Midtronics Celltron ULTRA User manual

Universal Stationary
Battery Analyzer
For testing stationary batteries
used in UPS systems, power
utility, and telecommunications
industries
INSTRUCTION MANUAL
®
September 2008
168-641G
INNOVATION TECHNOLOGY QUALITY WORLDWIDE
INNOVATION TECHNOLOGY QUALITY WORLDWIDE

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Contents
Celltron ULTRA

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Contents Celltron ULTRA

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This manual provides operating instructions for the
Midtronics Celltron®ULTRA Universal Stationary Battery
Analyzer. The instructions will help you to properly
congure 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 guide-
lines:
• 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sys-
tems 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 con-
tain 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 conguration:
UPSSystems,120,220/240,480,600volts
PowerUtility(Switching,SCADA,etc.)
TelecomOSP,–48/+24volts
TelecomCentralOce,–48/+24volts
CATV
The analyzer features two backlit graphical LCD, a digital
multimeter,aUSBport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 conductance values in
mhos (
Ω
). 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.
Chapter 1: Introduction
Celltron ULTRA
Chapter 1: Introduction

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Test Range
Theanalyzerhasanoperatingrangeof0to20,000
Ω
.Thisrangeincludesjarsthathaveabout5to6000Ahofreserve
capacity.
Kit accessories
Item Description
X Clamps 166.7 mm (6.56 in.) length clamps and 50.8 mm (2.0 in.) maximum opening
X Probes 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 conned 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 7.2 V, 2500 mAh
Spare extender lamps Lamps are replaceable: peel them off; use alcohol wipes to clean the surface, and
attach the new lamps
Carrying Case Hard side carrying case.
Chapter 1: Introduction Celltron ULTRA

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Display, keypad, and connections
3
1
2
4
6
NOTE: Theanalyzershutsoafterapproximately2minutes
of inactivity to conserve its battery pack.
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)
TITLE
Status/Instruction Areas
Selection/Option Area
Battery pack charge level
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-dened 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
5
7
8
10
9
11
12
13
14
Chapter 2: Description
Celltron ULTRA
Chapter 2: Description

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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 rst 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t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-dened” 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 nished.
Chapter 2: Description Celltron ULTRA

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Chapter 2: Description
Celltron ULTRA
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ndmoredetailedinformationonhowtoselectoptionsandtestparametersinChapters4and5.
Main 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 les, 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 alphanumeric 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 parameters 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)de-endsonwhetheryouaretestingJARSONLYorJARS&1
STRAP,JARS&2STRAPSandthenumberofPOSTSPERJAR.
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.

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Chapter 2: Description Celltron ULTRA
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.
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 manufacturer.
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 (– – – – – –
Ω
).
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.
VOLT & CONDUCTANCE (default)
PressENTER to measure volts only; volts and conductance simultaneously; or voltage rst, 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

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change with jar temperature. 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:0to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oatvoltage.
DC FLOAT (scrolling/numeric)
Select from 0.00 to 600.00 volts.
DC FLOAT A.
PressENTERtoselectthestring’sDCoatcurrent.
DC FLOAT A.(scrolling/numeric)
Select from 0.000 to 99.999 amps.
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under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parametersyouwanttouse,andscrolltoSAVE
ANDTEST.Otherwise,makechangesusingtheNEW(TEST)function.Main Menu (menu icon)
Chapter 2: Description
Celltron ULTRA

• 12 •
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le.PressENTER to continue or the BACK key to cancel.
DELETE ALL FILES (icon)
PressENTER to delete all les.
WARNING
Theanalyzerwillaskifyouwanttodeleteallles.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 le 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.
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)
Chapter 2: Description Celltron ULTRA

• 13 •
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 battery when you are nished
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 rst used.
REPORTS (menu icon)
VERSION (icon)
PressENTERtodisplaytheserialnumbersoftheanalyzer,cable,ashmemory,andEEPROMrmwareversions.
The information will be helpful when you call Midtronics for software updates, service, and parts.
UTILITIES SETUP (menu icon)
PressENTERtodisplaytheUTILITIESSETUPmenu.Thismenuhassevenutilities,fourofwhichsupportthetest
process.
WARNING (icon)
PressENTER to select a percentage of the reference value below which a jar and string must fall to generate a
warning or failure notice.
STRING INFO (scrolling)
Select a site name and press ENTER.
STRING INFO (scrolling)
STRING WARN
PressENTER.
STRING INFO (scrolling/numeric)
Select from 0to 100%.
STRING FAIL
PressENTER.
Chapter 2: Description
Celltron ULTRA

• 14 •
STRING INFO (scrolling/numeric)
Select from 0to 100%.
JAR WARN
PressENTER.
STRING INFO (scrolling/numeric)
Select from 0to 100%.
JAR FAIL
PressENTER.
STRING INFO (scrolling/numeric)
Select from 0to 100%.
SAVE AND CONTINUE
PressENTERtoreturntotheUTILITIESSETUPMenu.
TEMP (icon)
PressENTER to select the temperature unit of measure.
TEMP. UNITS (checkboxes)
DEGREESF
DEGREESC
MODE (icon)
PressENTER to select a test startup mode.
MODE (check boxes)
MANUAL START
This mode prompts you to press ENTERtostartatestwhenyouconnecttothenextjarwhileinthejarresults
screen.
AUTO START
This mode begins a test automatically when you connect to the jar.
CLOCK (icon)
PressENTER to set the date and time.
CLOCK ADJUST (scrolling)
ThedateformatisDD/MM/YYYY(Day/Month/Year).
A24-hourclockkeepsthetime.
DISPLAY (icon)
PressENTER to adjust the display contrast and the amount of time the screen background stays illuminated.
DISPLAY OPTIONS (scrolling)
CONTRAST LEVEL
PressENTER.
CONTRAST LEVEL (scrolling)
The range is 0(lightest) to 10 (darkest).
Chapter 2: Description Celltron ULTRA

• 15 •
Page 22 168-641G
BACKLIGHT TIME (scrolling)
Press ENTER.
BACKLIGHT TIME (scrolling)
Select the duration of the backlight when the analyzer is inactive. The range is 0to 10 seconds.
LANGUAGE (icon)
Press ENTER to select a language.
LANGUAGE (check boxes)
7 LANGUAGES: ENGLISH, GERMAN, SPANISH, ITALIAN, FRENCH,
PORTUGUESE AND RUSSIAN
UPDATE (icon)
The UPDATE utility installs ULTRA software upgrades from an SD memory card.
MAIN MENU (icon)
Displays the Main Menu.
DMM (icon)
Press ENTER to display the digital multimeter menu.
DC VOLTS (icon)
Press ENTER.
DC VOLTMETER
The DC voltmeter measures from real-time DC voltage from 0 to 25 Vdc.
AC VOLTS (icon)
Press ENTER.
AC VOLTMETER
The AC voltmeter measures real-time AC voltage from 0 to 10 Vac.
SCOPE (icon)
SCOPE
Real-time voltage trace with a range of 0 to 25 Vdc and four options: AUTO SETUP, RUN/HOLD, TIME
DISPLAY, and FFT DISPLAY.
(To CURRENT)
Main Menu (menu icon)
Chapter 2: Description
Celltron ULTRA

• 16 •
DMM (icon) (Continued from SCOPE)
CURRENT (icon)
CURRENT
Connect to the jar to estimate the AC ripple current in the jar.
BATTERY MANAGER (icon)
Press ENTER to add or edit models and reference values in the database.
SELECT MFGR (scrolling)
Select from an alphabetical list of 16 manufacturers, or select USER VENDOR
(3 available) for an unlisted manufacturer.
SELECT MODEL (scrolling)
Select from an alphabetical list of over 200 models, or select USER
DEFINED (64 available) for an unlisted model.
EDIT MFGR (scrolling)
(Selected manufacturer name)
Accept the manufacturer name by scrolling past it, or select it to create a user-dened name.
MFGR ID
Edit the manufacturer name.
EDIT MODEL
(Selected model name)
Accept the model name by scrolling past it, or select it to create a user-dened name.
MODEL ID
Edit the model name.
REFERENCE
Press ENTER to change the value.
BATTERY RATING
Select a reference value. The range is 0to 20,000 .
SAVE AND CONTINUE
Press ENTER to save the settings and return to the Main Menu.
Chapter 2: Description Celltron ULTRA

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Chapter 2: Description
Celltron ULTRA

• 18 •
Chapter 2: Description Celltron ULTRA

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Chapter 2: Description
Celltron ULTRA

• 20 •
Before you test a string
• Notethevoltageofthejars
• Determineareferencevalue
• SetoptionsintheUTILITIESSETUPmenu
• SettestparametersintheBATTERYSETUPmenu
Reference values are average conductance values from a
sampleofstrongjarssimilarinconditionandage.Generally,
asampleof30neworhealthybatteriesistestedtoobtain
avaluerepresentativeofanewonlinebattery90daysafter
installation.Youcancomparereferencevaluestotestresults
from a string. The dierences between test results and
reference values help you determine the string’s capacity to
provideenoughconductancefortheload.Dierencescan
reecthowastringwastreated,installed,ormaintained.
Options in determining a reference value
If you want a value specic to the string you are testing,
Midtronics recommends that you create your own reference
value. The following options are listed in the order you
should take to obtain a reference value.
•Consult your company documentation for reference
values that were created for the string you are testing.
•Test a sample of jars. Refer to Testing a sample of jars to
establish a reference value in this chapter.
•Test the jars in the string and use the highest conduc-
tance value as a reference value.
• UsetheaveragefromSTRINGSUMMARY after you test
the string. Refer to Using the average in STRING SUMMA-
RY in this chapter).
• UseREFERENCE DEVELOPERtodetermine a reference
value based on a selected percentage of jars on the
string with the highest conductance value.
• Use the reference value in the BATTERY MAN-
AGER database for the model of jar you
are testing. If the model is not in the database, contact
the battery manufacturer or visit www.midtronics.com
for a list of reference values for common jar types.
The reference values in STRING SUMMARY, BATTERY
MANAGER, and on the website are only guidelines.
Midtronics updates the website with new reference values
when they are created. If you create a reference value for
a jar model, e-mail the value and information to net@
midtronics.com or fax it to 630-323-7752 (Attn: Reference
value list).
CAUTION: DonotusetheCelltronULTRAtotesttheentire
stringatonce.Testonlyindividualjars/batteries.
IMPORTANT: Always test on the lead post for the most con-
sistent results. To prevent lower measures, avoid
tests on stainless-steel hardware or bolts.
Notes:
• The rst time you turn on or connect the Celltron UL-
TRA, it will display a reminder to set preferences for
the temperature units (Celsius or Fahrenheit) and
thejarandstringWARN/FAILthresholds.Although
you can press the BACK key to bypass the message,
it will continue to appear until you change or accept
the default settings.
•To protect its circuitry, the analyzer will not turn on if
the clamps/probes are connected in reverse polarity
(red to negative, black to positive).
• Poweroutagescan aecttest results.Donot testthe
string if a power outage occurred recently and the
string is boost-charged.
•If the last le created, opened, or used does not match
any les on the memory card, the analyzer will beep
and display FILE NOT FOUND.The analyzer’s internal
EEPROM memory stores the last test used. When the
analyzer powers on, it looks for the last le used on the
memory card. To prevent the message from reappear-
ing,insertthecardcontainingthele,openanexisting
le, or create a new le on the card.
Chapter 3: Determining a reference value Celltron ULTRA
Chapter 3: Determining a reference value