Fluke BT520 Operating Manual

BT520

Battery Analyzer

May 2014 Rev.1, 08/15

© 2014, 2015 Fluke Corporation. All rights reserved. Specifications are subject to change without notice.
All product names are trademarks of their respective companies.

Users Manual

LIMITED WARRANTY AND LIMITATION OF LIABILITY

Each Fluke product is warranted to be free from defects in material and workmanship under normal use and
service. The warranty period is three years and begins on the date of shipment. Parts, product repairs, and
services are warranted for 90 days. This warranty extends only to the original buyer or end-user customer of
a Fluke authorized reseller, and does not apply to fuses, disposable batteries, or to any product which, in
Fluke's opinion, has been misused, altered, neglected, contaminated, or damaged by accident or abnormal
conditions of operation or handling. Fluke warrants that software will operate substantially in accordance
with its functional specifications for 90 days and that it has been properly recorded on non-defective media.
Fluke does not warrant that software will be error free or operate without interruption.

Fluke authorized resellers shall extend this warranty on new and unused products to end-user customers
only but have no authority to extend a greater or different warranty on behalf of Fluke. Warranty support is
available only if product is purchased through a Fluke authorized sales outlet or Buyer has paid the
applicable international price. Fluke reserves the right to invoice Buyer for importation costs of
repair/replacement parts when product purchased in one country is submitted for repair in another country.

Fluke's warranty obligation is limited, at Fluke's option, to refund of the purchase price, free of charge repair,
or replacement of a defective product which is returned to a Fluke authorized service center within the
warranty period.

To obtain warranty service, contact your nearest Fluke authorized service center to obtain return
authorization information, then send the product to that service center, with a description of the difficulty,
postage and insurance prepaid (FOB Destination). Fluke assumes no risk for damage in transit. Following
warranty repair, the product will be returned to Buyer, transportation prepaid (FOB Destination). If Fluke
determines that failure was caused by neglect, misuse, contamination, alteration, accident, or abnormal
condition of operation or handling, including overvoltage failures caused by use outside the product’s
specified rating, or normal wear and tear of mechanical components, Fluke will provide an estimate of repair
costs and obtain authorization before commencing the work. Following repair, the product will be returned to
the Buyer transportation prepaid and the Buyer will be billed for the repair and return transportation charges
(FOB Shipping Point).

THIS WARRANTY IS BUYER'S SOLE AND EXCLUSIVE REMEDY AND IS IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTY
OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. FLUKE SHALL NOT BE LIABLE
FOR ANY SPECIAL, INDIRECT, INCIDENTAL OR CONSEQUENTIAL DAMAGES OR LOSSES,
INCLUDING LOSS OF DATA, ARISING FROM ANY CAUSE OR THEORY.

Since some countries or states do not allow limitation of the term of an implied warranty, or exclusion or
limitation of incidental or consequential damages, the limitations and exclusions of this warranty may not
apply to every buyer. If any provision of this Warranty is held invalid or unenforceable by a court or other
decision-maker of competent jurisdiction, such holding will not affect the validity or enforceability of any other
provision.

Fluke Corporation
P.O. Box 9090
Everett, WA 98206-9090
U.S.A.

11/99

Fluke Europe B.V.
P.O. Box 1186
5602 BD Eindhoven
The Netherlands

Table of Contents

Chapter Title Page

1 Product Overview and Specifications ............................................... 1-1

Introduction ............................................................................................ 1-1

Contact Fluke ........................................................................................ 1-1

Product Overview .................................................................................. 1-1

Standard Equipment .............................................................................. 1-3

Safety Information ................................................................................. 1-5

Keys and I/O Terminals ......................................................................... 1-8

LCD Display .......................................................................................... 1-10

Specifications ........................................................................................ 1-11

General Specifications ....................................................................... 1-11

Accuracy Specifications ..................................................................... 1-12

Records Capacity .............................................................................. 1-13

2 Setup .................................................................................................... 2-1

Introduction ............................................................................................ 2-1

Tilt Stand ............................................................................................... 2-1

Belt Strap ............................................................................................... 2-2

Adjust Display Contrast ......................................................................... 2-3

Set Language ........................................................................................ 2-3

Set Date and Time ................................................................................ 2-3

Turn On/Off Beep .................................................................................. 2-4

AutoHold and AutoSave Modes ............................................................ 2-4

Set Auto Power Off Time ....................................................................... 2-5

View Device Information ........................................................................ 2-6

Reset to Factory Mode .......................................................................... 2-6

View Memory Usage Information .......................................................... 2-6

3 Use the Product ................................................................................... 3-1

Introduction ............................................................................................ 3-1

Switch Between Meter Mode and Sequence Mode ............................... 3-1

Use a Profile in Sequence Mode ........................................................... 3-3

Manage Profiles ................................................................................. 3-3

Create a Profile .................................................................................. 3-4

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Edit a Profile ...................................................................................... 3-5

Edit a Profile During Creation ........................................................ 3-5

Modify a Profile During Measurement ........................................... 3-5

Load a Profile .................................................................................... 3-5

Load a Profile When Switched to Sequence Mode ....................... 3-6

Load a Profile During Measurement in Sequence Mode ............... 3-6

Make Measurements ............................................................................. 3-7

Test Battery Internal Resistance and Voltage or Strap Resistance ... 3-7

Battery Test Probes ....................................................................... 3-8

View Test Readings on the Screen ............................................... 3-9

Measure Strap resistance in sequence mode ............................... 3-9

Set Measurement Range ............................................................... 3-10

Save Battery Test Readings .......................................................... 3-10

Erase Test Readings ..................................................................... 3-10

Activate Low-Pass Filter for Resistance Measurement ................. 3-10

Set Measurement Thresholds ....................................................... 3-11

How the Thresholds Work ............................................................. 3-12

Measure Discharge Voltage .............................................................. 3-12

Make Measurements ..................................................................... 3-12

Typical Display .............................................................................. 3-13

Measure DC Voltage ......................................................................... 3-14

Set Measurement Range ............................................................... 3-14

Save DC Voltage Readings ........................................................... 3-14

Measure AC Voltage ......................................................................... 3-15

Measurement Range ..................................................................... 3-15

Save AC Voltage Readings ........................................................... 3-15

Measure Ripple Voltage .................................................................... 3-16

Set Measurement Range ............................................................... 3-16

Save Ripple Voltage Readings ...................................................... 3-16

Measure Voltage with TL175 ............................................................. 3-17

4 Use the BTL20 Interactive Test Probe ............................................... 4-1

Introduction ............................................................................................ 4-1

BTL20 Overview .................................................................................... 4-1

Connect the Probe to the Product ......................................................... 4-2

Set the Audio ......................................................................................... 4-2

Turn On/Off Power ................................................................................ 4-2

Understand the Display ......................................................................... 4-3

Long and Short Extenders ..................................................................... 4-4

Replace the Probe Tips ......................................................................... 4-5

Zero Calibration ..................................................................................... 4-6

5 View Memory ....................................................................................... 5-1

Introduction ............................................................................................ 5-1

View Data Saved in Meter Mode ........................................................... 5-1

Delete Data Saved in Meter Mode ........................................................ 5-2

View Profiles Saved in Sequence Mode ............................................... 5-3

Delete Profiles Saved in Sequence Mode ............................................. 5-3

6 Connection to PC ................................................................................ 6-1

Introduction ............................................................................................ 6-1

Connect the Product to PC .................................................................... 6-1

ii

Contents (continued)

7 Maintenance ......................................................................................... 7-1

Introduction ............................................................................................ 7-1

Install or Replace the Battery Pack ....................................................... 7-3

Replace the Fuse .................................................................................. 7-4

Clean the Product .................................................................................. 7-5

Charge the Battery ................................................................................ 7-5

Parts and Accessories ........................................................................... 7-7

iii

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iv

List of Tables

Table Title Page

1-1. Standard Equipment .................................................................................. 1-3

1-2. Symbols ..................................................................................................... 1-7

1-3. Keys .......................................................................................................... 1-8

1-4. Typical Elements on the LCD Display ....................................................... 1-10

4-1. Elements of the Interactive Test Probe ..................................................... 4-2

4-2. Typical Elements on the BTL20 Display .................................................... 4-3

7-1. Parts and Accessories ............................................................................... 7-7

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vi

List of Figures

Figure Title Page

1-1. Standard Equipment .................................................................................. 1-4

1-2. I/O Terminals ............................................................................................. 1-9

2-1. Tilt Stand. .................................................................................................. 2-1

2-2. The Belt Strap ........................................................................................... 2-2

3-1. Test Battery Internal Resistance and Voltage or Strap Resistance .......... 3-7

3-2. Connect Test Probe to Battery .................................................................. 3-8

3-3. Measure DC Voltage ................................................................................. 3-14

3-4. Measure AC Voltage ................................................................................. 3-15

3-5. Measure DC Voltage with TL175 .............................................................. 3-17

4-1. BTL20 Interactive Test Probe .................................................................... 4-1

4-2. Long and Short Probes ............................................................................. 4-4

4-3. Replace the 4-Wire Pins ............................................................................ 4-5

4-4. Zero Calibration Setup .............................................................................. 4-6

6-1. Connection to PC ...................................................................................... 6-1

7-1. Install or Replace a Battery Pack .............................................................. 7-3

7-2. Replace the Fuse ...................................................................................... 7-4

7-3. Charge the Battery .................................................................................... 7-6

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viii 1-1

Chapter 1

Product Overview and Specifications

Introduction

This chapter supplies information about the Product, safety information, contact
information, and specifications.

Contact Fluke

To contact Fluke, call one of the following telephone numbers:

• Technical Support USA: 1-800-44-FLUKE (1-800-443-5853)

• Calibration/Repair USA: 1-888-99-FLUKE (1-888-993-5853)

• Canada: 1-800-36-FLUKE (1-800-363-5853)

• Europe: [phone]

• China: [phone]

• Japan: [phone]

• Singapore: [phone]

• Anywhere in the world: [phone]

Or, visit Fluke's website at www.fluke.com.
To register your product, visit http://register.fluke.com.
To view, print, or download the latest manual supplement, visit http://en-

us.fluke.com/support/manuals.

Product Overview

The Fluke BT520 Battery Analyzer (the Product) is a multifunctional meter designed for
the test and measurement of a stationary battery system. The Product can measure the
battery internal resistance and voltages. These measurements can be used to determine
the overall condition of the system. It can also measure electrical parameters for battery
system maintenance, including dc voltage up to 600 V, ac voltage up to 600 V rms, and
ripple voltage.

Features of the Product include:

• CAT III 600 V Safety Rated – The Product can measure a maximum of 600 V ac in

a Category III environment.

• Battery Internal Resistance – Via the Kelvin connections, the Product measures

the internal resistance. An increase in the internal resistance from a known baseline
indicates the battery is deteriorating. The testing takes less than 3 seconds.

BT520

Users Manual

• Battery Voltage – During the internal resistance test, the Product also measures the

voltage of the battery under test.

• Discharge Volts – The Discharge mode collects the voltage of each battery several

times at a certain interval during a discharge or load test. Users can calculate the
time a battery takes to drop to the cut-off voltage and use this time to determine the
capacity loss of this battery.

• Ripple Voltage Test – Measures the unwanted residual ac component of the

rectified voltage in dc charging and inverter circuits. Allows users to test ac
components in dc charging circuits and find one of the root causes of battery
deterioration.

• Meter and Sequence Modes – The Meter mode is used for a quick test or trouble-

shooting. In this mode you can save and read the readings in a time sequence. The
Sequence mode is for maintenance tasks with multiple power systems and battery
strings. Before a task starts, users can configure a profile for the task for data
management and report generation.

• Threshold and Warning – Users can configure a maximum of 10 sets of thresholds

and receive a Pass/Fail/Warning indication after each measurement.

• AutoHold – When AutoHold is turned on, the Product freezes the reading when it

remains stable for 1 second. The frozen reading is released when a new
measurement starts.

• AutoSave – When the AutoSave mode is on, measured values are saved to the

internal memory of the Product automatically after AutoHold.

• Fluke Battery Analyzer Software – Easily import data from the Product to a PC.

The measurement data and battery profile information is stored and archived with the
Analyze Software and can be used for comparison and trend analysis. All
measurement data, battery profile and analysis information can be used to easily
generate reports.

1-2

Product Overview and Specifications

Standard Equipment 1

Standard Equipment

Items listed in Table 1-1 are included with the Product. Figure 1-1 shows the items.

Table 1-1. Standard Equipment

Item No. Description Quantity

 Mainframe 1

 BTL10, Basic Test Lead 1

 TL175, TwistGuard™ Test Leads 1

 BTL_A, Voltage/Current Probe Adapter 1

 BTL20, Interactive Test Probe set, with extender 1

 BP500, 7.4 V 3000 mAh Lithium-ion battery 1

 BC500, 18 V dc charger 1

 Power cord 1

 Standard mini-b USB cable (cable length: 1 m) 1

 BCR, Zero calibration board 1

 Shoulder strap 1

 Belt strap 1

 Magnetic plate 1

 C500L Soft carrying case, large 1

 Spare fuse 2

 Paper battery tags 100

-- Safety Sheet, not shown 1

-- Warranty card, not shown 1

-- Quick Reference Guide, not shown 1

®

Battery (CD) containing USB driver and manuals

1

--

FlukeView
in all languages, not shown

1-3

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Users Manual

1 3

2

4

5

6

11

10

9

7

12

13

Figure 1-1. Standard Equipment

14

8

15

16

hsn056.eps

1-4

Product Overview and Specifications

Safety Information 1

Safety Information

A Warning identifies conditions and procedures that are dangerous to the user. A
Caution identifies conditions and procedures that can cause damage to the Product or

the equipment under test.

Warning

To prevent possible electrical shock, fire, or personal injury:

• Carefully read all instructions.

• Read all safety information before you use the Product.

• Use the Product only as specified, or the protection supplied

by the Product can be compromised.

• Do not use the Product around explosive gas, vapor, or in

damp or wet environments.

• Do not use the Product if it is damaged.

• Do not use the Product if it operates incorrectly.

• Do not apply more than the rated voltage, between the

terminals or between each terminal and earth ground.

• Do not touch voltages > 30 V ac rms, 42 V ac peak, or 60 V dc.

• Do not exceed the Measurement Category (CAT) rating of the

lowest rated individual component of a Product, probe, or
accessory.

• Do not use the HOLD function to measure unknown potentials.

When HOLD is turned on, the display does not change when a
different potential is measured.

• Use extreme caution when working around bare conductors or

bus bars. Contact with the conductor could result in electric
shock.

• Do not use test leads if they are damaged. Examine the test

leads for damaged insulation or exposed metal, or if the wear
indicator shows. Check test lead continuity.

• Connect the common test lead before the live test lead and

remove the live test lead before the common test lead.

• Avoid simultaneous contact with battery and frame racks or

hardware that may be grounded.

• Comply with local and national safety codes. Use personal

protective equipment (approved rubber gloves, face
protection, and flame-resistant clothes) to prevent shock and
arc blast injury where hazardous live conductors are exposed.

• Examine the case before you use the Product. Look for cracks

or missing plastic. Carefully look at the insulation around the
terminals.

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Users Manual

• Use only correct measurement category (CAT), voltage, and

amperage rated probes, test leads, and adapters for the
measurement.

• Measure a known voltage first to make sure that the Product

operates correctly.

• Limit operation to the specified measurement category,

voltage, or amperage ratings.

• Keep fingers behind the finger guards on the probes.

• Remove all probes, test leads, and accessories before the

battery door is opened.

• Use the correct terminals, function, and range for

measurements.

• Use only test leads and adapters supplied with the Product.

• Install the CAT III protective cap of test lead when you use the

product in CAT III environment. The CAT III protective cap
decreases the exposed probe metal to <4 mm.

• Do not operate the Product with covers removed or the case

open. Hazardous voltage exposure is possible.

1-6

Product Overview and Specifications

Safety Information 1

See Table 1-2 for a list of symbols used in this manual and on the Product.

Table 1-2. Symbols

Symbol Description Symbol Description















WARNING. RISK OF DANGER.
See manual.

WARNING. HAZARDOUS
VOLTAGE. Risk of electric shock.

Earth

Measurement Category II is
applicable to test and measuring
circuits connected directly to
utilization points (socket outlets
and similar points) of the low­voltage MAINS installation.

Measurement Category IV is
applicable to test and measuring
circuits connected at the source
of the building’s low-voltage
MAINS installation.

Certified by TÜV SÜD Product
Service.

Conforms to European Union
directives.















AC (Alternating Current)

DC (Direct Current)

Fuse

Measurement Category III is applicable to
test and measuring circuits connected to the
distribution part of the building’s low-voltage
MAINS installation.

Conforms to relevant South Korean EMC
Standards.

Certified by CSA Group to North American
safety standards.

Conforms to relevant Australian EMC
Standards.



This product complies with the WEEE Directive marking requirements. The affixed label
indicates that you must not discard this electrical/electronic product in domestic household
waste. Product Category: With reference to the equipment types in the WEEE Directive Annex
I, this product is classed as category 9 "Monitoring and Control Instrumentation" product. Do
not dispose of this product as unsorted municipal waste.

1-7

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Users Manual

Keys and I/O Terminals

Table 1-3 identifies and describes the keys.

Table 1-3. Keys

1 2 3

78 4

Item Key Function

















12
34

L







M





Softkeys that work flexibly for various functions on the display.

Selects an item in a menu and scrolls through information.

Switches between manual ranging and auto ranging. Cycles through all ranges in
manual ranging mode.

Turns on or turns off backlight.

Opens the Setup menu for configurations such as contrast, language, date/time,
and power off time.

Switches between Meter and Sequence measurement modes. For details, see
Chapter 3. Switches between Meter and Sequence memories. For details, see
Chapter 5.

Turns on or turns off the Product.

Freezes the current reading on the display and allows the display reading to be
saved.

6

5

hsn001.eps

1-8

Product Overview and Specifications

Keys and I/O Terminals 1

Figure 1-2 shows the terminals of the Product.

Figure 1-2. I/O Terminals

hsn002.eps

1-9

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Users Manual

LCD Display

The Product has an LCD display that shows different elements for each measurement
function. Table 1-4 describes the typical elements for battery internal resistance
measurement in Sequence mode.

Table 1-4. Typical Elements on the LCD Display

1 2 3 4

20

19

18

17

16

15

5

6

7

8

9

10

11

121314

hsn055.eps

Item Description Item Description

1-10

 Profile name  Average readings

Probe connection status. A full circle means



connected; an empty circle means not

 Softkey F4 – Profile

connected

 Current date  Softkey F3 – Threshold
 Current time  Softkey F2 – Low Pass Filter
 Battery usage  Softkey F1 – Save (save current reading)

 Threshold indication 

Tested batteries VS Total number of
batteries in a string

 Test result (PASS, WARN, or FAIL)  Cursor position

Reading of battery internal resistance



At least one “data hold” succeeded (manual



or auto)

 Voltage reading  AutoHold function enabled
 Progress bar (Sequence mode only)  AutoSave function enabled

Product Overview and Specifications

Specifications 1

Specifications

General Specifications

 Fuse Protection for Resistance ...................... 0.44 A (44/100 A, 440 mA), 1000 V FAST Fuse, Fluke specified part

Power Supply

Battery power ...................................................... BP500 smart battery pack: double cell lithium-ion, 7.4 V, 3000 mAh

Battery life ........................................................... >8 hours in continuous full-load operation

Battery charging time .......................................... ≤4 hours

Power adapter output voltage ............................. Use only BC500 battery charger: 18 V, 840 mA

Line power .......................................................... 100 V ac to 240 V ac adapter with country specific plug

Frequency ........................................................... 50 Hz to 60 Hz

Temperature

Operating ............................................................ 0 °C to 40 °C

Storage ............................................................... -20 °C to 50 °C

Lithium-ion battery charging ............................... 0 °C to 40 °C

Relative Humidity (non-condensing, 10 °C)

Operating ............................................................ ≤80 % at 10 °C to 30 °C

≤75 % at 30 °C to 40 °C

Altitude

Operating ............................................................ 2,000 m

Storage ............................................................... 12,000 m

Temperature Coefficient ....................................... 0.1 x (specified accuracy) /°C (<18 °C or >28 °C)

Size ......................................................................... 58 x 103 x 220 (mm)

Weight .................................................................... 850 g

Memory

Data/Setup flash memory ................................... 4 MB

Real-Time Clock .................................................... Time and date stamp for measurement. The RTC works >50 days

IP Rating ................................................................ IEC 60529: IP 40

Safety ..................................................................... IEC 61010-1, IEC 61010-2-030, IEC 61010-031, Pollution Degree 2

EMI, RFI, EMC, RF ................................................. EC 61326-1: Portable Electromagnetic Environment; IEC 61326-2-2

Electromagnetic Compatibility ............................ Applies to use in Korea only. Class A Equipment (Industrial

[1] This product meets requirements for industrial (Class A) electromagnetic wave equipment and seller or user should take notice of it.

This equipment is intended for use in business environments and is not to be used in homes.

only

without battery.

600 V CAT III; Derated to CAT II with CAT II probe cap installed

CISPR 11: Group 1, Class A

Group 1: Equipment has intentionally generated and/or uses
conductively-coupled radio frequency energy that is necessary for
the internal function of the equipment itself.

Class A: Equipment is suitable for use in all establishments other
than domestic and those directly connected to a low-voltage
power supply network that supplies buildings used for domestic
purposes.

EN 300 328, EN 301 489-1, EN 301 489-17, FCC Part 15 Subpart C
Sections 15.207, 15.209, 15.249

CONTAINS FCC IDs: T68-FWCS, XDULE40-S2
IC: 6627A-FWCS, 8456A-LE4S2 (For more information, go to

www.fluke.com and search for “Radio Frequency Data for Class A”.)

[1]

Broadcasting & Communication Equipment)

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