KONNWEI KW650 Battery Tester User Manual

1. Product Summary

1.1 Product Profile

The KONNWEI KW650 Battery Tester utilizes advanced conductance testing technology to quickly and accurately measure the cold cranking amps (CCA) capability of vehicle starting batteries. It assesses the battery's health, detects common faults in the starting and charging systems, and aids maintenance personnel in rapid vehicle repair.

Key features and capabilities include:

• Tests all automotive cranking lead-acid batteries, including ordinary lead-acid, AGM flat plate, AGM spiral, and Gel batteries.
• Directly detects batteries with bad cells.
• Features reverse polarity protection, preventing damage to the tester or vehicle/battery from incorrect connection.
• Can test batteries with low charge; full charge is not required.
• Supports major global battery standards: CCA, BCI, CA, MCA, JIS, DIN, SAE.
• Offers multi-language support, including Chinese, Dutch, English, French, German, Italian, Japanese, Korean, Portuguese, Polish, Russian, and Spanish.
• Allows uploading recorded test data to a Windows computer for printing.
• Provides lifetime free software updates via the BTLINK tool from www.konnwei.com.
• Contact for support or suggestions: konnwei@konnwei.com.

1.2 Product Function

The KW650 battery tester performs several functions:

• Battery Test: Analyzes battery health, calculates cold cranking capability, and assesses aging, providing evidence for maintenance and replacement decisions.
• Cranking Test: Tests and analyzes the starting motor's performance by measuring required cranking current and voltage.
• Charging Test: Checks the vehicle's charging system (alternator, rectifier) to ensure proper output voltage and detect issues like overcharging or incomplete charging.
• Other Additional Functions.

1.3 Technical Parameters

Cold Cranking Amps Measurement Range

Voltage Measurement Range

6-16V DC

1.4 Working Environment Requirement

Temperature: 0°C – 50°C / 32°F – 122°F

This tester is suitable for automotive manufacturers, maintenance and repair workshops, automotive battery factories, automotive battery distributors, and educational organizations.

2. Product Information

2.1 Tool Description

The KONNWEI KW650 tester features an LCD display and navigation buttons:

• UP SCROLL BUTTON: Moves the cursor up for selection.
• DOWN SCROLL BUTTON: Moves the cursor down for selection.
• ENTER BUTTON: Confirms a selection or action.
• ESC BUTTON: Returns to the previous menu.
• WAVEFORM FUNCTION: Displays voltage waveform data.

The device has a compact design with connection clamps for battery terminals.

2.2 Product Specifications

• Display: LCD
• Operating Temperature: 0°C – 50°C / 32°F – 122°F
• Storage Temperature: -20°C – 70°C / -4°F – 158°F
• Power: Provided via cable from the car battery.
• Dimensions: Length: 124mm (4.88"), Width: 70mm (2.76"), Height: 20mm (0.79").

2.3 Accessories Included

• 1 x Mini USB cable
• 1 x User's Manual

2.4 Tool Setup

From the startup screen or Main Menu, press ESC to access the Main Menu. Use UP/DOWN buttons to select [Setup] and press ENTER.

Language Selection

In the "Tool Setup" menu, select "LANGUAGE" using UP/DOWN buttons and press ENTER. The screen will display a list of available languages: Chinese, Japanese, English, French, Spanish, German. Use UP/DOWN to select a language and press ENTER to confirm.

Beeper Settings

In the "Tool Setup" menu, select "BUZZ" and press ENTER to turn the beeper ON or OFF.

Device Test

In the "Tool Setup" menu, select "Device test" and press ENTER. This menu includes:

• Screen test: Checks if the LCD display is working correctly.
• Key test: Verifies the functionality of each button. Press any key, and its name should appear on the screen. If a key name does not appear, the key is not functioning properly.

2.5 About

Access the "About" section from the Main Menu to view software version (SW VER:1.2.7, SW VER:V1.1.0) and serial number (SN:202004247760).

3. Car Battery Test

After entering the battery test program, the tester displays the Main Menu. Select "Car" to begin.

Battery Location

Choose whether the battery is "IN-VEHICLE" or "OUT-OF-VEHICLE" and press ENTER.

3.1 Battery Test in vehicle

If surface charge is detected, the tester prompts: "Surface charge, turn lights on". Turn on the vehicle's lights to eliminate surface charge. The tester will then proceed with the test.

Select Battery Type

After selecting the battery charge status, choose the battery type: Regular Flooded, AGM Flat plate, AGM Spiral, Gel, or EFB. Press UP/DOWN to select and OK to confirm.

Battery System Standard and Rating

The KW650 tests each battery according to the selected system and rating. Use UP/DOWN keys to select the standard and rating marked on the battery.

Standard Definitions:

• CCA (Cold Cranking Amps): Specified by SAE&BCI, used for starting battery at 0°F (-18°C).
• BCI (Battery Council International): A standard for battery classification.
• CA (Cranking Amps): Standard effective starting current value at 0°C.
• MCA (Marine Cranking Amps): Standard effective starting current value at 0°C.
• JIS (Japan Industrial Standard): Displayed on batteries with alphanumeric codes (e.g., 55D23, 80D26).
• DIN (German Auto Industry Committee): A German standard.
• IEC (Internal Electron technical Commission): An international technical standard.
• EN (European Automobile Industry Association): A European standard.
• SAE (Society of Automotive Engineers): A standard for automotive applications.

After selecting the standard, the tester displays the "SELECT STANDARD" screen. Input the correct test standard and rating, then press ENTER to start the test. The interface will show "Under measurement..."

Test Results Interpretation

The test results are displayed approximately 1 second after initiation.

• 1 Good Battery: Indicates the battery is in excellent condition (e.g., SOH 100%, CCA: 670A, VOL: 12.54V). No action needed.
• 2 Good, Recharge: The battery is good but has low current (e.g., SOH 19%, CCA: 88A, VOL: 11.94V). Recharge the battery before use.
• 3 Replace: The battery is nearing the end of its life (e.g., SOH 3%, CCA: 87A, VOL: 13.94V). Replace the battery to avoid potential issues.
• 4 Bad cell, Replace: The battery has internal damage, a bad cell, or a short circuit (e.g., SOH 0%, CCA: 10 A, VOL: 7.89V). Replace the battery immediately.
• 5 Charge, Retest: The battery's condition is unstable (e.g., SOH 4%, CCA: 86A, VOL: 11.95V). Recharge and retest. If the result remains the same, the battery is likely damaged and needs replacement.

Attention: If a "Replace" result occurs in IN-VEHICLE mode, ensure the vehicle cable is properly connected. Retest OUT-OF-VEHICLE before making a final decision.

3.2 Battery out of vehicle test

This mode is used when the battery is disconnected from the vehicle.

Follow similar steps as the "Battery Test in vehicle": select location (OUT-OF-VEHICLE), battery type, and standard/rating. The test results interpretation is the same.

3.3 Waveform

Access the WAVEFORM FUNCTION from the Main Menu to view voltage waveforms.

The waveform display shows Current Voltage (CUR), Maximum Voltage during Ignition (MAX), and Minimum Voltage during Ignition (MIN).

Vehicle Voltage Analyses:

• Discharge Voltage: Should be around 12V when the ignition and engine are OFF for over 20 minutes. Below 11V indicates difficulty starting; consistently below 11V suggests aging and replacement is needed.
• Starting Voltage: During ignition, voltage drops to a minimum (around 7.5-9.5V). If it stays below 7.5V, the battery capacity is low and needs replacement.
• Charging Voltage: When the ignition and engine are ON, the alternator should charge the battery to around 14V.

Battery Status corresponding with Battery Voltage

Before Ignition:

After Ignition:

Notice: If the battery voltage is 11.9V after a trip and remains low, it may indicate battery damage, especially with a normal alternator. Replace the battery promptly.

3.4 Review

Access the [Review] function from the Main Menu to view saved test data.

• Review waveform: View saved voltage waveforms.
• Review the last result: Display the most recent test result, including SOH, status (e.g., GOOD-RECHARGE), internal resistance (R), standard value (STD), and voltage (VOL).

3.5 Print

The Print Data function allows printing test data or customized reports.

To print:

1. Ensure you have the tester tool, a PC/laptop with USB ports, and a USB cable.
2. Download the required application from www.konnwei.com.
3. Connect the tester to the computer using the USB cable.
4. Run the `btlink.exe` application on your computer.
5. From the tester's Main Menu, select [Print] and press ENTER.
6. Choose to "Upload result" or "Upload waveform" and press ENTER.
7. Alternatively, select "Delete result" to clear saved test data.

4. Update Mode

This function allows updating the tester's software.

To update:

1. Gather the tester tool, a PC/laptop with USB ports, and a USB cable.
2. Download the update application from www.konnwei.com.
3. Run `btlink.exe` (Note: Mac OS and Linux are not compatible).
4. Connect the USB cable to the tester while holding down any button. Release the button once the screen displays "Update Mode".
5. Open the `btlink` software and click "Check Update" to download the upgrade file.
6. Wait for the update to complete.
7. Restart the tester tool to finish the update process.

Note: If the tool malfunctions due to an incorrect selection, you can force it into update mode by holding the LEFT scroll button and pressing the power button.

5. Service Procedures

For any questions, please contact your local store, distributor, or visit www.konnwei.com.

If the tool requires repair, contact your local distributor for further assistance.