Megger BITE3 Operating Manual
AVTMBITE 3
Rev 6
July 2010
Instruction Manual
BITE 3
Battery Impedance Test Equipment
HIGH VOLTAGE EQUIPMENT
Read this entire manual before operating.
M
Valley Forge Corporate Center
2621 Van Buren Avenue
Norristown, PA 19403-2329
U.S.A.
610-676-8500
www.megger.com
BITE 3
Battery Impedance Test Equipment
Copyright© 2004 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.
M
Valley Forge Corporate Center
2621 Van Buren Ave
Norristown, PA 19403-2329
610-676-8500 (Telephone)
610-676-8610 (Fax)
www.megger.com
Table of Contents
1 INTRODUCTION ............................................................................................................................................. 1
About the BITE 3… ....................................................................................................................................... 1
Electrical Theory and Practice ....................................................................................................................... 2
How the BITE 3 Works ................................................................................................................................. 2
Applications for the BITE 3 .......................................................................................................................... 3
Upon Receipt of the BITE 3 .......................................................................................................................... 3
Safety First ........................................................................................................................................................ 4
How to Use This Manual ................................................................................................................................ 4
Typographic Conventions .............................................................................................................................. 4
2 SAFETY ................................................................................................................................................................ 5
Overview ........................................................................................................................................................... 5
Safety Requirements ........................................................................................................................................ 5
Cautions and Warnings ................................................................................................................................... 6
3 CONTROLS, CONNECTORS, INDICATORS & MENUS ..................................................................... 7
Overview ........................................................................................................................................................... 7
Switches and Connectors ................................................................................................................................ 8
The Battery Module ...................................................................................................................................... 12
Battery Charging............................................................................................................................................ 12
4 TEST PROCEDURES .................................................................................................................................... 15
Overview ........................................................................................................................................................ 15
Step One: Perform Pre-Test Activities. .................................................................................................. 15
Step Two: Turning on the BITE 3 and Connecting the Lead Set. ..................................................... 16
Step Three: Select a Site/String and Take Measurements. ..................................................................... 17
Step Four: Perform Post-Test Activities. ................................................................................................ 17
Reviewing a Test ........................................................................................................................................... 18
Retesting a Cell/Jar or a Strap .................................................................................................................... 18
Analyzing a Test (See Chapter 5) ................................................................................................................ 18
Testing Noisy Battery Systems .................................................................................................................... 18
Tests Using Optional Lead Sets .................................................................................................................. 18
Reviewing and retesting ............................................................................................................................... 19
5 Interpreting Test Results .................................................................................................................................. 21
Overview ........................................................................................................................................................ 21
Viewing (Printing) Test Results on the LCD ............................................................................................ 21
Instantaneous Mode of Analysis ................................................................................................................. 22
Short-term Mode of Analysis ...................................................................................................................... 23
Long-term Trending ..................................................................................................................................... 23
6 Communicating with ProActiv ........................................................................................................................ 25
Overview ........................................................................................................................................................ 25
Information & Settings ................................................................................................................................ 26
String Information Export .......................................................................................................................... 27
Firmware Updates ......................................................................................................................................... 28
Data and Information Export/Upload to a PC/Laptop ........................................................................ 29
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7 MAINTENANCE AND TROUBLE SHOOTING................................................................................... 31
Overview ......................................................................................................................................................... 31
Status LEDs .................................................................................................................................................... 31
Lead Set 31
Out of Range Impedance Values ................................................................................................................ 31
Battery 32
Probe Tips....................................................................................................................................................... 32
Printer (Optional) .......................................................................................................................................... 32
Configuration ................................................................................................................................................. 32
If the BITE 3 Needs Repairs ....................................................................................................................... 34
APPENDIX A - TECHNICAL SPECIFICATIONS ..................................................................................... 35
Electrical .......................................................................................................................................................... 35
Environmental................................................................................................................................................ 36
Safety ............................................................................................................................................................... 36
Mechanical ...................................................................................................................................................... 36
APPENDIX B - Replaceable Parts ...................................................................................................................... 37
APPENDIX C - Compatibility ............................................................................................................................ 39
Hardware - Unit Firmware Compatibility .................................................................................................. 39
Software - Firmware Compatibility ............................................................................................................. 39
Firmware Modifications ................................................................................................................................ 40
List of Figures
Figure-1: BITE 3 Transceiver ................................................................................................................................ 7
Figure-2: BITE 3 Lead Connections .................................................................................................................... 8
Figure-3: BITE 3 Battery Charger Connections ................................................................................................. 8
Figure-4: BITE 3 Battery Charger Condition .................................................................................................... 12
Figure-5: Printer Configuration Printout ........................................................................................................... 33
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INTRODUCTION
About the BITE 3…
NOTE: Before attempting to use the BITE 3, be sure that you read and
understand the safety requirements and operating procedures contained in
this manual.
Thank you for selecting a Megger product. This instrument has been thoroughly
tested and inspected to meet rigid specifications before being shipped.
It is ready for use (after charging the battery for 24 hours) when set up and
operated as described in this manual.
The BITE 3 is a testing device used to evaluate the condition of stationary
battery systems. It measures:
AC impedance, an internal ohmic value,
DC terminal voltage,
Intercell connection resistance,
Float current,
Ripple current, and
Harmonic content
These measurements, along with other maintenance data such as ambient and
cell temperatures, help determine the condition of a battery system.
The BITE 3 is the first instrument of its kind that can be configured through
PC-based software, called ProActiv. This provides the ultimate in versatility and
ease-of-use. The data from the BITE 3 is uploaded with the click of the mouse
and the site/string is updated with the latest data. Furthermore, the software of
the BITE 3 can be updated via the Internet to ensure that the most recent
updates and enhancements are downloaded to the BITE 3.
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The BITE 3 generates data that describes an overall condition of a battery. Weak
batteries are due to a number of reasons, some of which are sulphated plates,
dry-out (loss-of-compression), loose intercell connectors, grid growth, etc. The
BITE 3 also measures float current which increases over time as batteries
degrade. In the case of VRLAs, increasing float current can indicate impending
thermal runaway. [Flooded batteries can’t runaway thermally due to the large
volume of acid which merely boils off limiting battery temperature to about
260 F (125 C).]
Also measured is ripple current which is an indicator of charger output
condition. Battery chargers convert ac into dc but no charger is 100% efficient.
Some ac carries over into the dc network and is called “ac ripple”. If that ripple
current is above about 5% (5A rms per 100Ah) then battery heating can occur
thus shortening batteries’ lives. Normal aging of chargers causes a slow and
tolerable increase in ac ripple. But if a diode blows, ripple current can increase
three to four times which can heat the battery. Measuring ripple current helps to
identify the general condition of the charger output.
Electrical Theory and Practice
A battery string is a series circuit of cells that look like resistors to the applied
current. Current flows due to a voltage applied from the charger. In a series
circuit, Kirchhoff’s law states that the current is the same everywhere in that
circuit. Ohm’s law states that each resistor will have a voltage drop in response to
the applied current regardless of whether that current is ac, dc or both.
Impedance works by applying an ac current signal to the battery and measuring
the resulting voltage drop. Impedance is then calculated using Ohm’s Law,
Z = E/I. To get accurate internal ohmic values (impedance, etc.) the current
must also be measured. A battery is connected in parallel with a load and the
charger and frequently it is connected to other parallel strings. The actual current
can vary based on relative condition and parallel paths for the current. Hence, it
is necessary to measure current that is causing the voltage drop in order to obtain
accurate impedance values.
How the BITE 3 Works
The BITE 3 works by applying an ac current signal across an individual cell/jar
and measuring the ac voltage drop caused by that ac current as well as the
current in the individual cell/jar. It will then calculate the impedance. The
standard lead set used is dual-point, Kelvin-style. One point is for applying the
current and the other for measuring the potential.
In addition to the standard impedance cell voltage and intercell connection
resistance, the BITE 3 uses a patent pending technique to measure float and
rippled currents. The best method to measure current is by measuring the voltage
across a shunt. Megger uses the idea that there are many shunts within a battery.
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By first obtaining a strap resistance value, then using that as a shunt, the float and
ripple currents can be determined. The accuracy of the float and ripple currents
measurements is determined by the shunt value. See the Technical Specification
Section for accuracy.
The BITE 3 does more than take measurements; it also has an on-board, userconfigurable database replete with percent allowable changes. The BITE 3 works
in tandem with ProActiv to configure the instrument and site/strings based on
user choices. The BITE 3 and ProActiv work together to have the latest data
from ProActiv downloaded into the instrument for superior on-board data
analysis. All BITE 3s can then have all of the necessary information and data
regardless of which BITE 3 took the last set of battery data.
Applications for the BITE 3
Some of the many types of installations that can be tested and analyzed with the
BITE 3 are:
Introduction
Telecommunications – Wireline and Wireless
Substations and Generating Stations
UPS systems
Service Companies
Railroad – Substations and S&C including CTC
Heavy Industrial battery back-up systems
Battery Manufacturing Plants
Emergency Lighting Units
Marine and Military applications
Many Others
Please call Megger or visit our website www.megger.com for more information.
Upon Receipt of the BITE 3
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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 1-610-676-8500.)
The BITE 3 is easily operated by one technician. It is housed in a rugged plastic
case and includes the following components and accessories:
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The BITE 3 instrument with neck strap
Dual-point Lead Set with LED and spare tips
AC line cord and charger
Download cable, RS-232 null modem
Canvas carrying case
ProActiv software CD
Instruction manual
Please examine the instrument for damage received in transit. If you find
damage, file a claim with the carrier at once. Also notify Megger or our nearest
authorized sales representative, and describe the damage in detail.
Safety First
Be sure to read the safety information in Chapter 2 thoroughly and observe all
safety precautions and recommendations.
How to Use This Manual
Typographic Conventions
Cautions alert you to possible damage to
G
F
NOTE: Notes provide important information.
equipment.
Warnings alert you to conditions that are
potentially hazardous to people.
CAUTION
WARNING
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SAFETY
Overview
The BITE 3 and its 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.
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 electrolyte spills, explosion, and electrical shock.
Safety Requirements
This instrument has been designed to the IEC 61010-1 safety standard. Observe
all industry standard safety rules for testing batteries.
The BITE 3 is designed for connection to energized systems.
Always disconnect optional lead sets from the battery under test.
The purpose of this instrument is limited to use as described in this manual.
Do not use the equipment or its accessories in an explosive atmosphere.
Explosive gases such as hydrogen can be present around batteries. Regardless
of room ventilation, verify the conditions before testing.
Wear protective clothing and eye protection.
Ensure that test leads and probes are in good condition
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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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Cautions and Warnings
This manual provides cautions and warnings where applicable, and these should
be strictly observed.
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CONTROLS, CONNECTORS, INDICATORS & MENUS
Overview
The front panel of the BITE 3 comprises (clockwise from the top) the
1. Test button (used for optional lead sets)
2. Alpha-numeric keypad (symbols, too)
3. On-off switch, S1 (but it is not labeled S1.)
4. Enter button
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5. LCD, ¼ VGA, monochrome
6. Audible alarm
7. Comms/Printer port, J3 (but it is not labeled J3)
8. Cursor Control
9. Menu button
10. Contrast buttons
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10
1
2
7
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Figure-1: BITE 3 Transceiver
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The side panels comprise the lead set connection, J1 and the CT connection, J2.
(again, the ports are not labeled Jx)
J2
J1
Figure-2: BITE 3 Lead Connections
The battery charger connection, battery state indicator and slow charge control
are here:
J6
Figure-3: BITE 3 Battery Charger Connections
J5
Switches and Connectors
S1 switch
The on-off switch energizes/de-energizes the
instrument. It takes about 30 seconds to boot-up
and about ten seconds to shut down.
J4
J1 Lead set
J2 CT
The lead sets are connected here. The connector is
keyed.
The optional external CT, when used, connects into
J2. It is also keyed.
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