Midtronics Celltron ULTRA User manual

Form 080/01
Complimentary Reference Material
This PDF has been made available as a complimentary service for you to assist in
evaluating this model for your testing requirements.
T G offers a wide range of test equipment solutions, from renting short to long
term, buying refurbished and purchasing new. Financing options, such as
Financial Rental, and Leasing are also available on application.
T G will assist if you are unsure whether this model will suit your requirements.
Call T G if you need to organise repair and/or calibrate your unit.
If you click on the “Click-to-Call” logo below, you can all us for FREE!
TMG Corporate Website TMG Products Website
Disclaimer:
All trademarks appearing within this PDF are trademarks of their respective owners.

Universal Stationary
Battery Analyzer
For testing stationary batteries
used in UPS systems, power
utility, and telecommunications
industries
INSTRUCTION MANUAL
Battery Management Innovation
®

This page intentionally left blank.

• 3 •
ContentsCelltron ULTRA
Contents
Chapter 1: Introduction...................................................................................... 7
Safety ..............................................................................................................................7
About the analyzer ..........................................................................................................7
Test capability........................................................................................................................ 8
Measurements ...................................................................................................................... 8
Test range ............................................................................................................................. 8
Data storage.......................................................................................................................... 8
Kit accessories .................................................................................................................... 10
Chapter 2: Description......................................................................................11
Display, keypad, and connections ................................................................................ 11
Selection screens..........................................................................................................12
Menu icons.......................................................................................................................... 12
Scrolling lists ....................................................................................................................... 12
Check boxes ....................................................................................................................... 12
Alphanumeric selections ..................................................................................................... 12
Menu structure ..............................................................................................................12
Chapter 3: Determining a reference value ..................................................... 24
Before you test a string .................................................................................................24
Options in determining a reference value......................................................................24
Testing a sample of jars ...................................................................................................... 25
Using the average in STRING SUMMARY ......................................................................... 25
Chapter 4: Utilities............................................................................................ 26
Selecting a warn/fail threshold (WARNING) ......................................................................... 26
Selecting Celsius or Fahrenheit (TEMP) .............................................................................. 26
Selecting a manual or automatic test-start mode (MODE) ................................................ 27
Setting the date and time (CLOCK)....................................................................................... 27
Adjusting the display contrast (CONTRAST LEVEL)............................................................ 27

• 4 •
Contents Celltron ULTRA
Adjusting the display’s backlight duration (BACKLIGHT TIME) .......................................... 28
Selecting the language (LANGUAGE)................................................................................... 28
Using UPDATE to install new software...........................................................................28
Chapter 5: Selecting test parameters............................................................. 29
Creating a string name (FACTORY TEST)............................................................................ 29
Creating a TECH ID ......................................................................................................30
Selecting the number of JARS PER STRING ...................................................................30
Selecting the number of VOLTS PER JAR........................................................................30
Setting the LOW VOLTAGE threshold............................................................................31
Selecting a test mode (JARS ONLY).................................................................................31
Selecting the number of POSTS PER JAR .......................................................................31
Using a reference value from the database (BATTERY MANAGER) ............................... 32
Using REFERENCE DEVELOPER to calculate a reference value.................................32
Selecting a REFERENCE value .......................................................................................32
Selecting what to measure (VOLT & CONDUCTANCE) ...................................................33
Selecting the string TEMPERATURE ................................................................................33
Saving the BATTERY SETUP ............................................................................................33
Adding jar model information to the database...............................................................34
Changing a reference value ................................................................................................ 34
Adding a jar model .............................................................................................................. 34
Chapter 6: Testing ............................................................................................ 35
Selecting clamps or probes...........................................................................................35
Attaching the cable to the analyzer ..................................................................................... 35
How the analyzer labels jars and straps........................................................................35
Label information................................................................................................................. 36
Jar labels............................................................................................................................. 36
Strap labels ......................................................................................................................... 36
Recommendations ........................................................................................................37
Recording jar information .................................................................................................... 37

• 5 •
ContentsCelltron ULTRA
Identifying jars and straps ................................................................................................... 37
Determining a test pattern................................................................................................... 37
The test order of posts and straps ...................................................................................... 37
The test pattern for a string ................................................................................................. 38
Starting the test .............................................................................................................39
Guidelines ........................................................................................................................... 39
Attaching the cable to jar posts ........................................................................................... 39
Selecting the last used test setup with the TEST option ..................................................... 40
Using the OPEN option ....................................................................................................... 40
Attaching the cable to a strap........................................................................................41
Retesting jar posts or straps..........................................................................................42
Retesting after immediately testing the jar post or strap ..................................................... 42
Retesting after testing the string ......................................................................................... 42
Adding a placeholder for a missing or dead jar/battery.................................................42
When testing a string ..........................................................................................................42
When testing is finished ...................................................................................................... 43
Chapter 7: Test results and reports ................................................................ 44
Viewing test results .......................................................................................................44
String test results ................................................................................................................ 44
Jar and strap test results.....................................................................................................44
Interpreting test results..................................................................................................45
String summary (for a string of 12 V jars) ........................................................................... 45
Jar statistics ........................................................................................................................ 46
Jar data ............................................................................................................................... 47
Determining the strength of the string ...........................................................................48
Archiving test results .....................................................................................................48
Options................................................................................................................................ 48
Printing the STRING SUMMARY results............................................................................. 49
Printing the JAR DATA results............................................................................................. 49

• 6 •
Contents Celltron ULTRA
Transferring test results to a PC with the IR receiver (TRANSFER) ................................... 50
Transferring files to a PC from the memory card ................................................................ 50
Additional options in the REPORTS menu....................................................................51
Counting the number of tests performed (TEST COUNTER) ............................................. 51
Finding the analyzer software VERSION ........................................................................... 51
Chapter 8: Digital Multimeter (Dmm) .............................................................. 52
DC voltmeter .................................................................................................................52
AC voltmeter..................................................................................................................52
Scope ............................................................................................................................52
1. Auto setup ....................................................................................................................... 52
2. Run/hold.......................................................................................................................... 52
3. Time Display.................................................................................................................... 52
4. FFT display...................................................................................................................... 52
Current ..........................................................................................................................52
Chapter 9: Troubleshooting............................................................................. 53
Screen does not power on during testing (no text/graphics).........................................53
Recharging the analyzer battery pack................................................................................. 53
Replacing the analyzer battery pack ................................................................................... 54
Probe tip is bent or stops retracting...............................................................................54
FILE NOT FOUND ........................................................................................................54
Data is corrupt on the memory card..............................................................................54
Test results do not print or print incorrectly....................................................................55
STATUS LED....................................................................................................................... 55
Solutions ............................................................................................................................. 55
Product Specifications..................................................................................... 56
Patents, Limited Warranty, Service................................................................. 57

• 7 •
Chapter 1: Introduction
This manual provides operating instructions for the Midtronics Celltron®ULTRA Universal Stationary
Battery Analyzer. The instructions will help you to properly configure the analyzer, select test
parameters, conduct tests, and manage data. It also provides information on product maintenance,
warranty, and service.
NOTE: The analyzer and manual use the word “jar” when referring to a monobloc, which can
contain 1 to 8 cells.
Safety
IMPORTANT: Read this instruction manual before using the analyzer.
WARNING: To avoid electric shock when testing jars, follow your company’s safety practices
and these guidelines:
• Wear safety glasses or a face shield.
• Wear protective rubber gloves.
• Wear a protective apron or shop coat.
• Perform service work only for which you have been trained.
• Do not disconnect the battery cables from power systems during the test without
authorization.
• Do not place yourself in an electrical circuit.
• Avoid simultaneous contact with the jar and with frame racks or hardware that may be
grounded.
• Do not operate the Celltron ULTRA with the battery charger (AC adapter) attached.
• Battery posts, terminals, and related accessories contain lead and lead compounds,
chemicals known to cause cancer and birth defects or other reproductive harm. Wash hands
after handling.
About the analyzer
The Celltron ULTRA performs conductance testing on stationary batteries used in UPS systems,
power utility, and telecommunications industries. Its advanced analysis and data management tools
are designed for universal use in the following applications regardless of configuration:
UPS Systems, 120, 220/240, 480, 600 volts
Power Utility (Switching, SCADA, etc.)
Telecom OSP, – 48/+24 volts
Telecom Central Office, – 48/+24 volts
CATV
Chapter 1: IntroductionCelltron ULTRA

• 8 •
The analyzer features a backlit graphical LCD, a digital multimeter, and an SD (Secure Digital) flash
memory card for data storage and transfer to a PC. The analyzer software includes an icon-based
menu and pre-loaded data on over 200 battery models to expedite testing and record-keeping.
Test capability
The Celltron ULTRA tests lead-acid batteries that are 2, 4, 6, 8, 10, 12, 14, and 16 V. The analyzer
can test batteries providing power to a load (in service) or not providing power (not in service).
Measurements
The analyzer measures the status of a jar in voltages and conductance values. It displays conduc-
tance values in mhos ( ). Ampere hours (Ah) are a typical measurement of jar capacity; however,
they are difficult to measure without knowing the load to which the jars supply power. Midtronics
recommends that you compare test results to a conductance reference value. For more information
about determining a reference value, refer to Chapter 3.
Test range
The analyzer has an operating range of 0 to 20,000 S. This range includes jars that have about 5 to
6000 Ah of reserve capacity.
Data storage
The analyzer’s SD memory card can store 480 test results per string for as many as 500 strings.
Tables 1 and 2 show the maximum number of jars you can test depending on the number of jar posts
and straps that you test.
Table 1: Maximum number of stored test results (jars only)
Number of jar posts Max. number of jars
2 480
4 240
6 160
8 120
Table 2: Maximum number of stored test results (jars & 1 strap)
Number of posts
per jar
Total straps for a
1-strap configuration
Max. number
of jars
2 1 240
4 2 120
6380
8460
Chapter 1: Introduction Celltron ULTRA

• 9 •
Table 3: Maximum number of stored test results (jars & 2 straps)
Number of posts
per jar
Total straps for a
2-strap configuration
Max. number
of jars
2 2 120
4460
6640
8830
Chapter 1: IntroductionCelltron ULTRA

• 10 •
Kit accessories
Item Description
DuraClamps Cables with 127 mm (5 in) clamps and 50.8 mm (2 in)
openings for large jar posts
DuraProbes Cables with 152.4 mm (6 in) probes with rotating heads and
27.7 mm (0.5 in) tips for quick contact with large jar posts
Probe-extender kit Lighted probes for increasing visibility in confined jar racks
and cabinets
Digital infrared temperature sensor Measures jar temperature in Celsius or Fahrenheit
SD memory card reader Transfers test data to a PC through a USB port
Midtronics printer with an AC
adapter (120 Vac, 60 Hz)
Handheld printer with infrared receiver for data transmitted
by the Celltron ULTRA; includes battery charger (output
10.2 Vdc, 800 mA) for charging the printer’s NiMH batteries
Infrared IR receiver and CD with
PC software
IR receiver that attaches to a PC serial port and software that
enables you to view and save test data on a PC
AC adapter, 120 Vac, 60 Hz
(Optional adapter: 110 to 240 Vac,
50/60 Hz)
Charger for the analyzer’s internal NiMH battery pack (output
12 Vdc, 100 mA)
Spare NiMH battery pack 9.6 V, 1800 mAh
Spare extender lamps Lamps are replaceable: peel them off; use alcohol wipes to
clean the surface, and attach the new lamps
For technical assistance and to purchase replacement parts, call Midtronics Customer Service. (See
“Patents, Limited Warranty, Service.”)
Chapter 1: Introduction Celltron ULTRA

• 11 •
Chapter 2: Description
Display, keypad, and connections
3
1
2
4
6
1 Connector for the NiMH battery pack charger
2 Infrared (IR) data transmitter
Sends test data to an IR printer or to a PC with an
optional IrDA cable and software
3 Connector for clamps or probes cables
4 Display (showing oscilloscope)
5
7
8
10
9
11
12
13
14
5 ENTER key
Press to select items and move to the next screen
6 ARROW keys
Press to scroll to preset selections or to highlight
menus ( scrolls left through the icons, and
scrolls right)
7 BACK (C) key
Press to clear/cancel entries or go back
8 Alphanumeric keys
Press to ENTER selections or user-defined names
in screens that allow direct entry of data
9 RETEST key
Press to retest a set of jar posts or a strap just after
you test it
10 PRINT key
Press to send test data to IR printer
11 POWER button
12 SD (Secure Digital) card
Removable memory storage for test data
13 Serial connector
For an optional bar code reader
14 DuraProbe cable set
Shows charge level of battery pack
TITLE
Status/Instruction Areas
Selection/Option Area
NOTE: The analyzer shuts off after approximately
2 minutes of inactivity to conserve its battery pack.
Chapter 2: DescriptionCelltron ULTRA

• 12 •
Selection screens
When you turn on the analyzer it will default to the last menu screen displayed. To move back to the
Main Menu, press the BACK key as each submenu appears.
The Main Menu has six menus: BATTERY SETUP, TEST, REPORTS, UTILITIES SETUP, DMM
(Digital Multimeter), and BATTERY MANAGER. The menus have several submenus or options to
help you set up the analyzer for testing, automate portions of the test process, and manage test data.
The settings contain factory defaults that you can overwrite using the keypad. For more information,
refer to the sections in the manual on selecting test parameters and utilities. The keys you use to
enter data depend on the type of selections displayed. There are four types:
Menu icons
A menu icon is a graphical representation of a function you can select and use, such as the BATTERY
SETUP icon in the Main Menu.
To select an icon, use the ARROW ( or ) keys to highlight it, and press the ENTER key. To return
to the previous menu, press the BACK key.
Scrolling lists
Scrolling lists contain items that extend above and below the screen or the selection box that contains
them. To indicate that there are more items, the symbols appear to the right of the first item on the
list. To select from a list, use the ARROW keys to scroll to the item and press ENTER.
Check boxes
Lists that fit the screen have check boxes before each item. Use the ARROW keys to place the check
in the box next to your selection, or use the numeric keys to enter the item number. Press ENTER
to select.
Alphanumeric selections
Some selections require you to use the alphanumeric keypad. These “user-defined” selections
are indicated by a blinking horizontal line (cursor) to the right of the last character. Display the
character, symbol, or number you want by rapidly pressing its key as many times as needed.
If you pause, the cursor moves to the right. To backspace one character, press the BACK key.
To enter a space between characters, press the key twice. Press ENTER when finished.
Menu structure
This section describes the menu structure using a tree diagram to help you navigate through the
screens. Selectable items are capitalized or in bold, and screen titles are italic.
You can find more detailed information on how to select options and test parameters in Chapters 4
and 5.
Chapter 2: Description Celltron ULTRA

• 13 •
Main Menu (menu icon)
BATTERY SETUP (menu icon)
The BATTERY SETUP menu displays options for setting new test parameters, starting a test
with stored parameters, deleting test files, and formatting the memory card.
NEW (TEST) (icon)
The NEW (test) menu enables you to set test parameters for a string. When you select
this icon, the screen displays RENAME NEW STRING.
STRING ID
RENAME NEW STRING
FACTORY TEST (default name)
Press ENTER to create a new string name (up to 500 strings).
STRING ID (alphanumeric selection)
FACTORY TEST_
A string ID stores your test parameters, eliminating the need to re-
ENTER data each time you test. The last name created is the default
name. Use the BACK key to clear the default characters and the alpha-
numeric keys to create a new name. Press ENTER to begin selecting
your test parameters.
STRING INFO (scrolling parameters list)
[NEW STRING NAME]
The string name you created appears at the top of the param-
eters list. The name is highlighted, enabling you to change it
before selecting your test parameters.
TECH ID 1 (default name)
Press ENTER to create a technician ID of up to 20 alphanumeric
characters. The ID will be linked to the new string ID.
SELECT TECH (alphanumeric selection)
Use the BACK key to clear the default characters. Use
the alphanumeric keys to create a new name.
JARS PER STRING
Press ENTER to select the number of jars you are testing per
string.
JARS PER STRING (scrolling/numeric keys)
The number of jars you can select (1 to 480) depends
on whether you are testing JARS ONLY or JARS &
1 STRAP, JARS & 2 STRAPS and the number of POSTS
PER JAR.
(To VOLTS
PER JAR)
Main Menu BATTERY SETUP MENU
Chapter 2: DescriptionCelltron ULTRA

• 14 •
Main Menu (menu icon)
BATTERY SETUP (menu icon)
NEW (TEST) (icon) (Continued from JARS PER STRING)
STRING INFO (scrolling parameters list)
VOLTS PER JAR
Press ENTER to select the number of volts per jar.
VOLTS PER JAR (scrolling/numeric)
Select the number of volts per jar (2, 4, 6, 8, 10, 12, 14,
or 16 V).
LOW VOLTAGE
Press ENTER to set the low voltage threshold for a jar.
LOW VOLTAGE (scrolling/numeric)
The range (1.000 to 22.000) depends on the VOLTS PER
JAR.
JARS ONLY
Press ENTER to select a test mode.
MODE (check boxes)
JARS ONLY
Test only the jars on the string.
JARS & 1 STRAP
Test jars and their connections on the string.
JARS & 2 STRAPS
Test jars and their connections on the string.
POSTS PER JAR
Press ENTER to select the number of posts per jar.
POSTS PER JAR (scrolling/numeric keys)
Select 2, 4, 6, or 8.
(To BATTERY MANAGER)
Main Menu BATTERY SETUP MENU
Chapter 2: Description Celltron ULTRA

• 15 •
Main Menu (menu icon)
BATTERY SETUP (menu icon)
NEW (TEST) (icon) (Continued from POSTS PER JAR)
STRING INFO (scrolling parameters list)
BATTERY MANAGER (scrolling)
Press ENTER to select a jar manufacturers and model, and
computer a reference value.
SELECT MANUFACTURER
Press ENTER to display jar manufacturers and models.
SELECT MFGR (scrolling/alphanumeric)
Select from an alphabetical list of approximately 16
manufacturers, or select USER VENDOR (three
available) to create a name for an unlisted manu-
facturer.
SELECT MODEL (scrolling/alphanumeric)
Select from an alphabetical list of over 200
models, or select USER DEFINED (approx.
64 available) to create a name for an unlisted
model.
REFERENCE DEVELOPER
Press ENTER to have the analyzer compute a reference
value.
REF DEVELOPER (scrolling/numeric)
Select a percentage of jars on the string on which to
base a reference (from 0to 100%).
REFERENCE (scrolling/alphanumeric)
The default is dashes (– – – – – – ).
Press ENTER to change the value. This setting uses the
manufacturer’s reference value for the model of jar selected in
BATTERY MANAGER. If you use REFERENCE DEVELOPER,
the setting displays asterisks (*****) and cannot be changed.
(To VOLT & CONDUCTANCE)
Main Menu BATTERY SETUP MENU
Chapter 2: Description
Celltron ULTRA

• 16 •
Main Menu (menu icon)
BATTERY SETUP (menu icon)
NEW (TEST) (icon) (Continued from REFERENCE)
STRING INFO (scrolling parameters list)
VOLT & CONDUCTANCE (default)
Press ENTER to measure volts only; volts and conductance si-
multaneously; or voltage first, then conductance.
MODE (check boxes)
VOLTAGE ONLY
VOLT & CONDUCTANCE
VOLTS THEN CONDUCT(ANCE)
TEMPERATURE
Press ENTER to select the units of measure and the temperature
of the string. Conductance measurements change with jar tem-
perature. To compensate, the ULTRA uses the temperature you
select to adjust the percentage of the reference value.
TEMP. UNITS (check boxes)
DEGREES F
DEGREES C
TEMPERATURE (scrolling/numeric)
Range: 0to 50 °C ( 32 to 122 °F).
AC RIPPLE
Press ENTER to select the string’s AC ripple.
AC RIPPLE (scrolling/numeric)
Select from 0.000 to 99.999 volts.
DC FLOAT V.
Press ENTER to select the string’s DC float voltage.
DC FLOAT (scrolling/numeric)
Select from 0.00 to 600.00 volts.
(To DC FLOAT A.)
Main Menu BATTERY SETUP MENU
Chapter 2: Description Celltron ULTRA

• 17 •
Main Menu (menu icon)
BATTERY SETUP (menu icon)
NEW (TEST) (icon) (Continued from DC FLOAT V.)
STRING INFO (scrolling parameters list)
DC FLOAT A.
Press ENTER to select the string’s DC float current.
DC FLOAT (scrolling/numeric)
Select from 0.000 to 99.999 volts.
SAVE AND TEST
This option enables you to save your test parameters and start
a test. If the analyzer is not connected to a jar, it prompts you to
connect to one before it starts the test.
SAVE AND CONTINUE
This option enables you to save your settings without starting
a test. When you press ENTER, your test setup is saved un-
der the string name you created. You are then returned to the
BATTERY SETUP menu.
OPEN (icon)
To use a saved test setup, press ENTER. The parameters list will appear; however,
you cannot change certain parameters without erasing string test data for completed
tests.
STRING INFO (scrolling)
Scroll to the string name to start the test.
WARNING
The analyzer will warn you that a test using the string name/setup was
already performed. If you want to change parameters, it will recommend
that you use the NEW (TEST) function. Press ENTER to continue or the
BACK key to cancel.
STRING INFO (scrolling parameters list)
The parameters list will appear. Verify that these are the param-
eters you want to use, and scroll to SAVE AND TEST. Otherwise,
make changes using the NEW (TEST) function.
Main Menu BATTERY SETUP MENU
(To DELETE)
Chapter 2: DescriptionCelltron ULTRA

• 18 •
Main Menu (menu icon)
BATTERY SETUP (menu icon) (Continued from OPEN)
DELETE (icon)
To delete a saved test setup, press ENTER.
STRING INFO (scrolling)
Scroll to the site name and press ENTER.
WARNING
The analyzer will ask if you want to delete the file. Press ENTER to con-
tinue or the BACK key to cancel.
DELETE ALL FILES (icon)
Press ENTER to delete all files.
WARNING
The analyzer will ask if you want to delete all files. Press ENTER to continue or
the BACK key to cancel.
FORMAT (icon)
Press ENTER to format the SD card.
WARNING
The analyzer will inform you that formatting will erase all disk data.
Press ENTER to continue or the BACK key to cancel.
TEST (icon)
The analyzer will test using the parameters file last used or saved. If there is no test setup in
memory, the analyzer will use the default parameters. If the cables are not connected before
you select the TEST option, the screen prompts you to connect to a jar or strap. Press ENTER
after you connect the cables to the jar posts.
REPORTS (menu icon)
Press ENTER to view and manage data.
STRING SUMMARY (icon)
Press ENTER to see test results for a string.
STRING INFO (scrolling)
Select a string name and press ENTER.
STRING SUMMARY (scrolling)
Scroll to display the complete test data.
(To JAR DATA)
Main Menu REPORTS MENU
Chapter 2: Description Celltron ULTRA

• 19 •
Main Menu (menu icon)
REPORTS (menu icon) (Continued from STRING SUMMARY)
JAR DATA (icon)
Press ENTER to see test results for jars and straps.
STRING INFO (scrolling)
Select a string name and press ENTER.
STRAP [number/letter] (scrolling)
JAR [number/letter] (scrolling)
TRANSFER (icon)
Press ENTER to transfer test results to a PC via the infrared (IR) receiver and the PC
software included in the Celltron ULTRA kit.
TRANSFER DATA (check boxes)
TRANSFER ALL DATA
Transfer all test data in memory.
SELECT FILE (scrolling)
Transfer the test data for a string.
ADD BATTERY
Select this option to create a placeholder in the test results for a dead or missing bat-
tery when you are finished testing.
STRING INFO (scrolling)
Select a string name and press ENTER to display the string’s test results.
JAR ID [number/letter] (scrolling)
Scroll to the jar number after which you want to insert a placeholder,
and press ENTER. If you have selected JARS & 1 STRAP or JARS &
2 STRAPS as the test mode, you must also add a placeholder for the
strap.
WARNING
The analyzer will ask you to verify the location before creating
the placeholder. Press ENTER to continue or the BACK key to
cancel.
TEST COUNTER (icon)
Press ENTER to see the total number of tests performed since the analyzer was first
used.
(To VERSION)
Main Menu
REPORTS MENU
Chapter 2: DescriptionCelltron ULTRA