Megger BITE2 Operating Manual

AVTM246004
July 2011
Rev. 4
Instruction Manual
BITE 2 and BITE 2P
Battery Impedance
(Includes AVOLink Addendum)
BITE 2: Catalog No. 246002B BITE 2P: Catalog No. 246004
HIGH-VOLTAGE EQUIPMENT
Read this entire manual before operating.
APARATO DE ALTO VOLTAJE
Ante de operar este producto lea este manual enteramente.
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2621 Van Buren Ave Norristown, PA 19403-2329 610-676-8500
www.megger.com
BITE 2 and BITE 2P
Battery Impedance Test Equipment
Instruction Manual
Copyright© 2003 by Megger. All rights reserved.
The information presented in this manual is believed to be adequate for the intended use of the product. If the product or its individual instruments are used for purposes other than those specified herein, confirmation of their validity and suitability must be obtained from Megger. Refer to the warranty information below. Specifications are subject to change without notice.
WARRANTY Products supplied by Megger are warranted against defects in material and workmanship for a
period of one year following shipment. Our liability is specifically limited to replacing or repairing, at our option, defective equipment. Equipment returned to the factory for repair must be shipped prepaid and insured. Contact your MEGGER representative for instructions and a return authorization (RA) number. Please indicate all pertinent information, including problem symptoms. Also specify the serial number and the catalog number of the unit. This warranty does not include batteries, lamps or other expendable items, where the original manufacturer’s warranty shall apply. We make no other warranty. The warranty is void in the event of abuse (failure to follow recommended operating procedures) or failure by the customer to perform specific maintenance as indicated in this manual.
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2621 Van Buren Ave Norristown, PA 19403-2329
610-676-8500 (Telephone) 610-676-8610 (Fax)
www.megger.com email: battery@megger.com
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Contents
INTRODUCTION ........................................................................................................................... 1
About the BITE 2 and BITE 2P…................................................................................................ 1
How the BITE 2/2P Works........................................................................................................... 2
Applications for the BITE 2/2P....................................................................................................3
BITE 2/2P Measurements............................................................................................................. 4
Upon Receipt of the BITE 2/2P....................................................................................................4
Safety First...................................................................................................................................6
How to Use This Manual.............................................................................................................. 7
Typographic Conventions..................................................................................................... 7
SAFETY..........................................................................................................................................9
Overview ..................................................................................................................................... 9
Safety Requirements .................................................................................................................... 9
Connection to Power Source....................................................................................................... 11
Fuse Replacement ...................................................................................................................... 11
Cautions and Warnings............................................................................................................... 11
CONTROLS, CONNECTORS, INDICATORS AND MENUS...................................................... 13
Overview ................................................................................................................................... 13
BITE 2 Transmitter..............................................................................................................14
BITE 2P Transmitter ...........................................................................................................16
Receiver ..............................................................................................................................18
Receiver Keys .....................................................................................................................19
Receiver Reset Switch.........................................................................................................24
STANDARD TEST PROCEDURE................................................................................................ 25
Overview ................................................................................................................................... 25
Step One: Prepare for Testing.....................................................................................................27
Step Two: Powering-on the Receiver .......................................................................................... 28
Step Three: Scanning Test Information with the Wand (Optional)................................................ 30
If You Do Not Want to Scan Information Using the Wand ..................................................30
If You Want to Scan Information Using the Wand...............................................................30
Step Four: Setting Baseline, Warning and Fail Values................................................................ 32
Step Five: Splitting the Strap (if needed)....................................................................................33
If You Do Not Want to Split the Strap.................................................................................33
If You Want to Split the Strap..............................................................................................33
Step Six: Connecting the Receiver and the BITE 2 or BITE 2P Transmitter to the Battery.......... 35
Connecting the BITE 2 or BITE 2P Transmitter...................................................................37
Step Seven: Measuring the Cell and the Strap............................................................................. 38
Measuring the Next Section of a Sectioned Battery String ...................................................42
Step Eight: What to Do When the Test Is Complete ................................................................... 43
Reviewing a Test.................................................................................................................43
Retesting Cells and Straps ...................................................................................................44
Printing an Active Test to Review the Data (BITE 2P).........................................................44
Powering Down and Disconnecting the BITE 2/2P..................................................................... 45
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MODIFIED PROCEDURES FOR SPECIAL CONDITIONS.........................................................47
Overview ....................................................................................................................................47
Reversing the Current Source Leads............................................................................................ 47
Verifying the Source Current ...................................................................................................... 48
Sectioning a Battery System................................................................................................49
TRANSFERRING, PRINTING, AND DELETING TEST RESULTS ............................................55
Overview ....................................................................................................................................55
Exporting Test Results from the Receiver to a PC.......................................................................56
Printing Test Results in the BITE 2P Transmitter Printer............................................................. 58
Deleting Test Results from the Receiver...................................................................................... 59
INTERPRETING TEST RESULTS................................................................................................61
Overview ....................................................................................................................................61
Instantaneous Interpretation........................................................................................................62
Short-Term Inter pretation............................................................................................................63
Long-Term Interpretation ............................................................................................................63
Temperature Corrections.............................................................................................................64
SETTING OPTIONS...................................................................................................................... 67
Overview ....................................................................................................................................67
Turning the Receiver Backlight ON and OFF..............................................................................68
Adjusting the Receiver Screen Contrast.......................................................................................68
Selecting the Receiver Language .................................................................................................69
Setting the Receiver Clock..........................................................................................................69
Selecting the Line Frequency...................................................................................................... 71
MAINTENANCE AND TROUBLESHOOTING ...........................................................................73
Overview ....................................................................................................................................73
Cleaning and Inspecting the BITE 2 and BITE 2P.......................................................................74
Charging the Receiver................................................................................................................. 74
Replacing Batteries in the Receiver............................................................................................. 75
Maintaining the Receiver Charger in the BITE 2 and BITE 2P....................................................78
Maintaining Fuses in the BITE 2 and BITE 2P Transmitters .......................................................78
Verifying a Transmitter Fuse Problem.................................................................................79
Replacing Fuses in the BITE 2 Transmitter .........................................................................82
Replacing Fuses in the BITE 2P Transmitter ....................................................................... 85
Interpreting Error Messages........................................................................................................88
If the BITE 2 or BITE 2P Needs Repairs.....................................................................................88
OPTIONAL EQUIPMENT.............................................................................................................89
Available Options .......................................................................................................................89
APPENDIX A: TECHNICAL SPECIFICATIONS......................................................................... 91
Application................................................................................................................................. 91
Electrical.....................................................................................................................................91
BITE 2 and BITE 2P Transmitters .......................................................................................91
Receiver..............................................................................................................................92
Fuses...................................................................................................................................93
Mechanical .................................................................................................................................93
Environmental.............................................................................................................................94
Accessories - Standard................................................................................................................95
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CONTENTS
APPENDIX B: REPLACEABLE PARTS...................................................................................... 97
Catalog Numbers 246002B and 246004...................................................................................... 97
Catalog Numbers 246002B and 246004...................................................................................... 98
How to Order Replaceable Parts for the BITE 2/2P.................................................................... 98
GLOSSARY..................................................................................................................................99
INDEX......................................................................................................................................... 101
Figures
Figure 1-1: BITE 2 instrument......................................................................................................... 5
Figure 1-2: BITE 2P instrument ...................................................................................................... 6
Figure 3-1: BITE 2 transmitter ...................................................................................................... 14
Figure 3-2: BITE 2P transmitter .................................................................................................... 16
Figure 3-3: Voltage Selector Card Orientation............................................................................... 17
Figure 3-4: Receiver controls, connectors, and indicators.............................................................. 18
Figure 3-5: Flowchart for Receiver menus..................................................................................... 20
Figure 3-6: Flowchart for Receiver menus..................................................................................... 21
Figure 3-7: Flowchart for Receiver menus..................................................................................... 22
Figure 3-8: Receiver menu ............................................................................................................ 23
Figure 3-9: Receiver RESET switch.............................................................................................. 24
Figure 4-1: Receiver controls, connectors and indicators............................................................... 28
Figure 4-2: Initialization screens ................................................................................................... 29
Figure 4-3: Scanning test information............................................................................................ 31
Figure 4-4: Receiver controls, connectors, and indicators.............................................................. 35
Figure 4-5: BITE 2/2P transmitter connected to the battery ........................................................... 36
Figure 4-6: Receiver and potential probe positioned on top of battery cell terminals...................... 39
Figure 4-7: Receiver and potential probe positioned on top of battery strap terminals.................... 40
Figure 5-1: Reversing the current source leads on a single string of cells when a high
or low current message is displayed. ......................................................................... 48
Figure 5-2: Sectioning a battery system greater than 275 V........................................................... 50
Figure 5-3: Sectioning a parallel string of cells.............................................................................. 52
Figure 6-1: Exporting data to a PC................................................................................................57
Figure 6-2: Printing test results...................................................................................................... 58
Figure 6-3: Deleting test results from the Receiver ........................................................................ 60
Figure 7-1: Generic curve of impedance vs. cell life...................................................................... 64
Figure 9-1: RTC battery "piggybacks" the system battery.............................................................. 77
Figure 9-2: BITE 2 transmitter secondary fuses (front view) ......................................................... 83
Figure 9-3: BITE 2P transmitter secondary fuses (front view) ....................................................... 86
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1
INTRODUCTION
About the BITE 2 and BITE 2P…
NOTE: Before attempting to use the BITE 2/2P, be sure that you read and understand the safety requirements and operating procedures contained in this manual.
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Thank you for selecting an Megger product. This instrument
has been thoroughly tested and inspected to meet rigid specifications before being shipped.
It is ready for use when set up and operated as described in this manual.
The BITE 2 and BITE 2P are testing instruments used to
evaluate the condition of stationary battery strings. They measure the complete electrical path of the battery:
internal ac impedance of each cell/jar in the string
dc terminal voltage of each cell/jar
interconnection resistance
These measurements, along with other maintenance data
such as ambient and pilot cell temperatures and ac ripple currents, help determine the condition of a battery system.
The BITE 2/2P consists of a transmitter and a receiver that
enable an operator to test for sulfating plates, post-strap corrosion, poor internal connections and poor intercell connections.
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How the BITE 2/2P Works
Average impedance values for different types of batteries are available from Megger.
The operator connects the current source leads from the BITE 2/2P transmitter to a battery string so that an ac test current is capacitively coupled through the battery. It is best to test the battery string when it is operating at full float, that is, a constant charge level.
Then the operator uses the receiver to measure the voltage drop across the cell terminals. When the voltage drop across the cell is divided by the total ac current passing through the battery, the calculated value is impedance according to Ohm's Law. This impedance value gives the operator an indication of the overall condition of the cell, with high impedance typically indicating an unhealthy cell.
Several factors influence an impedance value, for instance, the size and type of cell, ambient and electrolyte temperature, and state of charge. Therefore, to determine the impedance of a healthy cell, the operator should measure a large number of similar cells under similar conditions and then calculate the average value. Deteriorating cells are easily identified by their higher-than-average impedance.
The BITE 2/2P also automatically measures and records the cell voltage and the time and date of the test. This voltage represents individual cell float voltage while measuring an operational string of cells.
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The BITE 2/2P also measures intercell or strap connections and stores them with the cell impedance values. The BITE 2/2P can measure and record all aspects of the electrical path of the battery, including:
location ID
user ID
test current
total current
internal cell impedance
dc voltage
intercell connector resistance
specfic gravity
time and date
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Applications for the BITE 2/2P
INTRODUCTION
The BITE 2/2P measures the following battery types, ranging to 7000 Ah:
lead-acid flooded cells
sealed (VRLA) cells
nickel-cadmium cells
The BITE 2/2P tests many system types, including:
telecommunications
substations
UPS systems
electrical power substations
railroad signals and communications
motive power batteries
aircraft power supplies
marine and military applications
many others
For information about other installations that might benefit from impedance testing, contact Megger.
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BITE 2/2P Measurements
Impedance readings are calibrated to 5 percent of reading over the specified temperature range. For ac impedance, the receiver screen presents data as ranges: 1.000, 10.00, and
100.0 m. The maximum measurement is 200 mΩ.
Impedance precision (reproducibility) is 0.5%, and voltage precision is 0.5%.
Test numbers start with number one (001) and increment after each successful cell and strap reading. The operator initiates data acquisition by pulling a trigger on the receiver. The measurement range for dc voltage is from 1 to 25 V dc with an accuracy of 1 percent of reading.
Intercell (strap) and intertier connection measurements are made directly after the internal cell impedance measurement when STRAP is displayed on the LCD of the receiver. This feature provides resistance measurements in the same ranges as the cell/module impedance.
Total current is monitored with each impedance measurement to compute both cell and strap impedance and intercell (strap) resistance. The operator selects filtering in a menu in the receiver as either 50 Hz or 60 Hz depending on the line voltage.
A low current cutoff alarm is maintained at 3 A, and the maximum current allowed is 15 A. The LCD displays "Hi_A" to warn of an ac current over-range and "Lo_A" for current below 3 A.
Upon Receipt of the BITE 2/2P
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Check the equipment received against the packing list to ensure that all materials are present. Notify Megger of any shortage (tel: 610-676-8500).
The BITE 2 instrument is shown in Figure 1-1. The BITE 2 includes the following components and accessories:
transmitter with built-in receiver battery charger
receiver
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INTRODUCTION
current source leads
clamp-on current sensor (CT) with a 6-ft extension
cable
canvas carrying case for leads
instruction manual
null modem cable
Figure 1-1: BITE 2 instrument
The BITE 2P instrument is shown in Figure 1-2. The BITE 2P includes the following components and accessories:
transmitter with built-in printer and receiver battery
charger
receiver
current source leads
clamp-on current sensor (CT) with a 6-ft extension
cable
instruction manual
null modem cable
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Figure 1-2: BITE 2P instrument
Safety First
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Be sure to read the safety information in Chapter 2 thoroughly and observe all safety precautions and recommendations.
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How to Use This Manual
Typographic Conventions
INTRODUCTION
Cautions alert you to possible damage to equipment.
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Warnings alert you to conditions that are potentially hazardous to people.
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Figures and tables are numbered in sequence by
section.
Numbered lists show procedural steps.
Bullets list items and options.
Buttons represent elements on the BITE 2/2P control
panel.
CAUTION
Never allow water to enter the case of the BITE 2/2P.
WARNING Always power off and disconnect the BITE 2/2P before cleaning it.
Notes provide important information.
Margin notes offer extra information and assistance.
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NOTE: If you do not want to test the strap, pull the trigger and go directly to Step Six.
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2
SAFETY
Overview
The BITE 2 and BITE 2P and their recommended
operating procedures have been designed with careful attention to safety. However, it is not possible to eliminate all hazards from electrical test equipment or to foresee every possible hazard that may occur. The user not only must follow the safety precautions contained in this manual, but also must carefully consider all safety aspects of the operation before proceeding.
Safety Requirements
Any use of electricity inherently involves some degree of safety hazard. While Megger has made every effort to reduce the hazard, the operator must assume responsibility for his or her own safety. Any work on batteries is hazardous and requires constant attention to safety. You should guard particularly against the possibility of acid spills, explosion, and electrical shock.
The BITE 2/2P test instrument has been designed to the IEC-1010-1 safety standard. Observe all industry standard safety rules for testing batteries.
The BITE 2/2P transmitter is designed for connection
to energized systems. Keep the BITE 2/2P transmitter S1 power switch set to O (OFF) or turn off the Current On/Off switch when connecting or disconnecting to the battery. Always wear rubber gloves during these operations.
Always connect the source leads to the BITE 2/2P
before connecting to the battery under test.
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Always remove the instrument test leads from the
battery under test when not in use.
The purpose of this equipment is limited to use as
described in this manual. Do not use the equipment or its accessories for any purpose other than specifically described.
To avoid electric shock hazard, operating personnel
must not remove the protective instrument covers. Component replacement and internal adjustments must be made by qualified service personnel only.
Do not operate in an explosive atmosphere. Explosive
gases such as hydrogen can be present around batteries. A properly vented battery environment is considered safe, but it is the responsibility of the operator to verify conditions before using the
BITE 2/2P.
Wear protective clothing and eye protection to guard
against skin and eye damage from battery acid or in the event of short-circuit sparking.
Replacement leads can be obtained from Megger.
Ensure that test leads and probes are in good
condition, clean, and free of broken or cracked insulation.
Observe all cautions and warnings in this manual and
on the equipment.
This instrument is to be used only by suitably trained
personnel who are familiar with the hazards involved in testing high voltage dc systems.
Safety is the responsibility of the operator.
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Connection to Power Source
SAFETY
The BITE 2/2P test instruments operate from a single­phase power source. The three-wire power cord requires a two-pole, three-terminal, live, neutral, and ground type connector. The voltage to ground from either pole of the power source must be 100 – 240 volts (50-60 Hz) nominal. Do NOT exceed 264 V max.
Before connecting to the ac power source, determine that the instrument rating matches the voltage of the power source and has a suitable two-pole, three-terminal grounding type connector.
The power input plug must be inserted only into a mating receptacle with a ground contact. Do not bypass the grounding connection. Any interruption of the grounding connection can create an electric shock hazard. Make sure that the receptacle is properly wired before inserting the plug.
Depending on whether the test set is supplied with a black, white and green input supply cord or a brown, blue and green/yellow supply cord, the black or brown cord lead must be connected to the live pole and the white or blue cord lead must be connected to the neutral pole of an approved power input plug. The green or green/yellow ground lead of the input supply cord must be connected to the protective ground (earth) contact of the input plug.
Fuse Replacement
See "Maintaining Fuses in the BITE 2 and BITE 2P Transmitters" on page 78 for detailed instructions on fuse replacement.
Refer fuse replacement to qualified personnel only. To avoid electric shock and fire hazard, use only the fuse specified (see Appendix B), which is identical with respect to type, voltage rating, and current rating.
Cautions and Warnings
This manual provides cautions and warnings where
applicable, and these safety features should be strictly observed.
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CONTROLS, CONNECTORS, INDICATORS AND MENUS
Overview
This chapter explains the locations and functions of the
controls, connectors, indicators and menus for the BITE 2/BITE 2P transmitter and receiver. The first section covers the BITE 2 transmitter, the second covers the BITE 2P transmitter, and the third covers the receiver.
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J3 J2
F1
BITE 2 Transmitter
Current On/Off Switch
Figure 3-1 shows a front view of the BITE 2 transmitter.
Over Voltage
Current Ready
Control Panel
Digital Meter
J1
Power Switch
Receiver Charger On/Off Indicator
Receiver Charger On/Off Indicator
Figure 3-1: BITE 2 transmitter
Digital Meter—ac source current digital indicator with a scale of 0 to 15 A.
Power Switch—The power switch is pressed to turn the transmitter on and off. The power switch is marked with | (for ON) and O (for OFF).
Current On/Off Switch—The current on/off switch is
pressed to start or stop the flow of the test current to the battery.
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CONTROLS, CONNECTORS, INDICATORS AND MENUS
Receiver Charger On/Off Indicator—LED illuminates when the receiver is plugged into the receiver and the charger is energized. It also indicates the state-of-charge of the receiver battery. While the battery is charging, the LED remains constant; when the battery is fully charged, the LED blinks.
Indicator Lamps:
CURRENT READY—Illuminates after the coupling
capacitors in the transmitter are charged to the bus voltage. A delay timer allows current flow to the battery under test.
POWER—Illuminates whenever the Power Switch is in the | (ON) position and the unit is powered by 120 V (230 V) ac line voltage
OVER VOLTAGE—Indicates that the voltage across the current source leads is greater than 275 V dc. (The
READY light will go out and the current flow to the battery will stop when an over-voltage condition occurs.)
Transmitter Connector Panel
Power module—The transmitter power module comprises the following components:
J1 receptacle—The standard power cord supplied with the instrument is inserted into this 120 V/60 Hz (230 V/50 Hz) receptacle for ac power.
F1 Fuse carrier/voltage selector—The fuse carrier is removed as needed to replace fuses. The arrow located on the connector panel directly to the left of the J1 receptacle should point to the indicator on the fuse carrier that corresponds to the proper voltage (120 V or 230 V). See Figure 3-3.
J2 connector—The transmitter current source leads are connected from this connector to the battery under test.
J3 connector—The receiver battery is charged from this connector to J3 on the receiver to charge its battery.
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Receiver Charger
Bin
J3
Switch
BITE 2P Transmitter
Figure 3-2 shows a front view of the BITE 2P transmitter.
Printer
Storage
Current Ready
Over Voltage
Control Panel
Digital
J2
F1
Power Module
J1
Power
J4
Current On/Off Switch
Figure 3-2: BITE 2P transmitter
Digital Meter—ac source current indicator with a scale of 0 to 15 A.
Power Switch—The power switch is pressed to turn the
transmitter on and off. The power switch is marked with a | (for ON) and an O (for OFF).
Current On/Off Switch—The current on/off switch is
pressed to start or stop the flow of the test current to the battery.
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CONTROLS, CONNECTORS, INDICATORS AND MENUS
Indicator Lamps:
Note: Use only the 120V or 240V setting. The 100V and 230V will blow fuses.
RECEIVER CHARGER ON/OFF—Illuminates when the receiver is plugged into J4 and the receiver charger is
energized. It also indicates the state-of-charge of the receiver battery.
CURRENT READY—Illuminates after the coupling capacitors in the transmitter have been charged to the bus voltage. A delay timer allows current flow to the battery under test.
OVER VOLTAGE—Indicates that the voltage across the current source leads is greater than 275 V dc. (When an
over-voltage condition occurs, the CURRENT READY light will go out and the current will stop being applied to the battery.)
J1 receptacle—The standard power cord supplied with the instrument is inserted into this 120 V (230 V) receptacle for ac power.
F1 Fuse carrier/voltage selector—The fuse carrier is removed as needed to replace fuses.
To change selected voltage: open fuse cover, using small blade screwdriver or similar tool. Pull voltage selector card straight out of housing, using indicator pin. Orient indicator pin to point up when desired voltage is readable at bottom. Insert voltage selector card into housing with printed side of card facing forward toward IEC connector and edge containing the desired voltage first. Replace cover, and verify that indicator pin shows the desired voltage.
Figure 3-3: Voltage Selector Card Orientation
J2 connector—The transmitter current source leads are connected from this connector to the battery under test.
J3 connector—The printer cable from the receiver is connected to print test data.
J4 connector—The receiver battery is charged from the on the BITE 2P transmitter when the J4 connector on the transmitter is connected to the J3 connector on the receiver.
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POWER ON
ENTER Key
7-
Pin
4-Pin
Potential
3-Pin
TRIGGER
UP and
Receiver
The receiver is a universal device that can be used with the
entire BITE product family. Figure 3-4 shows a front view of the receiver.
DOWN ARROW Keys
Connector
Connector
LCD
Switch
Probe
Connector
Figure 3-4: Receiver controls, connectors, and indicators
POWER ON switch—The POWER ON switch is pressed to power on the receiver. However, it is important to note that this switch does not power off the receiver. You must choose POWER DOWN from Menu 1.
LCD—The graphics-type LCD displays menu choices and receiver-related information. (See the following subsection,
“Receiver Keys,” for information about keys associated with the screen.)
Potential probe—The potential probe is used in conjunction
with the receiver to take cell impedance, voltage, and strap resistance measurements.
Trigger—The trigger is pulled to perform functions on the
receiver, including entering test information.
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CONTROLS, CONNECTORS, INDICATORS AND MENUS
7-pin connector—The 7-pin connector is used to insert one
of the following: RS-232 communication cable, bar-code wand (optional), potential probe or printer.
Receiver Keys
4-pin connector—The 4-pin connector is used to connect the current sensor (CT).
3-pin connector—The 3-pin connector is used to connect the battery charger.
Buzzer—The buzzer prompts the user to input data. It also sounds under certain error conditions.
There are three keys located on the receiver that are used to operate the receiver and to navigate through the menus and displays on the LCD screen:
The UP ARROW and DOWN ARROW keys are used to select information displayed next to these keys on the screen. These keys are also used to scroll up and down through receiver screens.
The ENTER key is used to access receiver menus, which are shown in Figure 3-6 through Figure 3-7.
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Test Menu Structure
Megger
COPYRIGHT 2000
RELEASE 2.0
Figure 3-5: Flowchart for Receiver menus
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CONTROLS, CONNECTORS, INDICATORS AND MENUS
Main Menu Structure
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Figure 3-6: Flowchart for Receiver menus (cont'd)
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Print Menu Structure
Figure 3-7: Flowchart for Receiver menus (cont’d)
Example of How to Use the Receiver Keys
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1. Suppose that the following Menu is displayed on the screen as shown in Figure 3-6.
2. To select EXPORT DATA, press .
3. However, to move from menu to menu, press .
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