduce risk of damage to electric plug and cord, pull by plug rather than cord when
disconnecting charger.

1.6

Position 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.

1.7

Do not operate charger if it has received a sharp blow, been dropped, or otherwise damaged
in any way; take it to a qualified service center.

1.8

Do 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.

1.9

If the charger is in need of service, call Midtronics at 1-800-776-1995 or 1-630-323-2800.

1.10

To reduce risk of electric shock, unplug charger from the AC outlet before attempting any
maintenance or cleaning. Turning off the controls will not reduce this risk.

1.11

Do not overcharge battery. See Safety Instructions (3).

1.12

When charging a battery, locate in a dry, well-ventilated area.

1.13

Never place articles on or around charger, or locate charger in a way that will restrict the flow
of cooling air through cabinet.

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1.14

An extension cord should not be used unless absolutely necessary. See Safety Instructions (4.3).

1.15

Have damaged cord or plug replaced immediately.

1.16

Do not expose charger to rain or snow.

2.

PERSONAL PRECAUTIONS

2.1

Always have someone within range of your voice, or close enough to come to your aid, when
working around lead acid batteries.

2.2

Have plenty of fresh water and soap nearby in case battery acid contacts skin, clothing or eyes.

2.3

DANGER: Batteries contain sulfuric acid that can cause blindness or severe burns. Wear
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.

2.4

If battery acid contacts skin or clothing, wash immediately with soap and water. If acid enters eye,
immediately flush with running cold water for at least 10 minutes and get doctor’s attention.

2.5

NEVER smoke or allow a spark or flame in vicinity of battery or engine.

2.6

Be extra cautious to reduce risk of dropping a metal tool onto battery. It might spark or short
circuit the battery or other electrical part that may cause an explosion.

2.7

Before working with 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.

2.8

Use charger for charging LEAD-ACID batteries only. The charger is not intended to supply power
to a low-voltage electrical system other than applications using rechargeable, lead-acid type
batteries. Do not use 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. Charging will then be safer and more efficient.

3.

PREPARING TO CHARGE BATTERY

3.1

If necessary to remove battery from vehicle to charge, always remove grounded terminal
from battery first. Make sure all accessories in the vehicle are off, so as not to cause an arc.

3.2

Stud adapters must be used on side-post and group 31 batteries.

3.3

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.

3.4

Clean battery terminals. Be careful to keep corrosion from coming into contact with your eyes.

3.5

Study all battery manufacturer’s specific precautions such as removing or not removing cell
caps while charging and recommended rates of charge.

3.6

Determine voltage of battery by referring to car owner’s manual and make sure that the
output voltage menu selection is set at the correct voltage. The charger has adjustable
charge rates, so charge battery initially at lowest rate. If charger has only one voltage, verify
that battery voltage matches voltage of charger.

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4.

GROUNDING AND AC POWER CORD CONNECTION INSTRUCTIONS

4.1

Charger must be grounded to reduce risk of electric shock. 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.
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 THE RISK OF AN ELECTRIC SHOCK.

4.2

An extension cord should not be used unless absolutely necessary. Use of improper
extension cord could result in a risk of fire and electric shock. If extension cord must be
used, make sure that:
a) Pins on plus of extension cord are the same number, size, and shape as those of plug on charger;
b) Extension cord is properly wired and in good electrical condition; and
c) Wire size is large enough for AC ampere rating of charger as specified in the following table:

5.

CHARGER LOCATION

5.1

Locate charger as far away from battery as charger cables permit.

5.2

Never place charger directly above battery being charged; gases from battery will corrode
and damage charger.

5.3

Never allow battery acid to drip on charger when taking gravity readings or filling a battery.

5.4

Operate charger only in well ventilated area, free of dangerous vapors.

5.5

Store charger in safe, dry location and maintain in perfect condition.

5.6

Do not set battery on top of charger or where its acid might drip onto charger.

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6.

DC CONNECTION PRECAUTIONS

6.1

All switches should be set in OFF position and AC cord should be DISCONNECTED from
electrical outlet before you connect and disconnect charger clamps. Never allow clamps to
touch each other.

6.2

When attaching charger clamps, be certain to make the best possible mechanical as well as
electrical connection. This will tend to prevent clamps from slipping off connections, avoid
dangerous sparking, and assure safer and more efficient charging. Clamps should be kept clean.
CAUTION—Setting switches to OFF does not always disconnect charger electrical circuit
from AC power cord or DC charger clamps.

6.3

Attach clamps to battery as indicated in 7.7, 7.8, 7.9

7.

CHARGER CONNECTION

7.1

If charging in vehicle, firmly apply emergency brake and place gear shift to NEUTRAL; shift
an automatic transmission to PARK.

7.2

Locate charger as far away from battery as charger cords permit and position AC and DC
cords to avoid stepping on or tripping over them and to prevent damage by hood, doors, or
moving engine parts.

7.3

Stay clear of fan blades, belts, pulleys, and any other parts the can cause physical injury.

7.4

Turn OFF all vehicle loads, including door lights, and correct any defects in car’s electrical
system that may have caused low battery.

7.5

If necessary to remove battery from vehicle or equipment, always remove grounded terminal
from battery first.
WARNING: If charging out of vehicle, make sure all vehicle loads are OFF to prevent a
possible arc. A SPARK NEAR BATTERY MAY CAUSE AN EXPLOSION. TO REDUCE RISK
OF A SPARK NEAR BATTERY.

7.6

Check polarity of battery posts. POSITIVE (POS., P, +) post usually has larger diameter than
NEGATIVE (NEG., N, –) post.

7.7

Connect POSITIVE (RED) charger clamp to POSITIVE (POS., P, +) post of battery. Position
yourself as far away from battery as possible, then connect NEGATIVE (BLACK) charger
POSITIVE (POS., P, +) post.

7.8

Do not face battery when making final connection.

7.9

When disconnecting charger, always do so in reverse sequence of connecting procedure
and break first connection while as far away from battery as possible.

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OPERATION
OVERVIEW
The inCHARGE 940™ Diagnostic Conductance Charging Station (Model INC-940) integrates battery
conductance and load testing with charging. The inCHARGE940 safely and accurately tests and fastcharges most fully discharged batteries in under 2.5 hours and most partially discharged batteries in
less than an hour. Simply connect the inCHARGE940 to the battery, select your test parameters and
press ENTER. Using Midtronics’ patented RTD™ (Real Time Diagnostics) technology, the inCHARGE940
will continuously test and monitor the battery’s temperature, charging voltage, charging current, and
state of charge during the fast charging session. This real-time diagnostic evaluation prevents excessive
heat buildup, battery damage, and gassing common with other fast-charge methods.
With its comprehensive battery testing algorithm, the inCHARGE940 displays three battery decisions:
“Good Battery,” “Charging Required” (low state of charge), and “Replace Battery.” When charging is
required, the inCHARGE940 automatically starts charging the battery. After the charging session, the
inCHARGE940 displays a final result, “Good Battery” or “Replace Battery,” and generates a test code for
effective warranty management.
Safety features include reverse polarity detection/protection and automatic shut-off when charging
is complete or when an unsafe condition occurs. For more information on inCHARGE940 features
and specifications, see “Specifications.”

FRONT PANEL
Typical LCD screen showing a required
step in the test process (first line) and an
option (second line).

Push button sequence (UP or DOWN ARROW
and ENTER) to scroll and select the option.

CHARGING LED (red):
Lights when charging.
FAULT LED (yellow):
Lights when charging is
interrupted by the
inCHARGE940 or user.
COMPLETE LED (green):
Lights when charging cycle
is complete.
UP/DOWN
ARROWS: Press
to scroll options in
the display or
increase/
decrease
values. (Press
and hold to
rapidly scroll
values.)

ENTER:
Press to select
the displayed
option and
continue to the
next step.

INFO:
Press to access
setup options,
print/view
results, and
generate a test
code.

STOP:
Press to abort
the setup or
charging cycle
and reset the
inCHARGE940.

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INITIAL SETUP
Before you can begin using the inCHARGE940, you must enter your dealer information, and verify the
date and time. NOTE: After you complete the initial setup, you will have a chance to make revisions
before exiting. If you enter the incorrect dealer information or time in the initial setup, you can revise
your entries using the Options menu. (See “Options Menu” below.)
NOTE: If you inadvertently change the date from its correct setting during the initial setup, it cannot be
changed after inCHARGE940 restarts. You must return the inCHARGE940 to Midtronics to have the
date reset. (See “Patents, Limited Warranty, Service” for more information.)
DEALER NUMBER
When you turn on the inCHARGE940 for the first time, a screen appears requiring you to enter a DEALER
REGION. Use the ARROW buttons to scroll to USA, CANADA, or OTHER, and press ENTER to select.
The next screen will require a DEALER NUMBER. The cursor (a horizontal line) will be positioned below
the first alphanumeric character. Use the ARROW keys to scroll to the correct character
(0–9, A–Z) and press ENTER.
DATE AND TIME
NOTE: The date cannot be set outside of the initial setup. If the date is incorrect, you must return the
inCHARGE940 to Midtronics to have it reset. (See “Patents, Limited Warranty, Service” for more
information.)
The next screen will require you to verify the date and time. The cursor will be positioned under the
month segment. To make changes, press ENTER to move the cursor forward (it cannot be moved back)
to the segment you want to change (month, day, year, hour, or minute). Use the ARROW buttons to
scroll to the correct number, and press ENTER to select it and move to the next segment. When
finished, press ENTER after the cursor is positioned under the minutes segment.
The next screen, which shows the new date and time, enables you to accept or revise your entries.
To accept, use the ARROW buttons to scroll to ACCEPT, then press ENTER. The inCHARGE940 will
restart and be ready to begin battery testing and charging.
To revise, press the ARROW buttons to scroll to REVISE, then press ENTER. The DEALER REGION
screen will reappear enabling you to start over. Press ENTER to move past the screens containing the
correct information.
OPTIONS MENU
You can change the following in the Options menu:
•

Set Time

•

Printer Type (HP82240B, IrDA, or SERIAL)

•

Dealer Number

•

Language (used in the user interface and on printed test reports)

To display the Options menu, turn on the inCHARGE940 while pressing and holding the INFO ( i )
button. Press the ARROW buttons to scroll through the options, and press ENTER to select:
SET TIME
The cursor will be positioned under the hour segment. To change the hour, use the ARROW buttons to
scroll to the correct number, and press ENTER to accept it and move to the minutes segment. When
finished, press ENTER.
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NOTE: The date cannot be set outside of the initial setup. If the date is incorrect, you must return
the inCHARGE940 to Midtronics to have it reset. (See “Patents, Limited Warranty, Service” for more
information.)
PRINTER TYPE
Select HP82240B, IrDA, or SERIAL. The inCHARGE940 has an infrared sensor and a serial
connector for the printer options.
DEALER NUMBER
a) DEALER REGION: Select USA, CANADA, or OTHER, and press the ENTER button.
b)

DEALER NUMBER: The cursor (a horizontal line) will be positioned below the first
alphanumeric character. Use the ARROW keys to scroll to the correct character (0–9,
A–Z) and press ENTER to move the cursor forward (it cannot be moved back) to the
character you want to change.

LANGUAGE
You can select English, French, or Spanish as the language used in the display and on printed reports.

PRE-ANALYSIS BATTERY INSPECTION
Before using the inCHARGE940, inspect the battery for damages and check for:
•

A cracked case or broken terminals. Replace the battery.

•

Cracked or broken cables and connections. Repair or replace as needed.

•

Corrosion on the battery terminals, and dirt or acid on the case top. Clean with a mixture of
water and baking soda and a wire brush.