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
CS033663DEZP-CS01ETORKEL 900-SERIES
Visiting address:
Megger Sweden AB
Rinkebyvägen 19
SE-182 36 DANDERYD
SWEDEN
Index ....................................................... 50
CS033663DEZP-CS01ETORKEL 900-SERIES
5
Page 6
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
TORKEL910930950
Current (max)
Voltage (ma x)
BVM functionality
Charging measurement
Full report functionality
110 A220 A220 A
300 V300 V500 V
NoYesYes
NoYesYes
NoYesYes
6TORKEL 900-SERIESZP-CS01ECS033663DE
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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.
CS033663DEZP-CS01ETORKEL 900-SERIES
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Page 8
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.
8TORKEL 900-SERIESZP-CS01ECS033663DE
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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.
CS033663DEZP-CS01ETORKEL 900-SERIES
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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
1113
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.
10 TORKEL 900-SERIESZP-CS01ECS033663DE
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3 INSTRUMENT DESCRIPTION AND ACCESSORIES
3.2 Side panel
14
161817
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
CS033663DEZP-CS01ETORKEL 900-SERIES
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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)
12 TORKEL 900-SERIESZP-CS01ECS033663DE
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4 MENU SYSTEM
CS033663DEZP-CS01ETORKEL 900-SERIES
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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).
14 TORKEL 900-SERIESZP-CS01ECS033663DE
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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.
CS033663DEZP-CS01ETORKEL 900-SERIES
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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-SERIESZP-CS01ECS033663DE
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
Page 17
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]
CS033663DEZP-CS01ETORKEL 900-SERIES
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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
18 TORKEL 900-SERIESZP-CS01ECS033663DE
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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.
▪ 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.
CS033663DEZP-CS01ETORKEL 900-SERIES
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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.
20 TORKEL 900-SERIESZP-CS01ECS033663DE
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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
CS033663DEZP-CS01ETORKEL 900-SERIES
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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.
22 TORKEL 900-SERIESZP-CS01ECS033663DE
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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
CS033663DEZP-CS01ETORKEL 900-SERIES
23
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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.
24 TORKEL 900-SERIESZP-CS01ECS033663DE
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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 voltageThe voltage value prior the charger is
removed.
Open voltage The value prior start of discharge
test.
Start voltageThe value given after the first initial
decrease of the battery bank at a
start of a discharge test.
End voltageThe 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.
Ω.
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".
28 TORKEL 900-SERIESZP-CS01ECS033663DE
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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
TORKEL1 Measures the entire battery current.
TORKEL2 Measures all current except the current
through TORKEL1.
TORKEL3 Measures all current except the currents
through TORKEL2 and TORKEL1 (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.
30 TORKEL 900-SERIESZP-CS01ECS033663DE
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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.
32 TORKEL 900-SERIESZP-CS01ECS033663DE
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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-SERIESZP-CS01ECS033663DE
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 currentNo. of TORKEL 910
144 A11
221 A12
298 A13
376 A14
443 A24
24 V battery (12 cells)
Max constant current(A) No. of TORKEL 910
264 A11
419 A12
574 A13
Systems TORKEL 910 and TXL 850 (Pos 3)
48 V battery (24 cells)
Max constant current
342 A11
575 A12
No. of TORKEL 910
Systems TORKEL 910 and TXL 870 (Pos 3)
110 V battery (54 cells)
Max constant current
188 A11
266 A12
344 A13
422 A14
532 A24
No. of TORKEL 910
Systems TORKEL 910 and TXL 870 (Pos 1)
220 V battery (108 cells)
Max constant currentNo. of TORKEL 910
112 A11
156 A12
195 A13
235 A14
313 A24
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 currentNo. of TORKEL 930
183 A11
299 A12
414 A13
24V battery (12 cells)
Max constant current
384 A11
615 A12
846 A13
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 A11
685 A12
918 A13
1151 A14
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 A11
314 A12
392 A13
470 A14
628 A24
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 A11
156 A12
195 A13
235 A14
313 A24
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 A11
70 A12
90 A12
100 A13
120 A22
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-SERIESZP-CS01ECS033663DE
+ (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).
Page 37
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-SERIESZP-CS01ECS033663DE
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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”.
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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-SERIESZP-CS01ECS033663DE
Cable 5 m
Page 41
10 TROUBLESHOOTING
CS033663DEZP-CS01ETORKEL 900-SERIES
41
Page 42
10 TROUBLESHOOTING
Troubleshooting
10
Problem CauseRemedy
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 readingsClamp ratio not set
Faulty readingsZero adjustment not donezero adjust
Impossible to switch on the circuit breaker F1 on the TXL unit
Control cable from TORKEL to
TXL not connected properly
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-SERIESZP-CS01ECS033663DE
Page 43
11 CALIBRATION
CS033663DEZP-CS01ETORKEL 900-SERIES
43
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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-SERIESZP-CS01ECS033663DE
Page 45
12 SPECIFICATIONS
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45
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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 fieldThe instrument is intended for use in high-
Temperature
Operating0°C to +50°C (32°F to +122°F)
Storage & transport -40°C to +70°C (-40°F to +158°F)
Humidity5% – 95% RH, non-condensing
Shock/Vibration/Fall
Instrument onlyETSI EN 300 019-2-7 class 7M2
Instrument in
transport case
Altitude
Operating3000 m (10000 ft)
Storage10000 m (33000 ft)
Mains voltage100 – 240 V AC, 50 / 60 Hz
Power consumption 200 W (max)
Power interruption40 ms (max)
ProtectionThermal cut-outs, Automatic overload pro-
Dimensions519 x 315 x 375 m m, (20.5” x 12.4” x 14.7”)
Weight19.5 kg (43.0 lbs) instrument
Display7" LCD, Capacitive touch screen
Available languages
Measurement section
Current measurement
Display range0.0 to 2999.0 A
Basic inaccuracy±(0.5% of reading +0.1 A)
Resolution0.1 A
Internal current measurement
Range
TORK EL 9100 to 110 A
TORKEL 930 / 9500 to 220 A
Input for clamp-on probe
Range0 to 1000 mV DC
mV/A-ratio0.30 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
Voltage0 to 500 V DC
Inaccuracy±(0.5% of reading +0.1 V DC)
Resolution0.1 V
Sample rate
TORKEL 930 / 9500 to 220.0 A
Inaccuracy±(0.5% +0.2 A)
Resolution0.1 A
Ripplemax 0.5 A peak
Constant R
Range300 m to 3 k
Inaccuracy±1% typical
Resolution100 m
Constant P
Range0 to 15 kW
Inaccuracy±1% typical
Resolution10 W
7.5 V to 300 V
resistance, current or power profile
Inputs
1)
+
–0 V
I EXT ≤ 1 V1 V DC, 300 V DC to ground
VOLTAGE SENSEImpedance to the current terminals is >1 M
7.5 to 300 V
.
2)
/ 500 V
7.5 to 500 V
2)
.
46 TORKEL 900-SERIESZP-CS01ECS033663DE
Page 47
12 SPECIFICATIONS
Outputs
ALARM
Relay contact28 V DC, 8 A, 240 V AC, 8 A
TXL STOP
Relay contact250 V DC, 0.28 A, 28 V DC, 8 A, 250 V AC, 8 A
9 V DC9 V DC, ±7% max 100 mA
Devices higher than Cat II must not be attached
Communication ports
BVM1 BVM2USB 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 fieldThe instrument is intended for use in high-
Temperature
Operating0°C to +40°C (32°F to +104°F)
Storage & transport - 40°C to +70°C (-40°F to +158°F)
Humidity5% – 95% RH, non-condensing
CE-marking
EMC2004/108/EC
LVD2006/95/EC
General
Mains voltage100 – 240 V AC, 50 / 60 Hz
Power consumption75 W (max)
ProtectionThermal cut-outs, automatic overload
Dimensions
Instrument210 x 353 x 600 mm (8.3” x 13.9” x 23.6”)
Transport case265 x 460 x 750 mm (10.4” x 18.1” x 29.5”)
Weight13 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.
TXL83028 V300 A8.3 kW
TXL85056 V300 A16.4 kW
TXL865260 V (98 A max)117 A25.5 kW
TXL870280 V (56 A max)112 A15. 8 kW
TXL890480 V (32 A max)62 A15.4 k W
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