Midtronics MDX-655 User manual

For 6 & 12-volt automotive starting batteries
and 12 & 24-volt starting/charging systems
INSTRUCTION MANUAL
MDX-655
Battery Conductance &
System Analyzer
Battery Conductance and
Electrical System Analyzer

Blank page

•3•
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
Starter System Test 14
Starter System Test Results 14
Charging System Test 15
Charging System Test Results 15
www.midtronics.com

•4•
Test Messages 17
Error Messages 18
Maintenance & Troubleshooting 19
Changing The Cable Assembly 19
Troubleshooting the Display 20
Replacing the Battery 21
www.midtronics.com

•5•
!
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.
www.midtronics.com

•6•www.midtronics.com

•7•
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
www.midtronics.com

•8•
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”.
www.midtronics.com
1
2
Display Showing
Battery Result
3
4
IR Output
Decision
Measured rating
Measured voltage
Selected rating
Button
Toolbar

•9•
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.
www.midtronics.com

•10 •
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.
www.midtronics.com

•11 •
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
www.midtronics.com

•12 •
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.
www.midtronics.com

•13 •
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.
www.midtronics.com

•14 •
Starter System Test
IMPORTANT: Before starting the test, inspect the alternator drive belt. A belt
that is glazed or worn, or lacks the proper tension, will prevent the en-
gine from achieving the rpm levels needed for the test.
Once you have completed an in-vehicle test, the display alternates between
thebatterytestresultsandthemessagePRESSFORSTARTERTEST.
1. Press the ENTER () button to proceed with the starter test.
2. Starttheenginewhenprompted.
3. The tester displays the decision on the starter system, cranking voltage,
and cranking time in milliseconds.
Starter System Test Results
Decision Interpretation
CRANKING NORMAL The starter voltage is normal and the battery is
fully charged.
LOW VOLTAGE The starter voltage is low and the battery is fully
charged.
CHARGE BATTERY The starter voltage is low and the battery is
discharged. Fully charge the battery and repeat
the starter system test.
REPLACE BATTERY Battery must be replaced before the starting
system can be tested.
NO START No vehicle start detected.
CRANKING SKIPPED A start was not detected.
4. Press the ENTER () buttontoproceedwiththechargingsystemtest,BACK/
PRINT button to print the test results, 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CHARGINGTEST.
See “Maintenence & Troubleshooting” in this manual for more information
about the printer.
www.midtronics.com

•15 •
Charging System Test
Once you have completed an in-vehicle test, the display alternates between
thebatterytestresultsandthemessagePRESSFORCHARGINGTEST.Press
the ENTER () button to proceed with the charging test.
Following the on-screen prompts:
1. Rev the engine.
2. Turn on high beams headlights and the blower fan.
3. Rev engine with loads on.
4. Idle engine and turn o loads.
5. TheChargingSystemdecision is displayed at the end of the procedure.
Charging System Test Results
Decision Interpretation
NO PROBLEMS System is showing normal output from the alternator.
NO OUTPUT No alternator output detected.
√ Check all connections to and from the alternator,
especially the connection to the battery. If the
connection is loose or heavily corroded, clean or
replace the cable and retest.
√ If the belts and connections are in good working
condition, replace the alternator. (Older vehicles
use external voltage regulators, which may require
only replacement of the voltage regulator.)
LOW OUTPUT Alternator not providing sufcient current to power the
system’s electrical loads and charge the battery.
√ Check the belts to ensure the alternator is rotating
with the engine running. Replace broken or
slipping belts and retest.
√ Check the connections from the alternator to
the battery. If the connection is loose or heavily
corroded, clean or replace the cable and retest.
continued
www.midtronics.com

•16 •
Decision Interpretation
HIGH OUTPUT Alternator voltage output exceeds the normal limits.
√ Make sure there are no loose connections and
the ground connection is normal. If there are no
connection problems, replace the regulator. Most
alternators have a built-in regulator that requires
replacing the alternator. In older vehicles that
use external voltage regulators, you may need to
replace only the voltage regulator.
EXCESSIVE
RIPPLE
Excessive AC ripple detected.
√ One or more diodes in the alternator is not
functioning or there is stator damage.
6. PresstheBACK/PRINTbuttontoprintthetestresultsorMENUtoreturnto
the Options Menu.
See “Maintenence & Troubleshooting” in this manual for more information
about the printer.
www.midtronics.com

•17 •
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
www.midtronics.com

•18 •
Error Messages
Error Message Interpretation
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.
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.
www.midtronics.com

•19 •
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.
www.midtronics.com

•20 •
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.
www.midtronics.com