Megger TORKEL 910, TORKEL 930, TORKEL 950 User Manual

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TORKEL 900-series
Battery Load Unit
User’s Manual
Art No. ZP-CS01E Doc. CS033663DE V04a 2018
WWW.MEGGER.COM
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TORKEL 900-series
Battery Load Unit
User’s Manual
NOTICE OF COPYRIGHT & PROPRIETARY RIGHTS
The contents of this manual are the property of Megger Sweden AB. No part of this work may be reproduced or transmitted in any form or by any means, except as permitted in written license agreement with Megger Sweden AB. Megger Sweden AB has made every reasonable attempt to ensure the completeness and accuracy of this document. However, the information contained in this manual is subject to change without notice, and does not represent a commitment on the part of Megger Sweden AB. Any attached hardware schematics and technical descriptions, or software listings that disclose source code, are for informational purposes only. Reproduction in whole or in part to create working hardware or software for other than Megger Sweden AB products is strictly prohibited, except as permitted by written license agreement with Megger Sweden AB.
TRADEMARK NOTICES
Megger® and Programma® are trademarks registered in the U.S. and other countries. All other brand and product names mentioned in this document are trademarks or registered trademarks of their respective companies.
Megger Sweden AB is certified according to ISO 9001 and 14001.
Postal address:
Megger Sweden AB Box 724 SE-182 17 DANDERYD SWEDEN
T +46 8 510 195 00 F +46 8 510 195 95
CS033663DE ZP-CS01E TORKEL 900-SERIES
Visiting address:
Megger Sweden AB Rinkebyvägen 19 SE-182 36 DANDERYD SWEDEN
seinfo@megger.com www.megger.com
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Contents
1 Introduction
............................................................. 6
1.1 Product description ......................................6
1.2 Features and benefits ...................................6
1.3 Receiving instructions ...................................7
1.4 Warranty .....................................................7
Warranty repair ........................................................... 7
2 Safety
............................................................. 8
2.1 Symbols on the instrument ..........................8
2.2 Safety instructions ........................................8
Protection system ........................................................ 9
3 Instrument description and
Accessories ....................................... 10
3.1 Top panel ...................................................10
3.2 Side panel ..................................................11
3.3 Included accessories ...................................11
TORKEL 910 .............................................................. 11
TORKEL 930/950 ....................................................... 11
TORKEL Viewer ......................................................... 11
3.4 Optional accessories ...................................12
TXL extra loads .......................................................... 12
BVM - Battery Voltage Monitoring ............................. 12
Sensing leads ............................................................ 12
Clamp-on-probe ....................................................... 12
4 Menu system
........................................................... 14
4.1 Main menu ................................................14
Screen buttons .......................................................... 14
TEST menu ................................................................ 14
GRAPH ...................................................................... 17
RESULT ...................................................................... 17
REPORT ..................................................................... 18
CELLS (optional BVM) ................................................ 18
4.2 TORKEL Viewer ..........................................19
5 Making a test
........................................................... 20
5.1 Preparations for testing ..............................20
Connecting the current cables to the battery ............. 20
5.2 Test at constant current ..............................21
Preparations .............................................................. 21
Select "Test Method" ................................................ 21
Starting the test ........................................................ 21
Pausing the test ........................................................ 21
Ending the test .......................................................... 21
5.3 Test at constant power ...............................22
Preparations .............................................................. 22
Configuring TORKEL for constant power ................... 22
Select "Test Method" ................................................ 22
Starting the test ........................................................ 22
Pausing the test ........................................................ 22
Ending the test .......................................................... 23
5.4 Test at constant resistance ..........................23
Preparations .............................................................. 23
Select "Test Method" ................................................ 23
Starting the test ........................................................ 23
Pausing the test ........................................................ 23
Ending the test .......................................................... 23
5.5 Testing with a load profile ..........................24
Preparations .............................................................. 24
Select "Test Method" ................................................ 24
Starting the test ........................................................ 24
Pausing the test ........................................................ 25
Ending the test .......................................................... 25
5.6 V Logger ....................................................25
Starting "V Logger" directly after a discharge test ..... 25
Starting "V Logger" as a separate test ...................... 25
Ending the test .......................................................... 25
5.7 Viewing results and reporting ....................26
Viewing the results .................................................... 26
REPORT ..................................................................... 26
6 External current measurement .......... 28
6.1 General ......................................................28
6.2 Setting up external current measurement ...28
DC clamp-on current probe ....................................... 28
Troubleshooting ........................................................ 29
6.3 TORKEL used together with TXL Extra Load 29
Multiple units used together ..................................... 29
Constant current, regular load connected.................. 30
7 Alarm function
........................................................... 32
7.1 Description ................................................32
Resetting the alarm ................................................... 32
8 How to obtain the desired current .... 34
8.1 When a single TORKEL isn’t enough ...........34
TXL connected to TORKEL ........................................ 34
How many units are needed? .................................... 34
TORKEL 910 .............................................................. 35
TORKEL 950 .............................................................. 35
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9 Optional equipment
........................................................... 36
9.1 TXL830/850/865/870/890
Panel ......................................................................... 36
Using the TXL ............................................................ 36
Testing ...................................................................... 37
9.2 BVM - Battery Voltage Monitor ..................37
Power & signal connector unit ................................... 38
Test with BVM and TORKEL ....................................... 38
Test with BVM – without TORKEL .............................. 40
Optional BVM equipment .......................................... 40
(Extra Loads) ......36
10 Troubleshooting
........................................................... 42
11 Calibration
........................................................... 44
11.1 General ....................................................44
11.2 How to calibrate ......................................44
12 Specifications
........................................................... 46
SPECIFICATIONS
TORKEL 900-series .................................................... 46
Specifications BVM .................................................... 48
Index ....................................................... 50
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1 INTRODUCTION
1
Introduction
1.1 Product description
This manual explains how to use TORKEL 900-series of battery load units, and it also covers the optional TXL (extra load units) and the BVM (Battery Voltage Moni­tor) system.
The instrument is designed mainly for capacity tests. The unit can be programmed to test a battery bank at constant current, constant power, constant resistance or using a user-defined load profile. TORKEL can also be used for testing battery chargers and other electri­cal equipment that require resistive load testing.
The BVM (Battery Voltage Monitor) is a battery voltage measurement device that is used for monitoring of cell voltages and battery blocks in battery banks com­monly found in electrical power sub-stations, telecom facilities and computer data center UPS systems.
1.2 Features and benefits
Model overview
TORKEL 910 930 950
Current (max)
Voltage (ma x)
BVM functionality
Charging measurement
Full report functionality
110 A 220 A 220 A
300 V 300 V 500 V
No Yes Yes
No Yes Yes
No Yes Yes
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1 INTRODUCTION
1.3 Receiving instructions
▪ Check the equipment received against the packing list to
ensure that all materials are present. Notify Megger of any shortage.
▪ Examine the instrument for damage received in transit. If
damage is discovered, file a claim with the carrier at once and notify Megger, giving a detailed description of the damage.
▪ This instrument has been thoroughly tested and inspected
to meet rigid specifications before being shipped. It is ready for use when set up as indicated in this user manual.
1.4 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.
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 negligence abuse (failure to follow recommended operating procedures) or failure by the customer to perform specific maintenance as indi­cated in this manual.
Warranty repair
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.
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2 SAFETY
2
Safety
2.1 Symbols on the instrument
Caution, refer to accompanying docu­ments.
Caution, risk of electric shock.
Hot, do not cover
Protective conductor terminal.
WEEE, Waste Electronic Equipment. Please utilize your local WEEE collec­tion facilities in the disposition of this product and otherwise observe all applicable requirements. The unit can also be returned to Megger at any time at no charge for the disposal.
2.2 Safety instructions
▪ All safety and operating instructions must be read before
using TORKEL.
▪ All safety and operating instructions for TORKEL must be
followed.
▪ All safety and operating instructions must be retained for
future reference.
WARNING
1.
The electrical voltage and current used in battery testing is potentially lethal. Ensure that the AC supply is disconnected and any battery under test is disconnected before attempt­ing any cleaning or maintenance of TORKEL.
2.
Connection and disconnection procedures are extremely important. Be sure to follow the instructions carefully..
3.
Do not touch conducting parts of the clamps on the current cables or the voltage sensing cables when they are connected to TORKEL.
4.
Never connect a TORKEL to a voltage higher than specified.
5.
Misuse of TORKEL can be extremely dangerous.
6.
Inspect cable connections to make sure there is no short circuit.
7.
Use an easily accessible power outlet. This will ensure that you can disconnect the power quickly in case of a problem.
8.
When a lead acid battery is charged or dis­charged i.e. when there is a current flow through the battery it is always a risk that the battery can explode. If there is a bad connection inside the battery and there is a current flow - the connection will burn off and there will be an arc, which will ignite the oxyhydrogen gas in the battery. For new open (vented) batteries the risk is me­dium to low but in old VRLA (sealed) batteries the risk is medium to high.
9.
To minimize the risk for personnel injuries: Always place TORKEL/TXL as far away from the battery as possible. Never stand close to a bat­tery during charge/discharge.
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2 SAFETY
10.
Too high discharge current applied on a battery can cause the battery to explode or get over­heated. Be sure to not set too high current.
11.
If the external current measurement is inter­rupted or giving false values during the test, the current will rise to a higher level than the set value before the test is shut down. If the battery is too small for this current or in a bad condition
- it may explode.
12.
Never use the TORKEL/TXL Extra Load in an explo­sive environment. Never put the TORKEL/TXL Extra Load where it can be reached by battery gas.
13.
Improperly connected cables carrying high cur­rent can cause fire. Make sure that the cables are not twisted in such a way that could cause them to turn and come loose from the connector.
14.
Make sure that there is no dust or dirt in or around the cooling fans before starting a discharge test. After starting a discharge test, check that the fans are running properly and that the airflow is good. Make sure no hair or clothing is sucked into the fans.
15.
Position TORKEL/TXL Extra Load where air flow is unobstructed and where it does not come into contact with any flammable or heat-sensitive material. Keep a free distance of 1.5 m (5 ft) to the vertical sides of TORKEL/TXL and 2.0 m (6.5 ft) above TORKEL/TXL.
16.
Do not place TORKEL a) near another TORKEL, a TXL Extra Load or any other heat source or b) where the cooling airflow can be blocked. TORKEL will overheat if there is insufficient cooling.
17.
External current shunt may not be used above 300 V DC
18.
Do not use any other equipment other than what is provided or specified.
4.
At high ambient temperatures and high loads, TORKEL will employ a heat reduction discharge scheme that under certain circumstances might induce a high frequency audible noise. This is normal, but can be taken as an indication that TORKEL is working close to its temperature limits.
Protection system
The unit has built-in protection system against over­heating and malfunctioning cooling fans. A built-in circuit breaker is an important component in the safety system. If the temperature will be too high and/ or the cooling fans malfunction, the circuit breaker will trip. There is also a melting fuse connected in series with the circuit breaker.
Always follow the safety instructions in section 2.2.
Important
1.
When using the external current measurement function:
Always replace the CT internal battery before a test or use the 9 V DC out from
Set the correct current ratio in the external current
measurement menu.
2.
Do not use liquid detergents or aero-sols when
TORKEL.
cleaning TORKEL or TXL units. Use a damp cloth.
3.
If TORKEL has been stored below freezing for an extended period of time, you must allow 3 hours for it to adapt to room temperature.
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3 INSTRUMENT DESCRIPTION AND ACCESSORIES
Instrument description and
3
Accessories
3.1 Top panel
1
3
2
5
4
6
7
8
9
10
1. TXL STOP
Output used for stop discharging from an external device (TXL). Galvanically isolated.
2. SERVICE
Connector for service purposes only.
3. ALARM
Output equipped with a relay contact for trigger­ing an external alarm device.
4. DC OUT
9 V output for external current clamp.
5. I EX T 1 V
Input used to measure current in an external path by means of a DC clamp-on current probe or a current shunt.
6. Display
Touch screen 7"
7. BVM1, BVM2
USB connections for BVM units.
12
11 13
9. Ethernet connection
For service of the instrument.
10. EMERGENCY STOP
Push to stop. The connection to the test object (battery bank) is interrupted in the same way as if mains would fail. In addition, a separate signal will stop the electron­ics and the discharge process stops. The emergency stop works even if the electronics fail. Reset the button by turning it right
11. Control knob
For entering settings etc. Press to confirm a setting.
12. Buzzer
For alarms.
13. ON/OFF switch
8. USB connection
For USB memory stick. The USB memory stick must be FAT32 formatted.
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3 INSTRUMENT DESCRIPTION AND ACCESSORIES
3.2 Side panel
14
16 1817
14.
Protective conductor terminal
15. MAINS
Connector for mains supply.
+
16.
Connection terminal (+) for the battery (or other DC source)
15
3.3 Included accessories
TORKEL 910
Cable set
Cable set, 2 x 3 m, 25 mm2 (10 ft), for connecting TORKEL to the battery.
Cable set (GA-00550)
TORKEL 930/950
Cable set
Cable set, 2 x 3 m, 70 mm2 (10 ft), for connecting TORKEL to the battery.
17. VOLTAGE SEN SE
Input for sensing voltage at the battery terminals. Impedance to the battery current terminals is >1 M
18. .
Connection terminal (-) for the battery (or other DC source).
Cable set (GA-09550)
TORKEL Viewer
TORKEL Viewer can be used to edit and print out reports
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3 INSTRUMENT DESCRIPTION AND ACCESSORIES
3.4 Optional accessories
TXL extra loads
See chapter "9 Optional equipment" on page 36
BVM - Battery Voltage Monitoring
Enables automatic battery cell voltage logging during capacity tests. Up to 2x120 units can be used (Daisy­chain). For complete information see the BVM data sheet.
Sensing leads
For measuring voltage at battery terminals. 2 x 5 m (16.4 ft).
Extension cables
Extension for GA-00550, 2 x 3 m, 25 mm2, male / female.
Extension cable set (GA-00552)
Extension for GA-09550, 2 x 3 m, 70 mm2, male / fe­male.
Extension cable set, high rating (GA-09552)
Sensing lead set (GA-00210)
Clamp-on-probe
Clamp-on probe, 1000 A DC. To measure current in external circuit.
Clamp -on-probe (X A-12991)
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4 MENU SYSTEM
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4 MENU SYSTEM
4
Menu system
4.1 Main menu
Screen buttons
Confirm
Exit without changes
Run
Pause the test to make any cor­rections/changes in the settings*
Stop
Temperature compensation Shown when compensation is enabled
Quick guide
Open test file library
New test
Test method
A test can be made in six test methods, "Constant I" is default.
1] Press the button and select test method.
Constant I (current)
▪ Constant P (power)
▪ Constant R (resistance)
▪ Profile I (current profile)
▪ Profile P (power profile)
)
▪ V Logger (Current with monitoring during charge)
A] For Constant I, P or R you press the numeric
field and make the settings for the parameter using the On-screen keyboard or the control knob.
B] For Profile I or Profile P a new tab will be
shown on top of the screen together with a window for the settings.
Test configuration
Information bar Shows messages and is used for acknowledge alarms
Information field Shows voltage and current
)
*
The pause time has limitations regulated by inter­national standards. If the pause time is too long the battery may have to be recharged before a new test is done.
TEST menu
Here you configure your profile and press to start the test or press TEST to return to the test menu.
C] For V Logger the voltage will be logged dur-
ing charge. You can set time values for warn­ing and stop.
Warning and stop limit parameters
You can set TORKEL to issue a warning and/or to stop:
When the voltage has reached a certain level.
▪ When a certain amount of capacity is discharged.
▪ After a specified time.
▪ When a cell voltage has reached a certain level (if BVM is
used, see section "9.2 BVM - Battery Voltage Monitor" on page 37).
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4 MENU SYSTEM
The warning and stop limits can be set and changed during a test.
The settings for the warning and stop levels are inde­pendent of each other.
See also chapter "7 Alarm function" on page 32
Warning limit
When a "Warning" limit is reached, the "information bar" turns yellow and the warning cause is displayed. The alarm buzzer sounds as well.
The warning is confirmed by pressing the "informa­tion bar" and the alarm buzzer stops to sound.
Stop limit
ID Labels
2] Click the label fields and enter the informa-
tion as desired.
Settings
When a "Stop" criteria is reached, the "information bar" turns red and the cause of stop is displayed.
Note This means that the discharge is stopped and
you can change parameters and continue the test or press to close the test.
When BVM stop limit is set and a BVM gets loose during test, the test stops.
Setting the limit parameters
1] Press the numeric field and make the settings
for the limit parameter using the On-screen keyboard or using the control knob (press to confirm).
2] Enable the limit by touching the checkbox.
3] Go on with the desired parameters.
Test configuration
Press
1]
▪ Select Internal (prefault) or External.
For external current clamp / current shunt set the Ratio, see section"6.2 Setting up external current measurement" on page 28.
▪ If desired enable temperature compensation.
▪ If desired enable cell numbering from plus (default
numbering is from minus).
Temperature compensation
If temperature compensation is enabled, see above, a
button
will be shown in TEST menu.
1] Press to make settings for the tempera-
ture compensated test.
2] Press button to the right to enable Rate or
Time correction.
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4 MENU SYSTEM
You can select according to IEEE and IEC standards or Manual setting:
Corrected capacity % => 39.4 Ah / 33 Ah = 119.5%
Time Correction
The time compensation is for tests longer than 1 hour. Measured capacity 52.7 Ah / comp factor at 40°C
(1.134) gives corrected capacity 46.5 Ah. And cor­rected capacity in % rel. to nom. capacity 46.5 / 37 =
1.256. Meaning 125.6%.
Language
▪ Manage language files for the internal software and select
U or V as the symbol for voltage.
Rate Correction
The rate compensation is for capacity tests up to 1 hour. Depending on the set temperature the nominal current will change.
It will be reflected in the “TEST SETTING” menu.
In this example 100 A is set as nominal current. The temperature is set to 35 degrees.
It gives a compensated current discharge level on
107.5 A.
About
▪ Information about software version etc.
▪ Upgrade License.
A license file is to be copied to TORKEL Upgrade can be performed to TORKEL 930/950.
System
▪ Select external keyboard.
▪ Set the time
▪ Simulator mode
Using simulator mode you are can simulate a test without a battery and BVM connected.
1] Enable "Simulator available".
Rate compensated. 200 A nominal current, compen­sated 215.1 A discharge current
Nominal capacity calculated on 200 A => nominal capacity 33 Ah
measured capacity 42.4 Ah and from that get cor­rected capacity 39.4 Ah.
16 TORKEL 900-SERIES ZP-CS01E CS033663DE
2] Shut down and restart TORKEL.
3] During start of TORKEL select the “BVM
Simulator “ button and “Simulator”.
4] When the start menu appears, tap on the
space bar and select “Connected” After a short while, the button gets
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activated. From here a discharge test simula­tion with BVM can be performed.
5] When the TORKEL has been turned off,
the simulator mode will be disabled when TORKEL is turned on again.
Calibration
See section "11.2 How to calibrate" on page 44.
Test Manager
The database can store up to 20 tests.
1] Press
4 MENU SYSTEM
Make settings for the axis. Above is an example of a setting that will show the voltage curve.
Zoom
1] Press to zoom the graph
2] Select a test by marking the checkbox.
3] You can use the buttons at the bottom for
actions described below:
to open a test
to put test in the trash can
to undelete all tests
to save test on USB stick for use in PC
to import data from USB
to save a test in TORKEL Win format wich makes it possible to open it in TORKEL Win
GRAPH
2] Set scale for y-axis and set the offset value or
select Auto scale.
RESULT
After ending a test you can go into the different tabs to se the result.
1] In the RESULT and BATTERY tabs you can add
information by pressing the "Edit" button.
Graph settings
Press
1]
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4 MENU SYSTEM
By pressing in the diagram, test data for the selected time will be shown in the table.
The specific time interval can also be examined by zooming the time axle.
1] Press in the diagram were you want to exam-
ine details on the voltage curve.
2] Press the control knob shortly and turn it
clockwise to zoom. Tap on the diagram and to scroll the cursor for this time interval.
▪ The FLOAT voltage means the voltage read prior to
removing the battery charger.
▪ The START voltage is when the discharge tests start.
1] By pressing a cell bar, readings can be seen in
the table as the "Sel" value.
3] To return to the full test, press the control
knob shortly and turn it counterclockwise.
REPORT
4] The saved tests can be stored on an USB
memory stick and transferred to a PC. The included PC software TORKEL Viewer can be used to edit and print out reports. Edited reports can be transferred back to TORKEL i.e. you can design the test and settings in TORKEL Viewer.
Note The USB memory stick must be FAT32 format-
ted.
CELLS (optional BVM)
When using the optional BVM equipment you get information of the cell voltages, see also section "9.2 BVM - Battery Voltage Monitor" on page 37.
Diagram shows voltage per cell during the test.
▪ The LIVE voltage means the present voltage
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4 MENU SYSTEM
4.2 TORKEL Viewer
TORKEL Viewer is delivered together with TORKEL (not with TORKEL 910) on a USB stick.
TORKEL Viewer runs under MS windows 7,8 and 10.
1] Double click the:
“TORKEL Viewer Setup.msi” file.
2] Follow instructions and the TORKEL Viewer
will be installed on your computer.
Note After installation you can find a demo file at
C:\Program Files (x86)\Megger\Torkel Viewer\ Reporting.
3] Click to open the program.
▪ The “Preview” tab is simply a way of checking the report
after modification, prior saving or print out of the report.
▪ The "TorkelCalc" tab is used for calculating how many
TORKELs and TXLs are needed.
▪ The "Settings" tab contains, among other things,
language setting.
▪ The "Report " tab includes several settings and options
on how to set up the test report. With the “Save test file” button a test can be prepared in advance with information of the test object.
▪ The “Plot” tab gives you the possibility to check the
battery measurements or the BVM voltages diagram. By right click and drag on the y-scale of resp. entity the diagram lines can be modified. The time scale can also be adjusted by right click and drag the scale. By placing the cursor in the diagram and scrolling with mouse, zooming of the time scale will be done. Clicking the “Auto zoom” will reset the diagram to the default appearance. Clicking the “Export Plot” button will export the diagram in a .png format. The BVM measurements can also be examined by selecting the BVM voltage diagram in the “Choose plot to display”. The diagram can be moved by right click and drag. Each voltage cell can be checked by clicking on the cell bar. Float, start and end values are presented.
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5 MAKING A TEST
5
Making a test
5.1 Preparations for testing
WARNING
See the chapter "2.2 Safety instructions" on page 8.
1] Connect TORKEL to the mains voltage. 2] Switch on TORKEL.
The display will show the following after a short time:
Tip
To get a more accurate voltage reading when current cables are long and the discharge current is high. Connect the voltage sensing cables between the “VOLTAGE SENSE” input on TORKEL and the battery terminals.
Connecting the current cables to the battery
Important
Connection and disconnection procedures are extremely important. Be sure to fol­low the instructions.
Use the cables supplied with TORKEL or other cables of suitable size. Follow the numbered steps that are set forth below. Inspect each connection to make sure it is securely fitted.
1] Connect one end of the first cable to the
negative (-) terminal on TORKEL.
2] Connect the other end of the first cable to
the negative (-) pole of the battery.
3] Connect one end of the second cable to the
positive (+) pole of the battery.
4] Connect the other end of the second cable to
the positive (+) terminal on TORKEL.
The sensing cables (dotted lines) are normally not needed.
Note TORKEL automatically selects the voltage
range when voltage is applied to the high­current terminals.
If load polarity is incorrect the load will not be connected internally. On the display the ”space bar” will be red and an alarm will sound. This is true for both the battery and voltage sense terminals.
You can start a test in any of the menus. While test is running you can go into any tab and pause the test and make changes and continue the test.
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5 MAKING A TEST
Emergency stop button
The button is intended to be used if a fault occur in the test object and/or the external testing cables.
1] Press the button to immediately inter-
rupt discharging. TORKEL will still have power and the cooling fans will run at maximum speed.
2] Reset the stop button by turning it right.
If you consider it safe to continue the test you can start the test again.
5.2 Test at constant current
Preparations
Follow the safety precautions set forth in section "2.2 Safety instructions" on page 8 and the prepara­tions for testing in section "5.1 Preparations for test­ing" on page 20.
Select "Test Method"
1] Press "Constant I" 2] Set the desired current by pressing the nu-
meric field and make the settings for current using the On-screen keyboard.
3] Make settings for warning and stop limits,
see section "Warning and stop limit param­eters" on page 14.
Tip
You can change the settings for current and limits at any time in "TEST".
Starting the test
1] Wait for "Connected ready" to be displayed
on the information bar and the control knob is lit.
2] Press
The current value (A) will be displayed and the control knob lamp will start blinking.
Pausing the test
1] Press 2] Restart by pressing
Note Any TXL Loads connected to TORKEL must be
restarted manually.
Ending the test
WARNING
Do not disconnect any cables until the test is completed and stopped
1] Press
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5 MAKING A TEST
2] Press "Yes"
3] Disconnect the cables in reverse order that
they were connected.
WARNING
Do not connect a discharged battery to a battery that has not been discharged. The batteries must be charged to the same potential (voltage) before they are con­nected together.
For viewing results and report see section "5.7 View­ing results and reporting" on page 26.
5.3 Test at constant power
TORKEL can be used to conduct a discharge test at constant power instead of constant current. All proce­dures are the same except that you must set TORKEL differently before starting – you set the power instead of the current.
Preparations
Follow the safety precautions set forth in section "2.2 Safety instructions" on page 8 and the prepara­tions for testing in section "5.1 Preparations for test­ing" on page 20.
Configuring TORKEL for constant power
1] Calculate the current at the end of the test
(divide the power by the voltage).
2] Then make sure that the total current does
not exceed 2999 A and that the TORKEL and TXL units can load with the required current throughout the test.
Select "Test Method"
1] Press "Constant P" 2] Set the desired Power by pressing the nu-
meric field and make the settings for power using the On-screen keyboard.
3] Make settings for warning and stop limits,
see section "Warning and stop limit param­eters" on page 14.
Tip
You can change the settings for power and limits at any time in "TEST".
Starting the test
4] Press
The power value (kW) will be displayed and the control knob lamp will blink.
Pausing the test
1] Press 2] Restart by pressing
Note Any TXL Loads connected to TORKEL must be
restarted manually.
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5 MAKING A TEST
Ending the test
WARNING
Do not disconnect any cables until the test is completed and stopped
1] Press
2] Press "Yes"
3] Disconnect the cables in reverse order as
described in section "Connecting the current cables to the battery" on page 20
WARNING
Do not connect a discharged battery to a battery that has not been discharged. The batteries must be charged to the same potential (voltage) before they are con­nected together.
5.4 Test at constant resistance
TORKEL can be used to conduct a discharge test at constant resistance instead of constant current. All procedures are the same except that you must set TORKEL differently before starting – you set the resist­ance instead of the current.
Preparations
Follow the safety precautions set forth in section "2.2 Safety instructions" on page 8 and the prepara­tions for testing in section "5.1 Preparations for test­ing" on page 20.
Select "Test Method"
1] Press "Constant R" 2] Set the desired Resistance by pressing the nu-
meric field and make the settings for resist­ance using the On-screen keyboard.
3] Make settings for warning and stop limits,
see section "Warning and stop limit param­eters" on page 14.
Tip
You can change the settings for resistance and limits at any time in "TEST".
For viewing results and report see section "5.7 View­ing results and reporting" on page 26.
Starting the test
4] Press
The resistance value (Ohm) will be displayed and the control knob lamp will blink.
Pausing the test
1] Press 2] Restart by pressing
Note Any TXL Loads connected to TORKEL must be
restarted manually.
Ending the test
WARNING
Do not disconnect any cables until the test is completed and stopped
1] Press
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5 MAKING A TEST
2] Press "Yes"
3] Disconnect the cables in reverse order as
described in section "Connecting the current cables to the battery" on page 20
5.5 Testing with a load profile
TORKEL can be used to conduct a test that incorpo­rates a current profile or power profile. A profile can consist of up to 20 time intervals. The duration and the magnitude of the load can be specified for each interval.
If you want step or steps to be repeated you enable the "Auto Loop".
Note Using more than 20 steps will slow the sys-
tem.
WARNING
Do not connect a discharged battery to a battery that has not been discharged. The batteries must be charged to the same potential (voltage) before they are con­nected together.
For viewing results and report see section "5.7 View­ing results and reporting" on page 26.
Preparations
Follow the safety precautions set forth in section "2.2 Safety instructions" on page 8 and the prepara­tions for testing in section "5.1 Preparations for test­ing" on page 20.
Select "Test Method"
1] Press "Profile I" or "Profile P"
2] Set the desired "Duration" by pressing the
numeric field and make the settings for dura­tion using the On-screen keyboard.
3] Set the desired current or power by pressing
the numeric field and make the settings for current using the On-screen keyboard.
4] Make settings for warning and stop limits,
see section "Warning and stop limit param­eters" on page 14.
Tip
You can change the settings for current/power and limits at any time in "TEST".
Starting the test
5] Press
The current value (A) or power (kW) will be displayed and the control knob lamp will blink.
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5 MAKING A TEST
Pausing the test
1] Press 2] Restart by pressing
Note Any TXL Loads connected to TORKEL must be
restarted manually.
Ending the test
WARNING
Do not disconnect any cables until the test is completed and stopped.
1] Press
2] Press "Yes".
5.6 V Logger
TORKEL can log the voltage during charging of the batteries.
Starting "V Logger" directly after a discharge test
Tip
You can select to make the charging test im­mediately after a discharging test and keep all connection as they are.
1] Press"Save and start V logger".
This will be a separate new test.
2] Press
3] Start charging the batteries.
4] You can change the Warning and Stop limits
during the test.
Starting "V Logger" as a separate test
3] Disconnect the cables in reverse order as
described in section "Connecting the current cables to the battery" on page 20
WARNING
Do not connect a discharged battery to a battery that has not been discharged. The batteries must be charged to the same potential (voltage) before they are con­nected together.
Tip
You can select to make the charging test im­mediately after a discharging test and keep all connection as they are.
For viewing results and report see section "5.7 View­ing results and reporting" on page 26.
Preparations
Follow the safety precautions set forth in section "2.2 Safety instructions" on page 8 and the prepara­tions for testing in section "5.1 Preparations for test­ing" on page 20.
Select "Test Method"
Press "V Logger" button.
1] 2] Make settings for warning and stop time, see
section "Warning and stop limit parameters" on page 14.
3] Press
4] Start charging the batteries.
Ending the test
WARNING
Do not disconnect any cables until the test is completed and stopped.
1] Press
2] Press "Yes".
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5 MAKING A TEST
3] Disconnect the cables in reverse order as
described in section "Connecting the current cables to the battery" on page 20
WARNING
Do not connect a discharged battery to a battery that has not been discharged. The batteries must be charged to the same potential (voltage) before they are con­nected together.
5.7 Viewing results and reporting
Viewing the results
1] Select the "RESULT" tab to view the test
results
2] In the RESULT and BATTERY tabs you can add
information by pressing the "Edit" button.
Float voltage The voltage value prior the charger is
removed.
Open voltage The value prior start of discharge
test.
Start voltage The value given after the first initial
decrease of the battery bank at a start of a discharge test.
End voltage The value at the end of discharge test
REPORT
The saved test can be stored on an USB memory stick and transferred to a PC. The included PC software TORKEL Viewer can be used to edit and print out reports, see paragraph "4.2 TORKEL Viewer" on page
19.
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6 EXTERNAL CURRENT MEASUREMENT
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6 EXTERNAL CURRENT MEASUREMENT
External current
6
measurement
6.1 General
External current measurement must be used when:
TORKEL is working together with TXL Loads.
▪ Testing without disconnecting the regular load.
Since total current is measured, TORKEL can compensate for changes attributable to the regular load. The total current from the battery is then kept at a constant value. This ensures accurate test results.
The external current measurement function enables TORKEL to measure the total current in an external path and base regulation on this measurement.
A DC clamp-on current probe (optional accessory) has to be used for this measurement. It can be applied at one of the battery terminals or at an inter-cell con­nector. The DC clamp-on current probe must measure the total current, including that which passes through TORKEL.
A current shunt can also be used, but this requires opening the current path and connecting the shunt in series. The current shunt must be connected to the negative side of the battery.
6.2 Setting up external current measurement
WARNING
See the chapter "2.2 Safety instructions" on page 8.
DC clamp-on current probe
Preparation and requirements of the DC clamp-on current probe to be used.
The DC clamp-on current probe output voltage must not exceed 1 V.
▪ Make sure that the DC clamp-on current probe has fresh
batteries. The batteries must last throughout the entire test.
▪ The DC clamp-on current probe must be accurate and
calibrated and it must be able to carry a load of 600 k Please note that a DC clamp-on current probe is usually less accurate in the lowest part of its measurement range.
.
WARNING
External current shunt may not be used above 300 V DC
Important
Always activate the warning and stop limit functions when using external cur­rent measurement. This will protect your batteries if the DC clamp-on current probe will malfunction.
Important
If a current shunt is used it must be con­nected on the negative side of the bat­tery.
Tip
For tests where it is important to obtain the desired current within a few seconds or less it is better to use internal current measurement since it provides faster regulation.
Resetting the output voltage
Place the DC clamp-on current probe as far as
1]
possible from any magnetic field
2] Connect a DC voltmeter (set to 2 V full scale)
to the DC clamp-on current probe.
3] Switch on the DC clamp-on current probe
and adjust its zero knob to set the output to
0.0 V
The mV/A ratio for the input can be set to a value between 0.1 mV/A and 100 mV/A.
1] In "TEST" press 2] Press "Settings".
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6 EXTERNAL CURRENT MEASUREMENT
3] Select "External" for "Current measure-
ment".
4] Press the numeric field to set the "Ratio" for
the current clamp to be used
5] Press
6] Activate the warning and stop limit func-
tions.
7] Connect the DC clamp-on current probe to
input I EXT 1 V. Best results are obtained if the cables running from the DC clamp-on current probe are twisted.
Note If the DC clamp-on current probe has an
adapter for using external power supply. Use the power supply from TORKEL (DC Out) con­nector, that gives 9 V.
Important
The DC clamp-on current probe must always be applied in such a way that cur­rent through TORKEL is included in the measurement.
6.3 TORKEL used together with TXL Extra Load
A current shunt can also be used, but this requires opening the current path and connecting the shunt in series.
8] Apply the DC clamp-on current probe to the
conductor.
9] Turn on the power switch on the DC clamp-
on current probe.
10] Make the setup for preferred test mode.
Troubleshooting
1] Check that the DC clamp-on current probe is
properly connected to TORKEL.
2] Check that the DC clamp-on current probe is
switched on.
3] Check that the DC clamp-on current probe
has fresh batteries.
4] Check the following settings in “TEST SET-
TINGS”, "Settings":
• “I measurement” must be set to “External”.
• The mV/A ratio must match the ratio that appears on the DC clamp-on current probe itself.
Multiple units used together
One TORKEL control
The first TORKEL regulate the TXLs.
1] Apply the clamp-on-probes as illustrated
above.
2] Set the desired total current on TORKEL 1
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6 EXTERNAL CURRENT MEASUREMENT
3] Set max current on TORKEL 2.
4] Set warning limits only on TORKEL 1.
5] Set the stop limits. The voltage and test
period (time) can be set on each individual TORKEL. Stopping after a certain capac­ity (Ah) is reached can only be activated on TORKEL 1.
Note Only TORKEL No. 1 is to control the TXLs.
6] Set switch <F1> to the upper (ON) position
on the TXLs.
7] Then start the TORKEL that has the highest
number (when numbered as set forth above). Now start the TORKEL with the second highest number, then the third highest, etc. Finally, start TORKEL 1. Starting the TORKELs in this order prevents the current from being higher than desired at the beginning of the test.
Two or more TORKEL and TXL units
TORKEL1 Measures the entire battery current. TORKEL2 Measures all current except the current
through TORKEL1.
TORKEL3 Measures all current except the currents
through TORKEL2 and TORKEL1 (and so forth).
The last TORKEL
Measures only the current through itself and the TXLs.
1] Apply the clamp-on-probes as illustrated
above.
2] Set the desired total current (same value) on
both (all) TORKEL units As a result, the maximum regulation capabil­ity of all TORKEL units will be used. You do not need to pay any attention to the mes­sage reading “Cannot regulate” as long as it does not appear on TORKEL No. 1.
.
3] Set warning limits only on TORKEL No. 1.
4] Set the stop limits. The voltage and test
period (time) can be set on each individual TORKEL. Stopping after a certain capac­ity (Ah) is reached can only be activated on TORKEL No. 1.
Note Only TORKEL No. 1 is to control the TXLs.
Only TORKEL No. 1 is to be connected to the PC.
5] Set switch <F1> to the upper (ON) position
on the TXLs.
6] Then start the TORKEL that has the highest
number (when numbered as set forth above). Now start the TORKEL with the second highest number, then the third highest, etc. Finally, start TORKEL No. 1. Starting the TORKELs in this order prevents the current from being higher than desired at the beginning of the test.
Example with two TORKELs. The first TORKEL regulate the TXLs and the second TORKEL contributes in the total regulation.
Constant current, regular load connected
A current shunt can be used instead of the DC clamp-on current probe but this requires opening the current path and connecting the shunt in series.
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7 ALARM FUNCTION
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7 ALARM FUNCTION
Alarm function
7
7.1 Description
The TORKEL alarm function is provided by a buzzer and a relay connected to the <ALARM> - connector. An external alarm device can be connected to this connector if desired.
Devices higher than Cat II must not be attached to the alarm connector.
Relay contact
8 A / 28 V DC
0.28 A / 250 V DC (resistive load only) 8 A / 240 V AC
Connector insulation
Voltage to ground must not exceed 250 V.
The following events can cause an alarm to be issued
▪ Warning level is passed.
▪ Discharging is stopped because a stop level is reached.
▪ TORKEL can not regulate the current to the desired level.
▪ Thermal protection device trips or a fan does not rotate as
expected.
▪ The connection to the battery is broken.
▪ Other fault situations such as battery voltage too high or
too low or excessive current through TORKEL.
Note TORKEL will safely interrupt the discharge and
issue an alarm if any of the internal tempera­tures should exceed the safe operating limits.
Resetting the alarm
1] You can reset the alarm by pressing the infor-
mation bar.
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8 HOW TO OBTAIN THE DESIRED CURRENT
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8 HOW TO OBTAIN THE DESIRED CURRENT
How to obtain the desired
8
current
8.1 When a single TORKEL isn’t enough
TORKEL regulates current by lowering its internal re­sistance as the voltage drops. However, the resistance elements built into TORKEL impose a limit beneath which further lowering is impossible.
You must make some simple calculations before starting
a test to find out whether or not TORKEL will be able to
provide the desired load current.
▪ You must also make certain that TORKEL will be able to
sustain this current until the test ends.
When a single TORKEL cannot provide the current you need, you can:
Connect one or more TXL Extra Loads to TORKEL.
▪ Connect two or more TORKELs in parallel.
▪ Connect two or more TORKELs and two or more TXL
Extra Loads into a single system.
When two or more TORKELs are connected into a sin­gle system, you will normally use the “External current measurement” function.
TXL connected to TORKEL
TXLs are resistive loads which are unable to provide any sort of regulation. Regulation is provided by TORKEL which measures the total current and keeps it constant. See the chapter headed “External cur­rent measurement” which shows how to connect the TXL(s) and TORKEL(s).
When TXL Extra Loads are connected to TORKEL, you must check:
That the current flowing through the TXLs when the test
is started is not higher than intended.
▪ That TORKEL has enough regulation capability a) to
compensate for the drop in current through the TXLs at
the end of the test and b) to set the current to the correct
value at the beginning of the test.
How many units are needed?
Manual calculation
1. Number of TXLs – Current flowing through TXL(s) at beginning of a test
At the beginning of the test, as high a percentage as possible of the current must flow through the TXLs, thereby providing the TORKEL(s) with as much reserve regulation capability as possible. However, the current through the TXLs must not, of course, exceed, the desired current value (A).
Tip
Remember that the internal resistances of the TXLs can be set manually. For accurate calcula­tion, add the cable resistance to the internal resistance.
▪ The current in an individual TXL can be obtained by dividing
the voltage at the beginning of the test by the internal resistance of the TXL in question (see tables below).
▪ Calculate the number of TXLs that you can connect
without exceeding the desired total current.
2. Current flowing through TXL(s) at final voltage
▪ Multiply the total current through the TXL(s) which you
obtained in step 1 above by the final voltage, and then divide by the voltage at the beginning of the test.
Automatic calculation - TorkelCalc
In TORKEL Viewer (not included with TORKEL 910) you can use TorkelCalc to figure out how many TORKEL and TXL are needed. See"4.2 TORKEL Viewer" on page 19.
34 TORKEL 900-SERIES ZP-CS01E CS033663DE
3. Number of TORKELs – for the current regulation
The TORKEL or TORKELs in the system must regulate the current to the desired value and compensate for the drop in current through the TXL(s) that occurs at the final voltage.
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8 HOW TO OBTAIN THE DESIRED CURRENT
▪ The amount of regulation needed can be obtained by
subtracting the current value (A) obtained in step 2 above from the desired current.
▪ Calculate the number of TORKELs required for the current
regulation.
4. Are all of the TXLs needed?
If the total load-providing capability of the TORKEL(s) exceeds the amount of regulation needed by a wide margin (as set fort in step 3 above), you can perhaps conduct the test with fewer TXLs. If this margin is wider than the current through one of the TXLs at the final voltage, this TXL is not needed.
Note Discharge is from 2.15 V to 1.8 V per cell
TORKEL 910
Systems TORKEL 910 and TXL 830 (Pos 2)
12 V battery (6 cells) Max constant current No. of TORKEL 910
144 A 1 1 221 A 1 2 298 A 1 3 376 A 1 4 443 A 2 4
24 V battery (12 cells) Max constant current(A) No. of TORKEL 910
264 A 1 1 419 A 1 2 574 A 1 3
Systems TORKEL 910 and TXL 850 (Pos 3)
48 V battery (24 cells) Max constant current
342 A 1 1 575 A 1 2
No. of TORKEL 910
Systems TORKEL 910 and TXL 870 (Pos 3)
110 V battery (54 cells) Max constant current
188 A 1 1 266 A 1 2 344 A 1 3 422 A 1 4 532 A 2 4
No. of TORKEL 910
Systems TORKEL 910 and TXL 870 (Pos 1)
220 V battery (108 cells) Max constant current No. of TORKEL 910
112 A 1 1 156 A 1 2 195 A 1 3 235 A 1 4 313 A 2 4
No. of TXL 830
No. of TXL 830
No. of TXL 850
No. of TXL 870
No. of TXL 870
TORKEL 930
Systems TORKEL 930 and TXL 830 (Pos 3)
12V battery (6 cells) Max constant current No. of TORKEL 930
183 A 1 1 299 A 1 2 414 A 1 3
24V battery (12 cells) Max constant current
384 A 1 1 615 A 1 2 846 A 1 3
No. of TORKEL 930 No. of TXL 830
No. of TXL 830
Systems TORKEL 930 and TXL 850 (Pos 3)
48 V battery (24 cells)
Max constant current
452 A 1 1 685 A 1 2 918 A 1 3 1151 A 1 4
No. of TORKEL 930 No. of TXL 850
Systems TORKEL 930 and TXL 870 (Pos 3)
110 V battery (54 cells) Max constant current
225 A 1 1 314 A 1 2 392 A 1 3 470 A 1 4 628 A 2 4
No. of TORKEL 930 No. of TXL 870
Systems TORKEL 930 and TXL 870 (Pos 1)
220 V battery (108 cells) Max constant current
112 A 1 1 156 A 1 2 195 A 1 3 235 A 1 4 313 A 2 4
No. of TORKEL 930 No. of TXL 870
TORKEL 950
Systems TORKEL 950 and TXL 890 (Pos 1)
480 V battery (240 cells) Max constant current
65 A 1 1 70 A 1 2 90 A 1 2 100 A 1 3 120 A 2 2
No. of TORKEL 950
No. of TXL 890
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9 OPTIONAL EQUIPMENT
Optional equipment
9
9.1 TXL830/850/865/870/890 (Extra Loads)
The TXL830, TXL850, TXL865, TXL870, and TXL890 Extra Loads comprise resistive loads. They can be used together with TORKEL Load Units to increase loading capability. The TXL Extra Loads can not provide regula­tion by themselves but TORKEL measures total current from the battery and regulates the load characteristic. When TORKEL is stopped it sends a stop signal to the TXL Extra Load.
TXL830 28 V
▪ TXL850 56 V
▪ TXL865 260 V
▪ TXL870 280 V
▪ TXL890 480 V
Panel
The panels for the TXL models differ somewhat but the functionality is the same.
1
1. Selector switch
Switch used to set the desired voltage range and/ or resistance value.
WARNING
Do not exceed maximum voltage.
2. Control
CONTROL IN
Input for control signal from TORKEL-unit. Gal­vanically isolated.
CONTROL OUT
Output used for the control signal sent from TORKEL to the adjacent TXL-unit. Galvanically isolated.
3. Circuit breaker
F1
Voltage-controlled circuit breaker that connects the resistors in the TXL Extra Load to the battery. Note F1 will not latch or remain at upper (ON) position unless the mains switch is turned on and a control signal from TORKEL is present at the “CONTROL IN” input..
WARNING The circuit breaker F1 is an important com­ponent in the safety system. If the tempera­ture will be too high and/or the cooling fans malfunction, the F1 will trip. It is important to never operate the unit if there is any dam­age or malfunction to the circuit breaker or if any damage or malfunction is suspected.
4. Mains inlet
MAINS
Connector used for mains supply, equipped with ON/OFF switch.
5. Connection terminals for the battery
2
3
4
5
36 TORKEL 900-SERIES ZP-CS01E CS033663DE
+ (Terminal)
Positive (+) current connection for battery or other DC source, being tested.
– (Terminal)
Negative (-) current connection for battery or other DC source, being tested. Insulation voltage to ground: 2200 V
Using the TXL
When an extra load is to be used, you must use the external current measurement function (see the chapter headed "6 External current measurement" on page 28).
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9 OPTIONAL EQUIPMENT
1] Set the range selector switch to the desired
position.
2] Connect as shown below.
3] Connect the control wires between the TXL
CTRL output on TORKEL and the CONTROL IN input on the TXL.
If two or more TXLs are to be used, provide a connection between the CONTROL OUT output on the first TXL and the CONTROL IN input on the second TXL, etc.
4] Connect the TXL to the mains voltage
5] Switch on the TXL.
Testing
WARNING
See the chapter "2.2 Safety instructions" on page 8. for safety precautions.
1] Proceed in the same way as set forth in the
chapter headed "5.1 Preparations for test­ing" on page 20 but before you start TORKEL you must set switch F1 to upper (ON) position on the TXL. (You must do this manu­ally.)
2] Start TORKEL by pressing
3] When TORKEL is stopped, manually or by any
stop condition, the TXL will also shut off the discharge current.
9.2 BVM - Battery Voltage Monitor
The BVM (Battery Voltage Monitor) is a battery volt­age measurement device that is used for monitoring of cell voltages and battery blocks in battery banks commonly found in electrical power sub-stations, tel­ecom facilities and computer data center UPS systems. In conjunction the TORKEL unit, and test data man­agement software, such as PowerDB or TORKEL Win, the BVM enables a completely automated battery bank capacity test to be performed.
BVM is available in three kits:
BVM150 with 16 BVM units
▪ BVM300 with 31 BVM units
▪ BVM600 with 61 BVM units
1
2
3
1. Control cable – Output socket
2. Control cable – Input socket
3. Battery sense – Dolphin clip
The BVM is designed in modular form where one BVM device is used for each battery or “jar” in the string to be tested. It measures the voltage for each battery cell and each unit can handle up to 20 V. The BVMs connects to the batteries in a “daisy-chain” fashion, thereby providing easy and economical expandability to meet the testing requirements for small-to-large battery bank systems. Up to 240 BVMs can be daisy­chained in a single battery bank under test.
The included dolphin-style battery clamp can be easily removed and exchanged with different styles of stand­ard banana plug clamps and/or extension cables to accommodate any battery connection requirement.
There is an Activity LED on the BVM that flashes when­ever an individual BVM transmits data back to the data acquisition host computer. This LED activity is useful for indicating that the device is functioning properly.
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9 OPTIONAL EQUIPMENT
The other parts of the BVM system: AC Adapter, Power and Signal Connector and cables.
Power & signal connector unit
The BVM units require external 24 DC power and RS­485 data communications for operation. These func­tions are provided by a combination of an external DC power supply and a Power & signal connector unit”. The Power & signal connector conversion is performed within a single moulded plug that connects directly to the laptop computer or other data acquisition device. The Power & signal connector has an RJ-45 connector that provides a connection to the first BVM unit in the chain, and this connection provides RS-485 data and power to all BVM units in the BVM string.
Test with BVM and TORKEL
WARNING
See the chapter "Safety" for safety pre­cautions.
1] Connect the BVM units as shown in the con-
nection diagram, see below. Each BVM is identical and can be connected in any battery test position. Up to 120 BVMs can be daisy-chained in a single battery bank under test. If you need more than 120 BVMs they must be connected in two loops, see connection diagram on next page.
Note The BVM units must be connected following
the battery cell sequence order. The BVM connected to the “To 1:st BVM unit” port of the Power and Signal connector must be con­nected to the most Negative pole of the bat­tery. The red dolphin clip shall be connected to the most Positive pole of the battery. The connection is the same regardless of the cell numbering selected in TORKEL. If more than 61 BVM units are connected an extra cable is needed. See the connection diagrams.
Fig.9.1 The BVM units must be connected following the battery cell sequence order. The red dolphin clip shall be connected to the most Positive pole of the battery.
38 TORKEL 900-SERIES ZP-CS01E CS033663DE
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9 OPTIONAL EQUIPMENT
Fig.9.2 When the battery bank exceeds 120 cells, this connection with 2 BVM loops shall be used. Connect the first loop to the BVM1 connector on TORKEL and the second loop to the BVM2 connector on TORKEL.
Fig.9.3 The connection shown above must be used when the battery bank voltage is between 300 V and 500 V. It includes two opto couplers and two ungrounded power supplies.
Warning
A BVM control cable must never be connected directly to a computer network inlet. When battery string voltage is over 300 V an opto coupler must be used, see Fig. 9.3.
4] Start TORKEL 900
The BVM “Auto Discovery” feature enables the host device to automatically determine the number of bat­teries under test and provide sequential identification of each BVM in the test string.
2] A. Battery string voltage max 300 V
Connect the cable from "Power & signal connector" to BVM1 / BVM2 terminals on TORKEL 900.
B. Battery string voltage max 500 V
Connect the cable from "Power & signal con­nector" to Opto Coupler (UH401-2kV).
3] A. Battery string voltage max 300 V
Connect to a grounded Power Supply B. Battery string voltage max 500 V Connect to a ungrounded Power Supply
Warning
Do not use any other Power Supply than the original delivered together with BVM.
Note The cell numbering can be done from minus
to plus or reversed and shall correspond to the setting in TORKEL. The red BVM conected to plus is not included in the numbering. When “Cell number from plus” is selected in TORKEL settings, the most positive cell is Cell 1, when this setting is not selected, then the most negative cell is Cell 1.
The initialization time for the BVMs depends on how many BVMs are connected. E.g. with 2 loops and 240 BVMs, it is about 3 to 4 minutes. With 1 loop and 12 BVMs, some seconds.
The connected cells are shown under tab “CELLS”.
CS033663DE ZP-CS01E TORKEL 900-SERIES
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9 OPTIONAL EQUIPMENT
Loose BVM unit detection
If BVM unit 1 comes loose during test, the first bar in the bar graph indicates and a beep sounds.
If the BVM unit between 2 and 3 cell becomes loose, the staple bars for cell 2 and 3 indicates.
If the last BVM unit is loose, the last staple in the sta­ple bar diagram indicates.
Test with BVM – without TORKEL
BVM can handle battery voltage upp to 600 V, but then without TORKEL 900. With this connection, only the voltage can be monitored.
Fig.9.4 The connection is made the same as in example above (Fig9.3) but without TORKEL 900.
Optional BVM equipment
BVM Cal Kit
Calibration system for BVM units. Instructions for calibration included with the
BVM Ca Kit.
Extension cables
The BVM cables (USB) may be extended 2 x 5 m with an Opto Coupler (e.g. B&B UH401 2 kV) in between.
Cable 5 m
Note "Active" USB cables does not work.
40 TORKEL 900-SERIES ZP-CS01E CS033663DE
Cable 5 m
Page 41
10 TROUBLESHOOTING
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41
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10 TROUBLESHOOTING
Troubleshooting
10
Problem Cause Remedy
BVM connected to TORKEL
BVM does not get initialized
Problem with the connection to BVM port
Check/verify BVM connector on TORKEL
Check cables, BVM units and Power supply to the BVM units.
Communication lost with BVM units
External measurement with current clamp
No readings Clamp ratio not set
Faulty readings Zero adjustment not done zero adjust
Impossible to switch on the circuit breaker F1 on the TXL unit
Control cable from TORKEL to TXL not connected properly
No voltage measurement in TORKEL
Torkel fans revs up
Cable/power fault
Emergency Stop button pressed Release emergency stop button
Fans blocked Remove blocking objects from fan
Check/replace the Power & Signal con­verter.
If more than 60 BVM units connected, extra cable needed. See the connection diagram.
Set ratio in “Configuration” “Settings
Turn on CT
Check battery/power supply
Check battery connectors
42 TORKEL 900-SERIES ZP-CS01E CS033663DE
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11 CALIBRATION
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11 CALIBRATION
Calibration
11
11.1 General
By using the internal calibration program TORKEL will be calibrated on internal/external current and internal/ external voltage. However, external instruments must be used.
Stable voltage power supply (vary less than 1% per second) with capability up to 200 V DC.
▪ Current source (vary less than 1% per second) supplying
upp to 100 A DC at a voltage between 10 and 30 V DC, e.g. a 12 V car battery can be used.
▪ Accurate reference instrument, e.g. HP 34401A, must be
used.
▪ A current shunt with accuracy class 0.1% for connection
in series with the current source.
11.2 How to calibrate
1] Switch on TORKEL. 2] Press button to enter the configura-
tion menu.
3] Press “Calibration” tab.
4] Press “Start” and follow on-screen instruc-
tions.
WARNING
Follow the instructions carefully. Battery connectors may have dangerous voltage
Note You can press “Skip” to continue to the next
calibration step. No value will be added. Press “Previous” to redo a calibration point.
5] Press "Store" to save the calibration values.
Note If the “Skip” button is pressed the calibration
values will not be saved.
6] Connect an USB stick to save a copy of the
calibration report that can be opened with Excel.
7] Press "Stop" to stop the calibration and leave
the calibration routine. The fans will start and run for about 10 sec­onds.
44 TORKEL 900-SERIES ZP-CS01E CS033663DE
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12 SPECIFICATIONS
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12 SPECIFICATIONS
Specifications
12
SPECIFICATIONS TORKEL 900-series
Specifications are valid at nominal input voltage and an ambient temperature of +25°C, (77° F). Specifications are subject to change without notice.
Environment
Application field The instrument is intended for use in high-
Temperature
Operating 0°C to +50°C (32°F to +122°F)
Storage & transport -40°C to +70°C (-40°F to +158°F)
Humidity 5% – 95% RH, non-condensing
Shock/Vibration/Fall
Instrument only ETSI EN 300 019-2-7 class 7M2 Instrument in
transport case
Altitude
Operating 3000 m (10000 ft) Storage 10000 m (33000 ft)
Encapsulation class IP20
CE-marking
LVD IEC61010 -1:2010 & IEC61010-2-030 EMC IE C61326 -1
General
Mains voltage 100 – 240 V AC, 50 / 60 Hz Power consumption 200 W (max) Power interruption 40 ms (max) Protection Thermal cut-outs, Automatic overload pro-
Dimensions 519 x 315 x 375 m m, (20.5” x 12.4” x 14.7”) Weight 19.5 kg (43.0 lbs) instrument
Display 7" LCD, Capacitive touch screen Available languages
Measurement section
Current measurement
Display range 0.0 to 2999.0 A Basic inaccuracy ±(0.5% of reading +0.1 A) Resolution 0.1 A
Internal current measurement
Range
TORK EL 910 0 to 110 A TORKEL 930 / 950 0 to 220 A
Input for clamp-on probe
Range 0 to 1000 mV DC mV/A-ratio 0.30 mV/A to 100.00 mV/A Input impedance >1 M Ω
voltage substations and industrial environ­ments.
Power derating at temperatures over +35°C (+95°F)
ISTA 2 A
tection, Emergency stop button
31.9 kg (70.3 lbs) incl. standard transport case 37 kg (82 lbs) incl. large transport case
English, French, German, Spanish, Swedish
Voltage measurement
Voltage 0 to 500 V DC Inaccuracy ±(0.5% of reading +0.1 V DC) Resolution 0.1 V Sample rate
Time measurement
Inaccuracy ±0.1% of reading ±1 digit
10 Hz, Values are saved when change is >10 mV
Load section
1)
Battery voltage
Power 15 kW (max) Load patterns Constant current, constant power, constant
Constant I
Range
TORK EL 910 0 to 110.0 A
TORKEL 930 / 950 0 to 220.0 A Inaccuracy ±(0.5% +0.2 A) Resolution 0.1 A Ripple max 0.5 A peak
Constant R
Range 300 m to 3 k Inaccuracy ±1% typical Resolution 100 m
Constant P
Range 0 to 15 kW Inaccuracy ±1% typical Resolution 10 W
7.5 V to 300 V
resistance, current or power profile
Inputs
1)
+
0 V
I EXT ≤ 1 V 1 V DC, 300 V DC to ground VOLTAGE SENSE Impedance to the current terminals is >1 M
7.5 to 300 V
.
2)
/ 500 V
7.5 to 500 V
2)
.
46 TORKEL 900-SERIES ZP-CS01E CS033663DE
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12 SPECIFICATIONS
Outputs
ALARM
Relay contact 28 V DC, 8 A, 240 V AC, 8 A
TXL STOP
Relay contact 250 V DC, 0.28 A, 28 V DC, 8 A, 250 V AC, 8 A
9 V DC 9 V DC, ±7% max 100 mA
Devices higher than Cat II must not be at­tached
Communication ports
BVM1 BVM2 USB connection for BVM units
USB connection for USB memory
SERVICE For service of the instrument
1) TORKEL 910 and 930
2) TORKEL 950
Specifications TXL 830 / 850 / 865 / 870 / 890
Specifications are valid at nominal input voltage and an ambient temperature of +25°C, (77°F). Specifications are subject to change without notice.
Environment
Application field The instrument is intended for use in high-
Temperature
Operating 0°C to +40°C (32°F to +104°F) Storage & transport - 40°C to +70°C (-40°F to +158°F)
Humidity 5% – 95% RH, non-condensing
CE-marking
EMC 2004/108/EC LVD 2006/95/EC
General
Mains voltage 100 – 240 V AC, 50 / 60 Hz Power consumption 75 W (max) Protection Thermal cut-outs, automatic overload
Dimensions
Instrument 210 x 353 x 600 mm (8.3” x 13.9” x 23.6”) Transport case 265 x 460 x 750 mm (10.4” x 18.1” x 29.5”)
Weight 13 kg (29 lbs) 21.4 kg (47 lbs) with trans-
Cable sets
for TXL83 0 / 850
for TXL8 65 / 870 / 890
voltage substations and industrial environ­ments.
protection
port case
2
2 x 3 m (9.8 ft), 70 mm male plug / clamp. Max. 100 V. 5 kg (11 lbs)
2 x 3 m (9.8 ft), 25 mm male plug / lug. Max. 480 V. 3 kg (6.6 lbs)
, 270 A, with fe-
2
, 110 A, with fe-
Load section
Voltage (DC) max. Current max. Power max. TXL830 28 V 300 A 8.3 kW TXL850 56 V 300 A 16.4 kW TXL865 260 V (98 A max) 117 A 25.5 kW TXL870 280 V (56 A max) 112 A 15. 8 kW TXL890 480 V (32 A max) 62 A 15.4 k W
Internal resistance, 3-position selector
Position 1 Position 2 Position 3
TXL830 0. 275 Ω 0.138 Ω 0.092 Ω TXL850 0.55 Ω 0.275 Ω 0.18 4 Ω TXL865 2.65 Ω 5.05 Ω 0.12 Ω TXL870 4.9 5 Ω 2.48 Ω 1.24 Ω TXL890 14 .10  7.05 Ω 3.52 Ω
Maximal currents, 3-position selector
Position 1
Current Voltage Cells Cell voltage
TXL830
28 V max
TXL850
56 V max
TXL865
260 V max
TXL870
280 V max
TXL890
480 V max
Position 2
TXL830
28 V max
TXL850
56 V max
TXL865
260 V max
TXL870
280 V max
TXL890
480 V max
Position 3
TXL830
28 V max
TXL850
56 V max
TXL865
14 V max
TXL870
140 V max
TXL890
250 V max
1) The data examples apply to lead batteries.
100 A 27.6 V 12 2.3 V
78.5 A 21.6 V 12 1.8 V 100 A 55.2 V 24 2.3 V
78.5 A 43.2 V 24 1.8 V
93.7 A 248.4 V 108 2.3 V
73.4 A 194 .4 V 108 1.8 V
50.1 A 248.4 V 108 2.3 V
39.2 A 194.4 V 108 1.8 V
32.3 A 469.2 V 204 2.3 V
26.0 A 3 6 7. 2 V 204 1.8 V
Current Voltage Cells Cell voltage
200 A 27.6 V 12 2.3 V 156 A 21.6 V 12 1.8 V 200 A 55.2 V 24 2.3 V 156 A 43.2 V 24 1.8 V
49.2 A 248.4 V 108 2.3 V
38.5 A 194.4 V 108 1.8 V
50.1 A 124. 2 V 54 2.3 V
39.2 A 97. 2 V 54 1.8 V
35.2 A 248.4 V 108 2.3 V
27. 8 A 194. 4 V 108 1.8 V
Current Voltage Cells Cell voltage
300 A 27. 6 V 12 2.3 V 235 A 21.6 V 12 1.8 V 300 A 55.2 V 24 2.3 V 235 A 43.2 V 24 1.8 V 115 A 13.8 V 6 2.3 V 90 A 10.8 V 6 1.8 V 100 A 124 . 2 V 54 2.3 V
74. 8 A 9 7. 2 V 54 1.8 V
70.5 A 248.4 V 108 2.3 V
55.2 A 19 4.4 V 108 1.8 V
1)
CS033663DE ZP-CS01E TORKEL 900-SERIES
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12 SPECIFICATIONS
Specifications BVM
Specifications are valid at an ambient temperature of +25°C, (77°F). Specifications are subject to change without notice.
Environment
Application field The instrument is intended for use in
Temperature
Operating 0°C to +50°C (32°F to +122°F) Storage & transport -20°C to +70°C (-4°F to +158°F)
Humidity 5% – 95% RH, non-condensing
CE-marking
LVD 2006/95/EC EMC 2004/108/EC
General
Power supply
Mains voltage 100 – 240 V AC, 50 / 60 Hz Power consumption 50 VA (max) Protection
Dimensions
BVM unit 75 x 64 x 25 mm (3” x 2.5” x 1”) Carrying case 575 x 470 x 205 mm (22.6” x 18.5” x 8.1”)
Weight
BVM unit 0.07 kg (0.15 lbs) With accessories
and carrying case
Measurement section
Maximum number of BVM
Voltage ranges
Resolution
Inaccuracy
Battery string voltage
Measurement input impedance
medium-voltage substations and industrial environments. Altitude <2000 m (6500 ft) above sea level.
Over voltage, reverse voltage, voltage transients, ESD
BVM system of 16 units 7 kg (15 lbs) BVM system of 31 units 8.8 kg (19 lbs) BVM system of 61 units 12.5 kg (27 lbs)
2 x 120
0-5 V DC and 0 -20 V DC
1 mV both ranges
< 0.1% of full scale ±0.01 V DC
300 V DC (max)
1 M
48 TORKEL 900-SERIES ZP-CS01E CS033663DE
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12 SPECIFICATIONS
CS033663DE ZP-CS01E TORKEL 900-SERIES
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Page 50
INDEX
Index
A
Alarm function................................................ 32
B
Battery Voltage Monitor ................................. 37
BVM ............................................................... 37
BVM Cal Kit ................................................... 40
C
Calibration ..................................................... 44
Clamp-on-probe............................................. 12
Conducting a test........................................... 20
Constant current ............................................ 21
Constant power ............................................. 22
Constant resistance ....................................... 23
Current cables ............................................... 20
Current, regulate............................................ 34
Current shunt ................................................. 28
D
Desired current .............................................. 34
E
EMERGENCY STOP ..................................... 10
Emergency stop button.................................. 21
Ending the test............................................... 21
Extension cables ........................................... 12
External current measurement ...................... 28
Extra Loads ................................................... 36
G
GRAPH .......................................................... 17
I
ID Labels ....................................................... 15
Introduction ...................................................... 6
L
License .......................................................... 16
Load prole .................................................... 24
Load-providing capability ............................... 35
O
Optional accessories ..................................... 12
Optional equipment ....................................... 36
P
Pausing the test ............................................. 21
Product description .......................................... 6
R
Regular load .................................................. 30
Regulate current ............................................ 34
Resetting the alarm ....................................... 32
S
Safety .............................................................. 8
Safety instructions ........................................... 8
Screen buttons .............................................. 14
Side panel...................................................... 11
Specications ................................................ 46
Starting the test ............................................. 21
Stop button .................................................... 21
Stop limit ........................................................ 15
Symbols on the instrumentI ............................. 8
T
Temperature compensation ........................... 15
Test at constant current ................................. 21
Test conguration .......................................... 15
TEST menu ................................................... 14
Test method ................................................... 14
Top panel ....................................................... 10
TORKEL Viewer ............................................ 19
TORKEL Win software...................................37
Troubleshooting ............................................. 42
TXL ................................................................ 36
TXL Extra Loads ............................................ 34
U
Upgrade License ........................................... 16
V
Voltage range ................................................20
W
M
Main menu ..................................................... 14
Menu system ................................................. 14
Multiple units.................................................. 29
50 TORKEL 900-SERIES ZP-CS01E CS033663DE
Warning limit .................................................. 15
Warranty .......................................................... 7
Warranty repair ................................................ 7
Z
Zoom ............................................................. 17
Page 51
Page 52
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Megger is certified according to ISO 9001 and 14001. Megger is a registered trademark.
Megger Group Limited UNITED KINGDOM Dover, Kent CT17 9EN ENGLAND
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Visiting address:
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seinfo@megger.com www.megger.com
Subject to change without notice. Printed matter No. ZP-CS01E Doc. CS033663DE V04a 2018
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