Midtronics CTS-655P User manual

INSTRUCTION MANUAL
CTS-655P Battery & Electrical Diagnostic Analyzer
CELLTRON GENSTART

•2•
Contents
Chapter 1: Before You Begin ..................................................................................................5
Starting the tester for the rst time..................................................................................................................5
Safety ...........................................................................................................................................................................5
Conventions used in this manual......................................................................................................................6
Utilisation in accordance with„intended purpose“ ....................................................................................6
Disposal.......................................................................................................................................................................6
Chapter 2: Description ..........................................................................................................7
Connections and Data Ports ...............................................................................................................................7
Connecting the Battery Test Cable....................................................................................................................8
Removing and Inserting the Data Card...........................................................................................................8
Display and Keypad................................................................................................................................................9
Data Entry Methods............................................................................................................................................. 10
Menu icons ......................................................................................................................................................................10
Option Buttons...............................................................................................................................................................10
Scrolling Lists..................................................................................................................................................................10
Numeric Entries..............................................................................................................................................................10
Menu Maps............................................................................................................................................................. 11
Main Menu.......................................................................................................................................................................11
Print/View Menu............................................................................................................................................................12
Utility Menu.....................................................................................................................................................................13
Contents

•3•
Chapter 3: Test Preparation ................................................................................................ 14
Inspecting the Battery........................................................................................................................................ 14
Testing Out of Generator................................................................................................................................... 14
Testing In Generator............................................................................................................................................ 14
Connecting the Battery Test Cable................................................................................................................. 14
Setting User Preferences.................................................................................................................................... 14
Chapter 4: Battery Testing .................................................................................................. 15
New Battery Test ................................................................................................................................................... 15
Out of Generator................................................................................................................................................... 16
In Generator ........................................................................................................................................................... 17
Additional tester messages .............................................................................................................................. 19
Deep Scan Test ............................................................................................................................................................... 19
Open Battery Switch Before Continuing...............................................................................................................19
System Noise...................................................................................................................................................................19
Battery Test Result................................................................................................................................................ 20
New Battery Test Result...................................................................................................................................... 20
Pair Test Result....................................................................................................................................................... 20
Pack Test Result ..................................................................................................................................................... 21
Contents

•4•
Chapter 5: Utilities............................................................................................................... 22
Cong Tester .......................................................................................................................................................... 22
Display...................................................................................................................................................................... 23
Language ................................................................................................................................................................ 24
Shop Info ................................................................................................................................................................. 24
Coupon .................................................................................................................................................................... 25
Edit Coupon............................................................................................................................................................ 25
Format Card............................................................................................................................................................ 25
Clear Counters....................................................................................................................................................... 25
Update...................................................................................................................................................................... 25
Chapter 6: Print/View .......................................................................................................... 26
Chapter 7: Version Info........................................................................................................ 27
Chapter 8: Troubleshooting................................................................................................ 28
Problems with the display................................................................................................................................. 28
Data Will not Print ................................................................................................................................................ 28
Chapter 9: Tester Internal Batteries ................................................................................... 29
Battery Power Indicator ..................................................................................................................................... 29
Replacing the Tester Batteries.......................................................................................................................... 29
APPENDIX A - Battery Congurations................................................................................ 30
APPENDIX B - Explanation JIS............................................................................................. 31
PATENTS & LIMITED WARRANTY ........................................................................................ 32
Contents

•5•
Chapter 1: Before You Begin
Starting the tester for the rst time
When the tester is started for the rst time the operator is asked to enter local language, local time and date
information.
Changes can be made afterwards by going in to the Utility Menu and selecting CONFIG TESTER.
Safety
ENSURE ALL RELEVANT BEST OPERATING PRACTICES (BOP’S) ARE STRICTLY ADHERED
TO WHEN CARRYING OUT ANY TASKS EXPLAINED IN THIS MANUAL.
Chapter 1: Before You Start

•6•
Conventions Used in This Manual
To help you learn how to use your analyzer, the manual uses these symbols and typographical conventions:
The safety symbol followed by the word WARNING or CAUTION indicates
instructions for avoiding hazardous conditions and personal injury.
The word CAUTION without the safety symbol indicates instructions for avoiding
equipment damage.
The wrench symbol indicates procedural notes and helpful information.
The text for keypad buttons and soft-key functions are in bold capital letters.
The text for screen options are in regular capital letters.
Utilization in accordance with “intended purpose“
The tester is to be used exclusively for its intended purpose. Utilization for any other purpose, or in any other
manner, shall be deemed to be„not in accordance with the intended purpose“. The manufacturer is not liable
for any damage, inadequate or incorrect results arising out of such misuse.
Utilisation in accordance with the “intended purpose” also comprises
- carefully reading and obeying all operating instructions and safety and danger notices
- performing all stipulated inspection and servicing work.
- following all instructions from the battery and generator manufacturers.
Disposal
Do not dispose of this device with normal domestic waste!
To comply with the European Directive 2002/96/EC on Waste Electrical and Electronic
Equipment and its implementation as national law, electrical equipment that has reached
the end of its life must be collected separately and returned to an approved recycling facility
Any device that you no longer require must be returned to our agent, or nd out about the
approved collection and recycling facilities in your area. Ignoring this European Directive
may have potentially adverse aects on the environment and your health! Please be aware
that in other parts of the world local legislation should be followed.
Chapter 1: Before You Start
!
CAUTION
UP ARROW
POST TYPE

•7•
Chapter 2: Description
Chapter 2: Description
Connections and Data Ports
Integrated thermal printer
Release lever for door to paper compartment
Paper slot
LCD screen with MAIN MENU
Control Panel: keypad and power button
6-pin connector for the battery test cable
Spring-loaded data card slot for test data
storage and software upgrades.
Infrared temperature sensor with a range of
-28 °C to +93 °C (-20 °F to +200 °F).
Data transmitter: sends test results to a PC
using an optional hardware and software kit

•8•
Chapter 2: Description
Connecting the Battery Test Cable
CAUTION: To prevent damage to the analyzer’s circuitry, do not connect the analyzer to a voltage
source greater than 30 Vdc.
To connect the battery test cable to the analyzer align the arrow on the cable connector with the arrows on
the analyzer’s housing. Hold the part of the cable connector as shown and rmly insert the connector into
analyzer’s six-pin receptacle. Do not twist.
To avoid damaging the battery test cable, always hold the ridged part of the cable connector (as shown in
the photo) when inserting and removing the cable.
Hold the cable
connector here
Arrows
Removing and Inserting the Data Card
The battery tester is delivered with an SD card installed in the data card slot to protect it from dust and
debris. To remove the SD card, push briey on its edge to release it and pull it from the slot.
When inserting a card, push it into the slot until it locks. The card is correctly inserted when it is not
protruding from the slot. To protect the card slot and enable the analyzer to read and write to the card,
leave the card in the slot.

•9•
Chapter 2: Description
Display and Keypad
The keypad and display work together to help you quickly nd and use the right tools at the right time. The
display also keeps you on track with on-screen navigation aids, directions and messages.
Internal Batteries Status Indicator
This indicator appears in the screen’s top left corner, lets
you know the status and charge level of the analyzer’s six
1.5-volt batteries. The Xin the top left corner of the screen
shows that the analyzer is powered by the battery you’re
testing to conserve the analyzer’s internal batteries.
Voltmeter
When you rst connect the analyzer to a battery it functions
as a voltmeter. The voltage reading appears above the left
soft key until you move to other menus or functions.
Soft Keys
Press the two Soft Keys linked to the bottom of the screen
to perform the functions displayed above them. The
functions change depending on the menu or test process.
So it may be helpful to think of the words appearing above
them as part of the keys. Some of the more common soft-
key functions are SELECT, BACK, and END.
POWER Key
Press the POWER button to turn the analyzer on and
o. The analyzer also turns on automatically when you
connect its test leads to a battery.
Title Bar
The title bar shows you the name of the current menu,
test tool, utility, or function.
Selection Area
The selection area below theTitle Bar contains selectable
items or dialog boxes that display information or require
a response.
Menu Screen Arrows
When displayed in menu screens, the menu screen
arrows show you which ARROW key on the keypad
to press to display other icons or screens. The Up and
Down Menu Screen Arrows, for example, indicate when
to press the UP ( ) and DOWN ( ) ARROW keys to
display the screens above and below the current screen.
The Left and Right Menu Screen Arrows tell you when to
use the LEFT ( ) or RIGHT ( ) ARROW keys to select an
icon. When displayed under a list of options, the menu
screen arrows show you which keypad arrow to press to
highlight a character or item in a list.
Scroll Bar
Another navigational aid is the scroll bar on the right
side of the screen. The position of its scroll box shows
you whether the screen is the top (or only screen),
middle, or last in a series.
Arrow keys
Press the UP or LEFT ARROW key to move up to the next
selectable item or row. When entering text, use the UP
or LEFT ARROW key to move to the previous character.

•10 •
Data Entry Methods
To perform a particular test or function, the tester will ask for dierent types of information. This means that
the methods you use to enter information will change depending on the type of information requested. The
four types of entry methods are described below.
Typically, the soft key below the right half of the screen conrms your choice, although the word above it
may vary. In a similar fashion, the soft key below the left half of the screen cancels your choice or returns you
to the previous screen, although the word above it may also vary.
Menu icons
A menu icon is a graphical representation of a function you can select. To select an icon, use the LEFT or
RIGHT ARROW key to highlight it. Highlighting changes the icon to a white picture on a black background.
To conrm your selection, press the appropriate soft key.
Option Buttons
Some lists have option buttons before each item. To select an item, use the UP/DOWN ARROW keys to move
the dot into the button next to the item you want. You can also use the alphanumeric keypad to enter the
number preceding the option button. To conrm your selection, press the appropriate soft 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 visible or highlighted
item on the list. To select from this type of list, use the UP/DOWN ARROW keys to scroll to the item, or use
the keypad to enter your choice, and press the appropriate soft key.
Numeric Entries
Even though the tester does not use a numeric keypad it is possible to enter numeric values.
When applicable the numeric values appear on the display. Use the UP/DOWN or LEFT/RIGHT ARROW keys
to scroll and conrm this with the key. To return one or more steps use the key.
Chapter 2: Description

•11 •
Menu Maps
This section will help you get to your destination while letting you know what test leads you may need when
you arrive. The test leads are represented by symbols for their connectors.
Main Menu
The MAIN MENU is the starting point for all tools and utilities, which are depicted as icons. Some icons lead
directly to the function they represent, while others are menu icons that lead to two or more functions.
Menu icons are marked here with an asterisk (
*
) and are mapped on the following pages.
MAIN MENU (Screen 1)
MAIN MENU (Screen 2)
Tests a battery, or bat-
teries, using the battery
information you select in a
series of screens.
Enables you to view your
stored test results and
print them to the internal
printer.
Utilities, many of which
customize your user inter-
face in the tester.
Chapter 2: Description
Displays the software ver-
sion, total tests from rst
use, and the serial number.

•12 •
RESULTS
to MAIN MENU an icon
Print/View Menu
The tester stores the last test results in its memory until you perform another test. To review or print results
before you retest, select a test type in the Print/View Menu.
Chapter 2: Description
Displays the last test results per test type (single, series or pack). The results can be printed to
the integrated printer.

•13 •
Utility Menu
The Utility Menu lets you customize your analyzer to suit your needs.
*Currently not used
SETUP (Screen 1)
SETUP (Screen 2)
SETUP (Screen 3)
Congur the tester by
selecting several specic
functions
Enables you to add a cus-
tom header to printed test
results.
Settings to adjust the
screen contrast and back-
light time.
If you’ve created a coupon
in the Edit Coupon utility,
use Coupon to turn it on
and o.
Enables you to create a
coupon at the bottom of
printed test results.
Sets the language of the
display and printouts.
an icon
to MAIN MENU an icon
to MAIN MENU an icon
to MAIN MENU
Formats the SD card to re-
ceive data. Also erases all
data on the card.
Enable you to Update the
software in the tester with
a specic SD Card
Chapter 2: Description
**

•14 •
Chapter 3: Test Preparation
Inspecting the Battery
Before starting the test visually inspect the battery for:
• Cracked, buckled, or leaking case. If you see any of these defects, replace the battery.
• Corroded, loose, or damaged cables and connections. Repair or replace them as needed.
• Corrosion on the battery terminals, and dirt or acid on the case top. Clean the case and terminals
using a wire brush and a mixture of water and baking soda.
• When electrolyte level is too low, replace the battery.
Testing Out of Generator
The preferred battery test location is in the generator. However, if you plan to test out of the generator:
• Always disconnect the negative cable from the battery first and reconnect it last.
• Always use a carry tool or strap to lift and transport the battery.
Testing In Generator
The preferred test position is at the battery posts.
Connecting the Battery Test Cable
CAUTION: Do not connect the tester to a voltage source greater than 30 Vdc.
Connect the clamps to the battery: the red clamp to the positive (+) terminal and the black clamp to the
negative (–) terminal. If you connect the clamps in the wrong polarity (positive to negative or negative to
positive), the tester displays CLAMPS REVERSED! Reconnect the clamps correctly.
To make sure both sides of the clamps are gripping the terminals, rock the each clamp back and forth. A
poor connection will prevent testing, and the tester will display the message CHECK CONNECTION. If the
message reappears after you have correctly reconnected the clamps, clean the terminals and reconnect.
Setting User Preferences
Before starting your test you may want to customize the use of your analyzer by setting preferences in the
Utility Menu. The menu has settings for the display’s date and time, the contrast and backlight time, a utility
to customize printouts, among others.
To conserve the analyzer’s internal batteries, the tester will turn o after 10 minutes of inactivity.
Chapter 3: Test Preparation

•15 •
Chapter 4: Battery Testing
The tester will guide you through the steps of selecting your battery test
parameters and interpreting the results. Before you start the test, review
the instructions in Chapter 3: Test Preparation.
New Battery Test
1. From the MAIN MENU choose BATTERY TEST.
2. Choose BATTERY TEST and you will see two options in BATTERY AGE:
• IN SERVICE
- OUT OF GENERATOR
- IN GENERATOR
• NEW BATTERY
IN SERVICE means the battery has been in use. NEW BATTERY means the
battery has never been in service (used) before. OUT OF GENERATOR
means that the battery has been in use, but is not installed at that
moment. IN GENERATOR means the battery is installed and so in service
at the moment.
NOTE: A new battery is always out of generator since it is never
been used before!
Please, choose NEW BATTERY.
3. Choose your BATTERY TYPE.
First check the OPTIMA REDTOP battery rating. If the battery rating is
910 CCA/SAE, please select OPTIMA. If the OPTIMA REDTOP rating is
other than 910 CCA/SAE, please select AGM SPIRAL, select the RATING
UNITS and the BATTERY RATING.
4. Choose the RATING UNITS and BATTERY RATING, or the part number
in case of ‘JIS’. Please see appendix B at the back of the manual for an
explanation of JIS.
5. Measure the temperature. Press NEXT to continue.
(The temperature can inuence the battery’s capability to deliver
energy.)
6. The test will be performed.
The results will be shown. You can print the results by selecting PRINT.
If END is pressed you will go back to the MAIN MENU.
For all the possible results please go to the ‘Test Results’ section, which can be
found on page 20 of this manual.
Chapter 4: Battery Test

•16 •
Chapter 4: Battery Test
Out of Generator
1. From the MAIN MENU choose BATTERY TEST.
2. Choose BATTERY TEST and you will see two options in BATTERY AGE:
• IN SERVICE
• NEW BATTERY
Please, choose IN SERVICE. In service means the battery has been in use,
and when performing the OUT OF GENERATOR test, the battery is NOT
installed in the generator.
3. Choose OUT OF GENERATOR
4. Choose your BATTERY TYPE.
First check the OPTIMA REDTOP battery rating. If the battery rating is
910 CCA/SAE, please select OPTIMA. If the OPTIMA REDTOP rating is
other than 910 CCA/SAE, please select AGM SPIRAL, select the RATING
UNITS and the BATTERY RATING.
5. Choose the rating system and rating, or the part number in case of ‘JIS’.
Please see appendix B at the back of the manual for an explanation of JIS.
6. Measure the temperature. Press NEXT to continue.
(The temperature can inuence the battery’s capability to deliver
energy.)
7. The test will be performed.
The results will be shown. When testing a single or series conguration
the individual battery result is shown. Whereas for the parallel
conguration you will see a pack result.
The results will be shown. You can print the results by selecting PRINT.
If END is pressed you will go back to the MAIN MENU.
For all the possible results please go to the ‘Test Results’ section, which can be
found on page 20 of this manual.

•17 •
Chapter 4: Battery Test
In Generator
1. From the MAIN MENU choose BATTERY TEST.
2. Choose BATTERY TEST and you will see two options in BATTERY AGE:
• IN SERVICE
• NEW BATTERY
Please, choose IN SERVICE. In service means the battery is in use, and when performing the
IN GENERATOR test, the battery is installed in the generator.
3. Please, choose IN GENERATOR.
A warning is shown:
4. Choose your BATTERY CONFIGURATION. Please see appendix A at the back of the manual for various
battery congurations.
Make sure to choose the correct conguration, otherwise the test and its result can be inaccurate.
When choosing a parallel conguration you will be asked to put in the number of batteries.
5. Choose your BATTERY TYPE. Press NEXT to continue.
First check the OPTIMA REDTOP battery rating. If the battery rating is 910 CCA/SAE, please select
OPTIMA. If the OPTIMA REDTOP rating is other than 910 CCA/SAE, please select AGM SPIRAL, select
the RATING UNITS and the BATTERY RATING.
6. Choose the rating system and rating, or the part number in case of ‘JIS’. Please see appendix B at the
back of the manual for an explanation of JIS.
7. Measure the temperature. Press NEXT to continue.
(The temperature can inuence the battery’s capability to deliver energy.)
8. The test will be performed.
The results will be shown. When testing a single or series conguration the battery test result is shown.
Whereas for the parallel conguration you will see a pack result. For all the possible results please go
to the ‘Test Results’section, which can be found on page 20 of this manual.
On the next page you can see the testing process per column for congurations up to 6 batteries per
pack.
Please see next page for the screen ow of this test

•18 •
Chapter 4: Battery Test

•19 •
Additional tester messages
Deep Scan Test
In some cases the tester may need to further analyze the battery to determine whether the battery should
be replaced or it has a signicant chance to be recovered. It will then conduct a Deep Scan Test of the battery
for a few seconds. This test will typically be performed on batteries that are in a low state of charge.
Open Battery Switch Before Continuing
Before testing the batteries the battery switch must be opened. Therefore a warning pops up. If the switch
is closed during the test, the test can be disrupted. If a system test is required, the tester will ask you to close
the switch.
Chapter 4: Battery Test

•20 •
Battery Test Results
After the test the tester will display the battery decisions with the complete results in a series of screens.
Use the UP/DOWN ARROW keys to scroll through each result. To print the results press the PRINT soft key.
To return to the MAIN MENU, press the END soft key.
Battery decisions and recommendations
Decision Recommended Action and Information
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
GENERATOR test before replacing it.
BAD CELL-REPLACE Replace the battery and retest.
FROZEN BATTERY Defrost the battery and retest.
24 VOLT SYSTEM 24-volt system detected. Connect to 12V battery instead of the system.
LOW VOLT REPLACE Battery voltage is too low.
SYSTEM NOISE If the result system noise keeps occurring, disconnect the batteries and
test each battery individually. System noise possibly means the generator
is interfering with the batteries. Therefore, an accurate test is impossible.
Chapter 4: Battery Test
Battery decision Measured voltage
Measured capacity
rating units
Temperature indication