Midtronics MDX-645P User manual

For 6 & 12-volt automotive starting batteries
INSTRUCTION MANUAL
MDX-645P
Battery Conductance
Analyzer
Battery Conductance
Analyzer

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Contents
Safety Guidelines 5
Capabilities 5
Registering Your MDX-Series Tester 7
Display and Keypad 7
User Interface 8
UP and DOWN Arrows 8
ENTER Button 8
BACK/PRINT Button 8
MENU Button 8
Options Menu 9
Procedure 9
Preparations Before the Test 10
Connecting the Tester 10
Battery Test 11
Battery Test Results 12
New Battery Test Results 12
Test Messages 14
Error Messages 15
Maintenance & Troubleshooting 16
Changing The Cable Assembly 16
Changing The Printer Paper 17
Printer Troubleshooting 18
Troubleshooting the Display 18
Replacing the Battery 19
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!
Safety Guidelines
Because of the possibility of personal injury, always use extreme caution when
working with batteries.
Battery posts, terminals, and related accessories contain lead and lead
compounds. Wash hands after handling.
Capabilities
The tester tests 6 & 12-volt regular ooded, AGM at plate, AGM spiral, and GEL
batteries. It displays the test results in seconds and features a built-in printer to
provide customers with a copy of the results.
Additional features include the ability to:
• testtheStartingandChargingsystem
• testbatteriesfromratedfrom100to2000CCA
• detectbadcells
• protectagainstreversepolarity
• testdischargedbatteries
• testmultipleratingsystems
• provideamulti-lingualuserinterface.
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Registering Your MDX-Series Tester
Before using your tester, we recommend that you register it online to activate
your warranty. Registration will also make it faster and easier for you to obtain
technical support and service.
To register, log on at www.midtronics.com/warranty.html and have your serial
number ready. The number is at the bottom of the label on the back of the
tester.
Display and Keypad
When you rst connect the tester to a battery, it functions as a voltmeter until
you press the ENTER button.
IMPORTANT:Ifyouconnectthetestertoavoltagesourcegreaterthan30Vdc,
you may damage the tester’s circuitry.
The menu-driven display will then guide you step by step through the test
process. Use the keypad buttons to scroll to and select options in the menu.
To turn o the tester when not connected to the battery, briey press and hold
the MENU button.
Serial Number Label
Serial
number
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User Interface
1 UP and DOWN Arrows
Use these keys to choose test
parameters and scroll to menu
options.
2 ENTER Button
Use this button to make
selections.
3. BACK/PRINT Button
Use this button to move to
the previous screen or move
back one space when creating
custom headers. You can also
use this button to printout test
results using the built-in printer.
4 MENU Button
Use the MENU button to
access the Main Menu options
of the tester.
For information about the
options, see “Options Menu”.
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1
2
Display Showing
Battery Result
3
4
IR
Output
Decision
Measured
rating
Measured
voltage
Selected
rating
Printer
Button
Toolbar

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Option Explanation
View/Print Display the previous test result. Press the PRINT
button to print the results.
QC Mode A quick test to check battery inventory
Export Data Export the last test result to an IR Reader program.
Perform Test Begin the Battery Test procedure.
Language Selection Select a language for the tester.
Set Address Enter the address to display on the top of the printout.
(Limit: 8 lines, 21 characters per line)
Time Select 24-hour or AM/PM and set the time.
Date Select the date format as well as set the correct date.
Counter Clear or display battery and system test by results.
Contrast Adjust the contrast setting of the tester display.
Temperature Units Select the temperature units
Degrees F or Degrees C
Voltmeter Automatically test battery voltage when the clamps are
rst connected to the battery terminals. Press ENTER
to continue testing the battery. Press BACK to return to
the menu. (Default: ON)
Options Menu
Procedure
1. Press the MENU button to access the Options Menu.
2. Use the UP (p) and DOWN (q) arrows to move to the line you want to edit.
3. Press the ENTER button to make highlighted line editable.
4. Use the UP (p) and DOWN (q) arrows to select the character for that cur-
sor location.
5. Press the ENTER button to move to the next location.
6. Press the MENU button to return to the Options Menu.
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Preparations Before the Test
Before connecting the tester, clean the battery posts with a wire brush and a
mixture of baking soda and water. When testing side-post batteries, install and
tighten lead terminal adapters.
IMPORTANT: Do not test at steel bolts. Failure to install terminal adapters or
installing terminal adapters that are worn or dirty may result in inac-
curate test results. To avoid damage, never use a wrench to tighten the
adapters more than 1/4 turn.
If you are testing in the vehicle, make sure all accessory loads are o, the key is
not in the ignition, and the doors are closed.
Connecting the Tester
• Connecttheredclamptothepositive(+)terminalandtheblackclampto
the negative (–) terminal.
• For a proper connection, rock the clamps back and forth.The tester re-
quires that both sides of each clamp be rmly connected before testing. A
poorconnectionwillproduceaCHECKCONNECTIONorWIGGLECLAMPS
message. If the message appears, clean the terminals and reconnect the
clamps.
• Thepreferredtestpostionisatthebatteryterminals.Ifthebatteryisnot
accessible, you may test at the jumper post; however, the available power
measurement may be lower than the actual value.
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Battery Test
When you rst connect the tester to the battery, it functions as a voltmeter
until you press the ENTER button to start the test. This function can be turned
o through the Options Menu
After you press ENTER, scroll to each parameter using the UP or DOWN
ARROW button and press ENTER to select. If any messages appear during the
test, see “Test Messages”
1. BAT.LOCATION:ScrolltoandselectINVEHICLEorOUTOFVEHICLEfora
batterynotconnectedtoavehicle.FollowinganINVEHICLEtestyouwillbe
prompted to test the starting and charging systems.
IMPORTANT: The performance of the starting and charging systems depends
on the battery’s condition. It is important that the battery is good and
fully charged before any further system testing.
BAT. AGE: Select new battery or in service :
New battery: battery is fresh produced and not yet installed in a ve-
hicle. For instance: the battery is in a warehouse waiting for delivery
to a customer.
In service: the battery is already used and cycled in the vehicle
2. APPLICATION:ScrolltoandselectAUTOMOTIVE,MOTORCYCLE,TRUCK.
3. BATTERYTYPE:ScrolltoandselectREGULAR FLOODED, AGM FLAT PLATE,
AGMSPIRAL,orGEL where applicable.
4. BATTERYSTANDARD:Scrolltoandselectthebattery’sratingsystem.Not
all rating systems are available for each application.
Standard Description Range
JIS#
Japanese Industrial Standard, shown on a
battery as a combination of numbers and letters.
26A17 thru
245H52
EN Europa-Norm 100–2000
DIN Deutsche Industrie-Norm 100–1200
SAE Society of Automotive Engineers, the
European labeling of CCA
100–2000
IEC International Electrotechnical Commission 100–1200
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5. BATTERYRATING:Scrolltoandselecttheratingunits.HolddowntheUP
or DOWN ARROW button to increase the scrolling speed.
6. Press ENTER to start test. After several seconds the tester displays the deci-
sion on the battery’s condition and the measured voltage. The tester also
displays your selected battery rating and the rating units.
Battery Test Results
Decision Interpretation
GOOD BATTERY Return the battery to service.
GOOD-RECHARGE Fully charge the battery and return it to service.
CHARGE & RETEST Fully charge the battery and retest. Failure
to fully charge the battery before retesting
may cause inaccurate results. If CHARGE &
RETEST appears again after you fully charge the
battery, replace the battery.
REPLACE BATTERY Replace the battery and retest. A REPLACE
BATTERY result may also mean a poor
connection between the battery cables and the
battery. After disconnecting the battery cables,
retest the battery using the out-of-vehicle test
before replacing it.
BAD CELL-REPLACE Replace the battery and retest.
24 VOLT SYSTEM 24-volt system detected. Disconnect batteries
and test individually.
READY TO INSTALL Battery has just been activated and is ready to
install in vehicle (Motorcycle only)
NEEDS CHARGE
Fully charge battery and retest using BEFORE
DELIVERY. (Motorcycle only)
Failure to fully charge the battery before
retesting may cause false readings.
New Battery Test Results
Besides the standard battery test results new battery has two more:
CYCLING REQUIRED Battery needs to be cycled for optimal
performance.
REST & RETEST Battery could have a surface charge, because it
has recently been charged.
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7. Press the ENTER () buttontoproceed,withthestartertest,BACK/PRINT
to print the test results or MENU to return to the Options Menu.
NOTE: For an in-vehicle test, the display alternates between the test results
andthemessage“PRESSFORSTARTERTEST.
See “Maintenence & Troubleshooting” in this manual for more information
about the printer.
IMPORTANT: The tester retains the results of the last test only. When you start
a new test, the last results are overwritten.
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Test Messages
For a more decisive result, the tester may prompt you for additional information.
The messages in the following table may appear before the tester can display
a result.
Test Message Interpretation
BAT. TEMPERATURE
Select ambient temperature above or below 0 ºC
CHARGE STATE Select before or after battery has been charged.
SURFACE CHARGE
DETECTED
Remove the surface charge before it begins testing.
Testing will resume after charge has been removed.
CHECK
CONNECTION
One or both clamps are not making proper contact
with the battery terminals.
ENGINE REV NOT
DETECTED PRESS
WHILE REVVING
Tester has not detected an increase in engine r.p.m.
REVERSE
CONNECTION
Clamps are connected in the wrong polarity:
positive to negative or negative to positive.
SYSTEM NOISE
CHECK LOADS
In-vehicle testing. Tester has detected computer,
ignition noise or parasitic drain. Make sure all vehicle
loads are off including open doors and ignition switch.
UNSTABLE
BATTERY
Out-of-vehicle. Weak battery, should be charged and
retested.
WIGGLE
CLAMPS
Clamps are not making good contact with
battery terminals
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Error Messages
Error Message Interpretation
BATTERY POWER TOO
LOW TO USE PRINTER.
CONNECT TO FULLY
CHARGED BATTERY
11.50 TO 16.00V
Battery being tested has fallen below 9 volts.
Connect to a fully charged battery to use the
printer.
CONNECT TO
12V BATTERY
Tester is not connected to the battery
LOW INTERNAL AA
BATTERIES. REPLACE
AA BATTERIES SOON!
Internal AA batteries are low and need to be
replaced. See “Maintenance & Troubleshooting”
section.
NON 12 VOLT SYSTEM
DETECTED
System being tested is not 12-volts.
PRINTER DOOR OPEN.
CLOSE DOOR AND TRY
TO PRINT AGAIN
Door covering printer paper is not secure.
PRINTER OUT OF PAPER
REPLACE WITH THERMAL
PRINTER PAPER.
2.5 IN. DIA. MAX.
2.25 IN. WIDE MAX
Printer is out of thermal paper. Replace with new
roll. See “Maintenance & Troubleshooting” section.
QC DATA MEMORY FULL
PRINT RESULTS OR
CLEAR MEMORY.
QC mode memory is full. Select QC mode from the
Options Menu to clear the memory.
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Maintenance & Troubleshooting
Changing The Cable Assembly
1. Identify the circled screw.
2. Remove the screw.
3. Grasp the housing and rmly pull the cable assembly from housing.
4. To attach a new cable, align the cable and tester housings and push to-
gether. Insert the screw and tighten.
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Changing The Printer Paper
The IR printer only uses thermal paper in a roll with the dimensions 2.25 in x 85
ft(57mmx25.9m).Youcanpurchasereplacementrollsatmostocesupply
stores.
To replace the paper roll:
1. Unlock the printer door by gently pressing on the red lever. Remove the
spent roll.
paper
compartment
release lever: press in this direction
paper
sensor
2. Place a new roll of paper in the compartment, and pull the paper forward
so that it extends past the serrated edge of the paper slot.
paper feeds from
underneath the roll
3. Closethedoorandmakesuretheleverlockssecurely.
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Printer Troubleshooting
If the tester is not connected to a 12-volt battery with at least 11.5 volts of power
or the paper sensor does not detect paper in the compartment during the print
process, the tester displays one of error messages described in the table:
Error Message Interpretation
PRINTER OUT OF PAPER
REPLACE WITH THERMAL
PRINTER PAPER.
2.5 IN. DIA. MAX
2.25 IN. WIDE MAX
√Verify that the paper is inserted correctly.
√Insert a new roll of paper.
√
Verify that the paper sensor is clean and undamaged
BATTERY POWER TOO
LOW TO USE PRINTER.
CONNECT TO FULLY
CHARGED BATTERY.
11.50 V TO 16.00 V
To print, the tester must be properly connected to a
vehicle battery having at least 9 volts.
√Connect to a vehicle battery with enough voltage to
enable printing.
√Make sure that the clamps are connected properly:
red clamp to the positive (+) terminal and the black
clamp to the negative (-) terminal.
√Check that both sides of the clamps are making con-
tact with the terminals.
PRINTER DOOR OPEN
CLOSE DOOR AND TRY
TO PRINT AGAIN
√Check that the door covering the printer paper is
properly closed and latched.
Troubleshooting the Display
If the display does not turn on:
• Checktheconnectiontothevehiclebattery.
• Thevehiclebatterymaybetoolow(below1volt)topowertheanalyzer.
Fully charge the battery and retest.
• The analyzer’s AA batteries may need to be replaced. (alkaline recom-
mended).
• IftheanalyzerdoesnotpoweronwhenyoupressandholdtheMENU but-
ton, replace the AA batteries.
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Replacing the Battery
The tester can test down to 5.5 volts when the unit’s internal batteries are not
functioning. The tester displays LOW INTERNAL AA BATTERIES, REPLACE AA
BATTERIESSOON! when the internal AA batsteries need to be replaced.
NOTE:Setupinformationwillberetainedwhileyouchangetheinternalbatteries.
Use the following procedure to remove and replace the internal AA batteries.
1. Turn the tester face down.
2. Remove the screw securing the battery compartment cover using a small
Phillips screwdriver.
3. Lift the door o and remove the discharged battery.
4. Insert fresh AA batteries making sure the positive and negative terminals
are positioned correctly.
5. Reposition the cover and tighten the screw.

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