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User`s Manual

1. 37 TORKEL 820 840 860 Systems containing TORKEL 820 Systems containing and TXL850 TORKEL 840 860 and TXL870 48 V battery 24 cells 110 V battery 54 cells Discharge from 2 15 to 1 8 V cell Discharge from 2 15 to 1 8 V cell Maximum con Number of units Number of units Maximum con Number of units TORKEL Number of units stant current A TORKEL 820 TXL850 stant current A 840 860 TXL870 499 1 1 188 1 1 729 1 2 266 1 2 959 1 3 344 1 3 1189 1 4 422 1 4 1459 2 4 532 2 4 1688 2 5 610 2 5 1918 2 6 688 2 6 2148 2 7 766 2 7 2578 2 8 845 2 8 2608 2 9 925 2 9 2837 2 10 1001 2 10 Systems containing TORKEL 840 860 and TXL830 24 V battery 12 cells Discharge from 2 15 to 1 8 V cell Maximum con stant current A 263 Number of units TORKEL 840 860 Number of units TXL830 445 670 895 1005 1230 1455 WN WI WIM O2 PO FR UI IWIWIlMIRlIR Systems containing TORKEL 840 860 and TXL850 48 V battery 24 cells Discharge from 2 15 to 1 8 V cell Maximum con Number of units Number of units stant current A TORKEL 840 860 TXL850 264 1 1 449 2 1 679 2 2 909 2 3 1019 3 3 1249 3 4 1478 3 5 38 120 V battery 60 cells Discharge from 2 15 to 1 75 V cell Maximum con stant curre
2. General TORKEL can be used to conduct a test that incorpo rates a current profile or power profile A profile can consist of up to 19 time intervals The duration and the magnitude of the load can be specified for each interval Preparations To configure TORKEL for a profile test proceed as follows 1 2 3 Press lt ESC gt repeatedly until you see the MAIN MENU Select Test method using the vertical arrow keys Vv or 4 and press ENTER Select PROFILE I for a current profile or PRO FILE P for a power profile and press ENTER Programma Electric AB ZP BSO6E R101 TORKEL 820 840 860 Testing Starting the test 1 Select Test battery and press ENTER Proceed in the same way as set forth in the chapter Set Profile headed Conducting a test Yes No 2 Select Ves and press ENTER if you want to set up the profile No of Intervals 02 3 Specify the number of time intervals you want to include in the profile and press ENTER SET T1 0 00 01 001 0A 4 Set the duration of the first time interval and the current or power value Press ENTER 5 Setthe other intervals in the same way Programma Electric AB ZP BSO6E R101 19 TORKEL 820 840 860 General 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 ammeter optional accessory has to be
3. Message reading 000 000 0 R 135 T 123 F1 6 Change the displayed numbers to read as follows by using the vertical arrow keys or 4 111 111 1 R 135 T 123 F1 7 17 Press ENTER The fans will start 8 Message reading Calib internal I Input 085 00A 9 set switch F1 to its upper ON position 10 Change the current value on the display to the value read from the reference instrument 11 Press ENTER F1 will trip Programma Electric AB ZP BSOGE R101 TORKEL 820 840 860 Note fa message reading Error Unstable current appears press ENTER and try again This can be caused by excessively high current from the batteries Repeat the calibration at a lower current by chan ging the numbers in the message shown in step 6 to 11101010r111 100 1 Note fa message reading Error gt 15 appears calibration has been rejected because it deviates too much from a cal culated standardized value Press ESC to repeat the calibration or to select No for this main step of the calibration If you skipped one of the main steps in the calibration procedure internal current for example the calibration value for the skipped main step will be set to a calcula ted standardized value 3 Calibrating internal and external voltage 1 Message reading Calibrate V No 2 Change to Yes using the vertical arrow keys Y or 4 The voltage measurement range must be calibrat ed at two points hereina
4. A Then make sure that the total current does not exceed 2999 A Also make sure that the TORKEL and TXL units can provide the required current load troughout the test Configuring TORKEL for constant power 1 Calculate the current at the end of the test divide the power by the voltage 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 2 Press ESC repeatedly until you see the MAIN MENU 3 Select Test method using the vertical arrow keys V or 4 and press ENTER 4 Select Constant P and press ENTER 5 Select Test battery and press ENTER 6 Setthe discharge power in the same way that you set the current See the chapter 5 Conduct ing a test Constant resistance mC WARNING See the chapter Conducting a test for safety precautions and how to prepare the test Configuring TORKEL for constant resistance 1 Press lt ESC gt repeatedly until you see the MAIN MENU 2 Select Test method using the vertical arrow keys W or 4 and press ENTER 3 Select Constant R and press ENTER 4 Select Test battery and press ENTER 5 Setthe resistance value in the same way that you set the current value See the chapter headed Conducting a test Programma Electric AB ZP BSO6E R101 TORKEL 820 840 860 Programma Electric AB ZP BSO6E R101 17 TORKEL 820 840 860
5. 1 24 Q is 93 6 A If two TXLs are set to 1 24 O and one TXL is set to 2 48 O the current will be 234 A and they can be connected without having the current exceed 250 A 2 Current flowing through TXL s at final voltage 234Ax97 2V 116 1V2 196A 3 Number of TORKELs for the current regulation 250A 196 A 54 A A single TORKEL 840 is enough for this Programma Electric AB ZP BSOGE R101 TORKEL 820 840 860 4 Are all of the TXLs needed The loading capability of the TORKEL unit is 110 A at the final voltage This exceeds the amount needed by 110A 5A A 56 A This unused margin is perhaps wide enough to eliminate the need for one TXL At the end of the test the current through the TXL that is set to 2 48 Wis 97 2 V 2 48 39 A Since the unused TORKEL margin is wider than 39 A this TXL is not needed TORKEL TXL system exam ples Systems containing TORKEL 820 and TXL830 12 V battery 6 cells Discharge from 2 15 to 1 8 V cell Maximum con Number of units Number of units stant current A TORKEL 820 TXL830 234 1 1 346 1 2 459 1 3 571 1 4 695 2 4 806 2 5 918 2 6 1031 2 7 24 V battery 12 cells Discharge from 2 15 to 1 8 V cell Maximum con Number of units Number of units stant current A TORKEL 820 TXL830 495 1 1 720 1 2 945 1 1170 1 4 1440 2 4 1665 2 5 1890 2 6 2115 2 7 2340 2 8
6. 2 V 0 241A 0 4 63 kw 48 V battery 24 cells Programma Electric AB ZP BSOGE R101 35 TORKEL 820 840 860 When a single TORKEL isn t enough When a single TORKEL cannot provide the current you need you can e Connect one or more TXL Extra Loads to TORKEL Connect two or more TORKELs in parallel e 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 sin gle system you will normally use the External current measurement function But in situations where it is important for current to be regulated to the correct value within a second or so it is better to use two or more TORKEL units set for internal current measure ment and no TXL Extra Loads since these latter must be started manually To obtain the total current you must then add the current values amperages shown on all TORKEL units The TORKEL units can be started and stopped synchronously via the START STOP input TXL Extra Loads 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 cur rent measurement which shows how to connect the TXL s and TORKEL s When TXL Extra Loads are connected to TORKEL you must check e That the current flowing through the TXLs when the test is started is not higher th
7. General Mains voltage 100 240 V AC 50 60 Hz Power consumption 150W max Protection Thermal cut outs automatic over load protection Dimensions Instrument 210x 353 x 700 mm 8 3 x 13 9 x 27 6 Transport case 265 x 460 x 750 mm 10 4 x 18 1 x 29 5 Weight 21 5 kg 47 4 Ibs 38 kg 83 8 lbs with accessories and transport case Display LCD Programma Electric AB ZP BSOGE R101 Available languages English French German Spanish Swedish Measurement section Current measurement Display range 0 0 2999A Basic inaccuracy 0 5 of reading 40 2 A Resolution 0 1A Internal current measurement Range 0 300A Input for clamp on ammeter Range 0 1V mV A ratio Software settable 0 3 to 19 9 mV A Input impedance gt 1 MQ Voltage measurement Display range 0 0 60 V Basic inaccuracy 0 5 of reading 0 1 V Resolution 0 1 V Display range 0 0 500 V Basic inaccuracy 0 5 of reading 1 V Resolution 0 1 V Time measurement Basic inaccuracy 0 1 of reading 1 digit Storage of measured values Torkel stand alone Time max 10h Time interval 6s Torkel Win 51 TORKEL 820 840 860 Time max 24h Time interval 1 24s 48 V battery 24 cells Load section Max battery voltage 288 V DC TORKEL 840 480 V DC TORKEL 860
8. MO 250V AC 8A Voltage measurement 50 Outputs maximal values Programma Electric AB ZP BSO6E R101 TORKEL 820 840 860 E DITE Torkel 840 860 TXL Relay contact O r e SERIAL lt 15V ALARM Relay contact Specifications are valid at nominal input voltage and an ambient Discharging capacity examples 12 V battery 6 cells temperature of 25 C 77 F Specifications are subject to change without notice Environment Final voltage Constant current Constant power 1 80 V cell 10 8 V 0 121A 0 131kW Application field The instrument is intended for use in high voltage substations and indus 1 75 V cell 10 5 V 0 117A 0 1 23 kW trial environments 1 67 V cell 10 0 V 0 110 A 0 110 kw Temperature 24 V battery 12 cells Operating 0 C to 40 C 32 F to 104 F 1 80 V cell 21 6 V 0 270A 0 5 8 kW Storage amp trans 40 C to 70 C 40 F to 158 F 1 75 V cell 21 0 V 0 266A 0 5 59 kW port 1 60 V cell 19 2 V 0 241A 0 4 63 kW Humidity 596 9596 RH non condensing 48 V battery 24 cells CE marking 1 80 V cell 43 2 V 0 270A 0 11 6 kw LVD Low Voltage Directive 73 23 EEC 1 75 V cell 42 0 V 0 270A 0 11 3 kW am by 93 68 EEC 1 60 V cell 38 4 V 0 259A 0 9 9 kW EMC EMC Directive 89 336 EEC am by 91 263 EEC 92 31 EEC and 2 2 15 V per cell when test starts 93 68 EEC
9. ap pears on the clamp on ammeter itself Programma Electric AB ZP BSO6E R101 TORKEL 820 840 860 Programma Electric AB ZP BSO6E R101 23 TORKEL 820 840 860 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 so desired When an alarm is issued the relay closes the circuit between pin 2 and 3 While no alarm is issued the circuit between pin 1 and 3 is closed Male connector for this terminal is Neutrik NC3MX Relay contact 8A 28V 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 e Warning level is passed e Discharging is stopped because a stop level is reached e TORKEL can not regulate the current to the desired level e Thermal protection device trips or a fan has stopped rotating The connection to the battery is broken e The mains line power to TORKEL is inter rupted while a test is in progress e Other fault situations such as battery volt age too high or too low or excessive current through TORKEL 24 Note The alarm output will be activated if TORKEL is switched off and also if no mains voltage is present When TORKEL is switched on the alarm is reset auto matically provided that a test was not in progress when the mai
10. automatically selects the volt age range when voltage is applied to the high current terminals Setting the current 1 Use the horizontal arrow keys 4 or to select the position and the vertical arrow keys or 4 to set the value Set Current 0001 0 A 2 Press ENTER After connecting the battery about 30 seconds must elapse before you can switch on the circuit breaker F1 and start the test TORKEL displays the amount of time you must wait as follows Please wait 25 sec When the time shown has elapsed the following will appear Switch on F1 Press ENTER 3 Switch on F1 press the lever upwards a second time if it fails to latch immediately 4 Confirm by pressing ENTER TORKEL now displays the values currently in effect 51 6V 0 0 Ah 0 0A 0 00 00 Tip X You can change the current at any time by pressing the SET LOAD key Warning and stop limit pa rameters You can set TORKEL to issue a warning and or to stop e When the voltage has reached a certain level e When a certain amount of capacity is dis charged e After a specified time The settings for the warning and stop levels are inde pendent of each other When a limit is reached the contacts in the ALARM relay operate and a buzzer sounds In addition the lamp associated with the parameter on the control Programma Electric AB ZP BSOGE R101 TORKEL 820 840 860 panel flashes when the warning level is reached and starts to glow
11. for the drop in current through the TXL s that occurs at the final voltage A The amount of regulation needed can be obtained by subtracting the current value A obtained in step 2 above from the desired current B 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 Programma Electric AB ZP BSO6E R101 TXL830 Max Possible resistance Position voltage settings nominal 28V 0 275 Q 1 0 138 Q 2 0 092 Q 3 TXL850 56 V 0 550 Q 1 0 278 Q 2 0 184 Q 3 TXL870 140 V 24800 2 1 240 Q 3 280V 4 950 Q 1 Example A lead acid battery with 54 cells has to be tested at 250 A Voltage at the beginning of the test Vstart is 116 1 V 54 x 2 15 V Voltage at end of the test Vend is 97 2 V 54 x 1 80 V Since the current is so high you must use TXLs A TXL870 is suitable since it is rated for the voltage in question 1 Number of TXLs Current flowing through TXL s at beginning of a test The current through a TXL870 set for a resistance of 2 48 O is 46 8 A and current through a TXL870 with a resistance of
12. in the table above the internal TORKEL resistance will limit the current so that it will be impos sible to reach Imax column 2 in the table above In such case you can calculate the current that will be obtained at the final voltage as follows 1 Add the TORKEL internal resistance column 3 to the cable resistance which is 1 5 mQ for TORKEL 820 and 4 MQ for TORKEL 840 860 if you are using standard cables 2 Subtract 2 2 V from the final voltage and di vide by the resistance you obtained in step one above Example The final voltage is 10 8 V and you want to find the maximum possible current at this voltage if you are using a TORKEL 840 and the voltage range is 10 27 6 V Calculate the resistance as follows 0 165 Q 0 004 Q2 0 169 O Calculate the maximum current as follows 10 8V 2 2V 0 1690 50 9 A Examples of load capacities TORKEL 820 840 860 1 80 V cell 43 2 V 0 270A 0 11 6 kW 1 75 V cell 42 0 V 0 270A 0 11 3kW 1 60 V cell 38 4 V 0 259A 0 9 9 kW 1 2 15 V per cell when test starts TORKEL 840 860 12 V battery 6 cells Final voltage Constant cur Constant rent power 1 80 V cell 10 8 V 0 50 0A 0 0 54 kW 1 75 V cell 10 5 V 0 49 0A 0 0 51 kW 67 V cell 10 0 V 0 46 0A 0 0 46 kw 24 V battery 12 cells 80 V cell 21 6 V 0 110A 0 2 37 kW 1 75 V cell 21 0 V 0 11
13. load profile 18 General c ecran t to ere eaten 18 PROD ARAM ONS ouest laid matte 18 TESTING E 19 Starting the AES cnsa ducere tori cir 19 8 External current measurement 20 Eau EE A 20 Applications srl 20 Setting up external current measurement 21 TORK E iier ie 21 DC clamp on ammeter 21 CONNECHONS cai 22 TRubleshooting a scri 22 9 Alarm function 24 DGSCEIDIIOP iii 24 Resetting the alarm ner 24 10 Auto limits ceto re e eet 26 Invoking the auto limits function 26 Activating auto limits ssssssusse 26 11 TORKEL connected to a PC 28 Genetica iaia 28 TORKEL WIN program sssrin 28 TORKEL Win features 28 Installing TORKELWIM scis dci s 29 gis PENA ERN E 29 Setting up communication 29 Loading the software key 29 Changing the language used in TORKEL 30 Testing with TORKEL Win 30 Viewing the results nea 30 12 Starting and stopping from an external OWN CS Mee cerca 32 Start Stop CORMECION pria 32 OC PERE RE E 32 StOPPINO aes 32 13 How to obtain the desired current 34 Generals araea aio 34 TORKEL load Capatlty secet sn ote 34 IM 34 MIK PONGE rinti iaia 35 Final VOllaOe iota eei tricot actis otis 35 Examples of load capacities 3b When a single TORKEL isn
14. memory after a message reading Checksum error has appeared Resetting TORKEL can never be fully equivalent with regular calibration carried out using accurate and traceable reference instruments However it provides you with a quick and simple way to deal with a situa tion in which no calibration values at all are available The result of the reset procedure is about 1 to 396 accurate except for the external current measurement where the accuracy will be poorer Resetting must always be followed by calibration of the zero levels which is a part of the regular calibration procedure A complete calibration procedure should be conducted as soon as possible however It is possible to combine resetting and calibration First perform a reset and then calibrate the measurement ranges for which required sources are available An swer No for the ranges that cannot be calibrated Standard calibration values will then be used for these ranges Note When a reset is performed on TORKEL the settings will be changed to the factory default settings Performing a reset 1 Press the lt ESC gt key and the arrow up 4 key simultaneously while switching on TORKEL 2 Press ENTER to confirm the reset as promted on the display Programma Electric AB ZP BSO6E R101 49 TORKEL 820 840 860 Torkel 820 Display range 0 0 60V Basic inaccuracy 0 5 of reading 40 1 V Resolution 01V Specifications are valid
15. must 1 Connectthe battery to TORKEL 2 Setthe current 3 Wait for message reading Switch on F1 4 Push the lever of F1 to the ON posi tion a second time if it does not latch directly Voltage reading on the display is lower than the battery voltage You responded to the Switch on F1 message by pressing ENTER without switching on F1 You have accidentally switched off F1 manually TXL connected to TORKEL When a TXL and TORKEL are connected via the signal cable connected to the Control In input the following can hap pen Impossible to switch on the circuit breaker F1 on the TXL unit You have not received the message Switch on F1 on TORKEL You have not connected the input CONTROL IN prop erly to TORKEL The TXL have no mains power If the fans are not running check the mains connection and the mains Switch Messages on display Connect battery does not disappear e Check connection to the battery e Check the polarity of the connec tion to the battery 44 e When you first connect a higher voltage to TORKEL and then a lower voltage you may have to wait for some time Error Connection TORKEL has indicated that the battery voltage has disappeared e Check the connection to the bat tery CHECK F1 This message appears if the current is 0 A when cur rent should be flowing e Check that circuit breaker F1 is switched on CHECK F1 Input voltage e Check that circui
16. steadily if TORKEL is stopped See also the chapter headed Alarm function Limits set up 1 Press LIMITS Warning Umin No 044 4 V 2 Use the horizontal arrow keys or to move the cursor and the vertical arrow keys Y or 4 to activate the warning Yes and to set the volt age level 3 Press ENTER 4 Proceed in the same way for other parameters you want to change 5 Press LIMITS when you have finished setting the parameters The limits can be changed at any time during a test Starting the test 1 Press START The current value A will be displayed and the OPERATING lamp will light up Pausing the test 1 Press STOP 2 Restart by pressing START Note Any TXL Extra Loads connected to TORKEL must be restarted manually Ending the test 1 Press the STOP key 2 Press lt ESC gt End Test Yes No 3 select Yes and press ENTER TORKEL 820 840 860 Constant power TORKEL can be used to conduct a discharge test at constant power instead of constant current All proce dures are the same except that you must set TORKEL differently before starting you set the power instead of the current mmm ES NEM AA ee Warning See the chapter Conducting a test for safety precautions and how to prepare the test Important When testing at constant power the cur rent will increase as the voltage decreases Calculate the current at the end of the test W V
17. used for this measurement It can be applied at one of the battery terminals or at an inter cell connec tor The clamp on ammeter 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 conected to the negative side of the battery Warning External current shunt may not be used above 300 V DC Important The current shunt 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 20 Applications e External current measurement must be used when TORKEL is working together with TXL Extra 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 Cc TORKEL TORKEL used together with TXL Extra Load TORKEL To regular load Constant current regular load connected e Two or more TORKEL and TXL units ca be used for discharging at up to 2 999 A Programma Electric AB ZP BSO6E R101 TORKEL 1 C CA TORKEL TORKEL Two TORKEL uni
18. 0 2 31 kW 1 60 V cell 19 2 V 0 100A 0 1 92 kw 52 Programma Electric AB ZP BSO6E R101 TORKEL 820 840 860 TXL 830 850 870 GL E 24x 2 3 V 235A at21 6V 43 2 A Specifications are valid at nominal input voltage and an ambient 24 x 1 8 V temperature of 25 C 77 F Specifications are subject to change 100A at 124 2 V without notice 54 x 2 3 V Environment 78 4A at 97 2 V 54 x 1 8 V Application field The instrument is intended for use in high voltage substations and indus trial environments Temperature Operating 0 C to 40 C 32 F to 104 F Storage amp transport 40 C to 70 C 40 F to 158 F Humidity 5 95 RH non condensing CE marking LVD Low Voltage Directive 73 23 EEC am by 93 68 EEC EMC EMC Directive 89 336 EEC am by 91 263 EEC 92 31 EEC and 93 68 EEC General Mains voltage 100 240 V AC 50 60 Hz Power consumption 75W max Protection Thermal cut outs automatic over load protection Dimensions Instrument 210x 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 28 7 Ibs 21 4 kg 47 2 Ibs with transport case Cable sets for TXL830 850 2x3 m 9 8 ft 70 mm2 270 A with cable lug Max 100 V 5 kg 11 Ibs for TXL870 2x3m 9 8 ft 25 mm2 110 A with cable clamp lug
19. 0 55A 0 11 9kW 1 75 V cell 210 V 0 55A 0 11 5 kW 1 60 V cell 192 V 0 55A 0 10 5 kW UPS battery 180 cells TORKEL 860 1 70 V cell 306 V 0 38A 0 15 kW 1 60 V cell 288 V 0 38A 0 15 kW UPS battery 204 cells TORKEL 860 1 80 V cell 367 V 0 34A 0 15 kW 1 60 V cell 326 V 0 34A 0 15kW 3 2 15 V per cell when test starts 1 Maximum value for a system with more than one load unit 2 TORKEL 860 Inputs maximal values EXTERNAL CURRENT 1 V DC 300 V DC to ground Cur MEASUREMENT rent shunt should be connected to the negative side of the battery START STOP Closing opening contact Closing and then opening the contact will start stop Torkel It is not possible to keep the contacts in closed position Min time open is 25 ms Delay until start 200 300 ms Stop delay 100 200 ms Battery 480 V DC 500 V DC to ground VOLTAGE SENSE 480 V DC 500 V DC to ground SERIAL 15V ALARM 250 V DC 0 28 A 28VDC8A 250VAC8A Outputs maximal values START STOP 5V 6 mA TXL Relay contact SERIAL lt 15V ALARM Relay contact Discharging capacity examples 12 V battery 6 cells Final voltage Constant cur Constant rent power 1 80 V cell 10 8 V 0 50 0A 0 0 54 kw 1 75 V cell 10 5 V 0 49 0A 0 0 51 kw 1 67 V cell 10 0 V 0 46 0A 0 0 46 kw 24 V battery 12 cells 1 80 V cell 21 6 V 0 110A 0 2 37 kW 1 75 V cell 21 0 V 0 110A
20. 0A 0 2 31 kW 1 60 V cell 19 2 V 0 100A 0 1 92 kW 48 V battery 24 cells 80 V cell 43 2 V 0 110A 0 4 75 kW 75 V cell 42 0 V 0 110A 0 4 62 kw 1 60 V cell 38 4 V 0 110A 0 4 22 kW 110 V battery 54 cells 1 80 V cell 97 2 V 0 110A 0 10 7 kW 75 V cell 94 5 V 0 110A 0 10 4 kW 1 60 V cell 86 4 V 0 110A 0 9 5 kW 120 V battery 60 cells 1 80 V cell 108 V 0 110A 0 11 9 kW 75 V cell 105 V 0 110A 0 11 5 kW 60 V cell 96 V 0 110A 0 10 5 kW 220 V battery 108 cells 1 80 V cell 194 V 0 55A 0 10 7 kW 1 75 V cell 189 V 0 55A 0 10 4 kW 60 V cell 173 V 0 51 0A 0 8 82 kw 240 V battery 120 cells 80 V cell 216 V 0 55A 0 11 9 kW 1 75 V cell 210 V 0 55A 0 11 5 kW 1 60 V cell 192 V 0 55A 0 10 5 kW 2 15 V per cell when test starts TORKEL 860 UPS battery 180 cells TORKEL 860 TORKEL 820 1 70 V cell 306 V 0 38A 0 15 kW 1 60 V cell 288 V 0 38A 0 15 kW 12 V battery 6 cells UPS battery 204 cells TORKEL 860 Final voltage Constant current Constant power 1 80 V cell 367 V 0 34A 0 15 kW 1 80 V cell 10 8 V 0 121A 0 1 31 kw 1 60 V cell 326 V 0 34A 0 15kW 1 75 V cell 10 5 V 0 117A 0 1 23 kW 1 2 15 V per cell when test starts 1 67 V cell 10 0 V 0 110A 0 1 10 kw 24 V battery 12 cells 1 80 V cell 21 6 V 0 270A 0 5 8 kW 1 75 V cell 21 0 V 0 266A 0 5 59 kW 1 60 V cell 19
21. 14 CONSTANT POW T ceesre 16 Constant resistance 16 Current regulate c es eite rre ote eens 36 Current CADIOS ocean cendres oett totem 14 Current liMitationi eee ian 36 CUfrenit Suh ierit Ia 22 D DC Clamp on Ammbeter aristus 23 Desired current si rana 36 po mm 12 E Endingthie test iD tee a 15 Error Extetrialll tes etes ter ette to eicere 47 Externalconttol i sete ertet etes 13 External current measurement sees 12 Extra OaS zd eese tee dete etes 42 54 F aj m M acarte 13 I Installing TORKEL Win 31 K Mic H 12 L WAM DS xe in ie sciet teen tee et Ps ep cocer biases At aay URN 12 IF fe UTE To T E 32 Load providing capability an 38 Load capacities teret nde det 37 Load Profile sss E 18 M DETROIT 10 MEMORY regattan Ae 10 N New language into TORKEL 31 O Operator COnltrol i seine 12 OVerCUFTeEL uec onem anandia 47 Overheated M c 47 P Pausing the test Rer tears 15 uo 30 Power falute opel 47 R Regulate current renar rer n rar rann 36 Regulation time 22 38 Resetting the alarm 26 Resetting TORKEL eintritt seite 51 Merc E 10 S Select language rn rna na 10 Programma Electric AB ZP BSO6E R101 SERA cre 13 ree EET 13 Setting the CUrrent rn rer annen nan 15 Setting up communication eiie
22. Display with at least 640 x 480 pixels e Windows 95 98 2000 NT XP e An unoccupied serial port Installation 1 Insert the program diskette or the CD 2 Click Start and then Run 3 Type ANTORKEL Win Setup or the drive for CD e g DA TORKEL Win Setup 4 Follow the installation wizard instructions which guide you through the installation procedure Setting up communication 1 Connectthe serial port on TORKEL to the serial port on the PC using a straight pin to pin cable 2 Start the TORKEL Win program 3 select the desired communication port Direct to COM1 for example when TORKEL Win asks for device selection 4 Switch on TORKEL 5 Wait until TORKEL Win indicates Online This appears under Status in the window Loading the software key Note fyou purchase a TORKEL together with TORKEL Win the software key is already loaded If you do not have a diskette drive contact GE Energy Programma for delivery of the software key 1 Proceed as stated in the section headed Setting up communication 29 TORKEL 820 840 860 2 Select File and click Load Software key Put the program diskette into the PC and instruct TORKEL Win to open the file with extension key on the diskette Changing the language used in TORKEL You can replace one of the languages in TORKEL with the contents in the language file 1 Proceed as set forth in the section headed Setting up communication 2 Sel
23. Max 480 V 3 kg 6 6 lbs Load section TXL830 TXL850 TXL870 Max voltage DC 28V 56V 140 V 280 V Max current 300A 300A 112Aat 140 V 56 A at 280 V Max power 8 3 kw 16 4 kW 15 8 kW Internal resistance 3 position selector Position 1 TXL830 TXL850 TXL870 Current 0 2750 0 55 0 4 950 100A at 27 6 V at 55 2 V 12x2 3V 24x2 3V 78 5 A at 21 6 V at 43 2 V 12x1 8V 24x1 8V 50 1A at 248 4 V 108 x 2 3 V 39 2A at 194 4 V 108 x 1 8 V Position 2 TXL830 TXL850 TXL870 Current 0 1380 0 2 5 2 480 200A at 27 6 V at 55 2 V 24 x 2 3 V 156 A at 21 6 V 43 2V 24 x 1 8 V Position 3 TXL830 TXL850 TXL870 Current 0 092 Q 0 1840 1 240 Programma Electric AB ZP BSOGE R101 53 TORKEL 820 840 860 A Aldair 13 ATTI LOT casses acce a 23 A to lirnits acie serie Aia 10 B sf i assi nu n o REIR m 10 C Cable 44 Calculating current arr r rn na 36 Calibrating internal and external voltage 49 Calibrating internal current 49 Calibrating of external current 50 Calibrating zero levels annen rann 48 Changing language in TORKEL 32 Changing the language used in TORKEL 32 Checksum error aeiiaaie iniaa ea 51 Checksurnderrorl i et ect aia 47 Circuit breaker 13 Clamp on Ammeter rer rnnrrnnnr rann 23 Connection to a PC 30 CONSTANT CUT F s ccc ae peteret piece tnb ett trus
24. Max current 110A Max power 15 kW Load patterns Constant current constant power constant resistance current or power profile Current setting 0 110 0 A 2999 9 A Power setting 0 15 00 kW 299 99 kW Resistance setting 0 1 2999 8 Q Battery voltage range TORKEL 840 4 ranges selected automatically at start of test Battery voltage range TORKEL 860 5 ranges selected automatically at start of test Stabilization For internal current meas 0 5 of reading 0 5 A urement Battery volt Highest permis Resistor ele age sible current ment Nomi nal values Range1 10 27 6V 110A 0 165 0 Range2 10 55 2V 110A 0 2750 Range3 10 144V 110A 0 550 Range4 10 288V 55A 3 30 Range 10 480 V 55 A max power 3 30 5 15 kW 1 80 V cell 43 2 V 0 110A 0 4 75 kW 1 75 V cell 42 0 V 0 110A 0 4 62 kW 1 60 V cell 38 4 V 0 110A 0 4 22 KW 110 V battery 54 cells 1 80 V cell 97 2 V 0 110A 0 10 7 kw 1 75 V cell 94 5 V 0 110A 0 10 4 kW 1 60 V cell 86 4 V 0 110A 0 9 5 kW 120 V battery 60 cells 1 80 V cell 108 V 0 110A 0 11 9 kW 1 75 V cell 105 V 0 110A 0 11 5 kW 1 60 V cell 96 V 0 110A 0 10 5 kW 220 V battery 108 cells 1 80 V cell 194 V 0 55A 0 10 7 kw 1 75 V cell 189 V 0 55A 0 10 4 kW 1 60 V cell 173 V 0 51 0A 0 8 82 kW 240 V battery 120 cells 1 80 V cell 216 V
25. R to leave the sub menu Programma Electric AB ZP BSO6E R101 TORKEL 820 840 860 Programma Electric AB ZP BSO6E R101 31 TORKEL 820 840 860 Start stop connector Discharging can be started and stopped from external equipment via the connector named START STOP din YZ Male connector for this terminal is Neutrik NC3MX The start stop circuits are galvanically isolated from other circuits in TORKEL Two or more TORKEL units can be started simultane ously since the START STOP connectors can be con nected in parallel and triggered by a single contact Starting 1 Connect a dry contact to pin 2 and pin 3 in the connector Closing and then opening the contact will cause TORKEL to start the discharge 5 Vis supplied for the dry contact and the current is limited internally to about 5 mA Stopping 1 Connect a dry contact to pin 1 and pin 3 in the connector Closing and then opening the contact will cause TORKEL to stop the discharge 5 V is supplied for the dry contact and the current is limited internally to about 5 mA 32 Programma Electric AB ZP BSO6E R101 TORKEL 820 840 860 Programma Electric AB ZP BSO6E R101 33 TORKEL 820 840 860 General You must make some simple calculations before start ing 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 end
26. RKEL has shut down because the voltage has dropped to the stop limit b LED will flash when the voltage has decreased to the warning limit let Ah a LED will glow steadily when TORKEL has shut down because the discharged capacity has reached the stop limit b LED will flash when the discharged capacity has exceeded the warning limit Time h a LED will glow steadily when TORKEL has shut down after completing the preset time cycle b LED will flash when the time has exceeded the warning limit External current meas urement External current measurement Input used to measure current in an external path by means of a clamp on ammeter or a current shunt Input impedance 1 Mohm Galvanically isolated Insulation voltage to battery current terminals 2300 V Insulation voltage to ground 1350 V 3 Circuit breaker F1 Voltage controlled circuit breaker that connects disconnects the loading circuits in TORKEL from the battery Programma Electric AB ZP BSO6E R101 mm HOO N END Note F1 will not latch in upper ON posi tion until TORKEL has issued a message reading Switch on F1 4 External control ALARM Output equipped with a relay contact for triggering an external alarm device Relay contact 1 A 100 VAC 1 A 50 VDC 0 3 A 250 VDC This latter 250 V DC is valid for resistive load only Connector insulation Voltage to ground may not exceed 250 V START STOP Input used for starting a
27. TORKEL 820 840 860 Battery Load Units AY 5 User s manual TORKEL 820 840 860 Battery Load Units NOTICE OF COPYRIGHT amp PROPRIETARY RIGHTS 2007 Programma Electric AB All rights reserved The contents of this manual are the property of Programma Electric 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 Programma Electric AB Programma Electric 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 Programma Electric 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 Programma Electric AB products is strictly prohibited except as permitted by written license agreement with Programma Electric AB TRADEMARK NOTICES Programma is a registered trademark of Programma Electric AB All other brand and product names mentioned in this document are trademarks or registered trademarks of their respective companies Programma Electric AB Eldarv gen 4 T 46 8 510 195 00 Box 2970 F 46 8 510 195 95 SE 187 29 T BY info programma se C Sweden www programma se Programm
28. UTET Mains voltage 100 240 V AC 50 60 Hz Lu voltage e SRO fd id a TOM AM Stabilization For 0 5 of reading 0 5 A Max internal current Protection Thermal cut outs automatic overload measurement protection Battery Highest permissi Resistor ele Dimensions voltage ble current ment Nominal Instrument 210 x 353 x 700 mm values 8 3 x 13 9 x 27 6 Range 10 276V 270A 0 069 0 Transport case 265 x 460 x 750 mm Range2 10 552V 270A 04380 10 4 x 18 1 x 29 5 rr i Weight 223 kg 49 2 Ibs 1 Maximum value ai system with more than one load unit 40 4 kg 89 1 Ibs with accessories and Inputs maximal values transport case EXTERNAL CURRENT 1VDC 300 V DC to ground Current Display LCD MEASUREMENT shunt should be connected to the nega Available lan English French German Spanish tive side of the battery guages Swedish START STOP Closing opening contact Measurement section Closing and then opening the contact will start stop Torkel It is not possible Current measurement to keep the contacts in closed position Display range 0 0 2999A Min time open is 25 ms Basic inaccuracy 0 5 of reading 0 2 A Delay until 200 300 ms Resolution 0 1A start Internal current measurement Stop delay 100 200 ms Range 0 300A Battery 60 V DC 500 V DC to ground Input for clamp on ammeter VOLTAGE SENSE 60 V DC 500 V DC to ground SERIAL 15V Range 0 1V mV A ratio Software settable 0 3 to 19 9 mV A ALARM Aa A Input impedance gt 1
29. a Electric AB 3 ZP BSOGE R101 TORKEL 820 840 860 Contents 1 Introduction c ca 6 Odile 6 TORKEL 820 840 860 6 TXL830 850 870 Extra Loads 6 TORKEL Win software optional 6 2 Salle 8 3 Menu system eeeeeee 10 Main MENU RR 10 REGUl ze TP 10 Test battery ET 10 ALIGHIMI Silio te 10 MEMORY iii lion 10 Select language nns 10 Basic settings ront mister acad 10 TESE method lia 10 4 Control panel 12 1 Operator control eee 12 2 External current measurement 12 3 Circuit breaker 13 4 External control 13 DOMAINS M nen E EEE EEE 13 6 Connection terminals for the battery 13 5 Conducting a test 14 Test at constant CUFTEDE ae care 14 Safety precautions iicet ia 14 Preparations for testing 14 Connecting the current cables to the DATTE AMNEM PR 14 Setting the current nns 15 Warning and stop limit parameters 15 Starting INERTE 15 Pausing the test rna 15 Ending the R1 IRE 15 6 Testing at constant power resistance 16 CONSTANT DOW ici erred rere Ra Sade 16 Configuring TORKEL for constant power 16 Constant resistance eerte 16 Configuring TORKEL for constant FOSISTANC QU cease cotes cesses poten nte nr tetas 16 7 Testing with a
30. an intended e That TORKEL has enough regulation capabil ity 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 36 Calculating how many TORKELs and TXLs are needed 1 Number of TXLs Current flow ing 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 Note Remember that the internal resistances of the TXLs can be set manually For accurate calculation add the cable resistance to the internal resistance A 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 B Calculate the number of TXLs that you can connect without exceeding the desired total current 2 Current flowing through TXL s at final voltage A 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 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
31. at nominal input voltage and an ambient Display range 0 0 500 V temperature of 25 C 77 F Specifications are subject to change Basic inaccuracy amp 0 596 of reading 1 V without notice Resolution 0 1 V Environment Application field The instrument is intended for use in high voltage substations and industrial environments Time measurement Basic inaccuracy 0 1 of reading 1 digit Storage of measured values Temperature Torkel stand alone Operating 0 C to 40 C 32 F to 104 F Time max 10h Storage amp 40 C to 70 C 40 F to 158 F Time interval 6s transport Torkel Win Humidity 5 95 RH non condensing Time max 24h CE marking Time interval 1 245 LVD Low Voltage Directive 73 23 EEC am Load section by 93 68 EEC Battery voltage 10 60 VDC EMC EMC Directive 89 336 EEC am by Max current 270A 91 263 EEC 92 31 EEC and 93 68 EEC qued Max power 15 kW Standards Load patterns Constant current constant power con Safety standards IEC 61010 1 2001 Incl national dev for stant resistance current or power profile US and CA A z 3 EN 61010 1 2001 Current setting 0 270 0 A 2999 9 A ij 1 EMC standards EN 61326 1997 A1 1998 A2 2001 Power setting 0 15 00 KW 299 99 KW 7 General fesistance setting T P
32. easurement malfunctions TORKEL might provide a higher load current than intended Do not use liquid detergents or aero sols when cleaning TORKEL or TXL units Use a damp cloth 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 Programma Electric AB ZP BSOGE R101 TORKEL 820 840 860 TORKEL 820 840 860 Main menu Results Displays voltage capacity current and testing period time from the last test Test battery Submenu used to perform a test Auto limits Submenu used to provide automatic calculation and setting of limit values Here you specify the desired voltage per cell at which a warnings are to be issued and b the test is to be stopped Examples warning at 1 85 V cell and stop at 1 75 V cell Then when you begin a test TORKEL asks you to enter the number of cells whereupon it calculates the voltage and sets this voltage as the limit Memory You can save and recall the settings in any of 9 memo ries Moreover you can recall the factory standard settings Select language Here you select the language that will be used in the display Basic settings Here you specify whether the current is to be meas ured internally within TORKEL or by means of a clamp on ammeter You can also adjust TORKEL to the mV A ratio that appears on the clamp on ammeter itself Test method Here you specify one of the f
33. ect TORKEL Commands and click Download Language Insert the Torkel Win CD into your CD drive and instruct TORKEL Win to open the desired language file 30 Testing with TORKEL Win 1 Proceed as set forth in the section headed Set ting up communication 2 Proceed as set forth in the sections headed Preparations and Setting the current in the chapter headed Conducting a test Note however that F1 must be switched on before you start conducting test with TORKEL Win 3 Select test method Select current or power or resistance as desired Set the desired warning limits and start the test with TORKEL Win 4 Proceed as set forth in the section headed Set ting up communication 5 Proceed as set forth in the sections headed Preparations and Setting the current in the chapter headed Conducting a test Note however that F1 must be switched on before you start conducting test with TORKEL Win 6 select test method Select current or power or resistance as desired Set the desired warning limits and start the test with TORKEL Win Viewing the results 1 Select the RESULT submenu via which you can read the values that were valid at the end of the last test Voltage and discharged capacity are displayed in the first line 2 Press the vertical up arrow key 4 key to view current and time You can scroll up and down among the displayed items with the vertical ar row keys Vv or 4 3 Press ENTE
34. eii 31 Setting up the extra load annen ana 43 Software key dite tene regit ase bed 31 51 START STOP x tesis e b eb Hen 13 Start Stop CONNECTOR sees sum ie eese de e rhe RR ERE 34 Stabtirig thie test sete eben ae 15 Stop limit parameters 15 Store voltage curve i 30 EU WEE 39 System of TORKEL and TXL units 41 System TORKEL and TXL UN tsS ne 41 T Testing with TORKEL Win 32 Testat constant CUNEN usos eren tenete tn 14 Test Method rer r rn nr rn e rare 10 TORKEL load capacCity 36 Torkel SYStemS rr nr ers n eran een 39 TORKEL VVI trahit teet ert estre ee uta 30 TORKEL Win software ense R 6 pd 13 U Unable to regulate artt tetti 46 V Voltage curve store rena 6 30 Voltage range 15 47 WwW Warning limit parameters 15 Programma Electric AB ZP BSOGE R101 TORKEL 820 840 860 55 iy S O au Subject to change without notice Printed matter ZP BSO6E R101 Doc No BS2395FE 2007
35. ent The current through TORKEL is higher than allowed because of a fault in TORKEL s internal current limita tion Input voltage too high The battery voltage is higher than specified for your TORKEL Input voltage 27 6 V Input voltage 55 2 V Input voltage 144 V Input voltage 288 V Input voltage 480 V When you connect the battery TORKEL will automati cally select the voltage range and arrange the internal resistors for highest possible current If one of the messages above appears TORKEL has stopped because the input voltage has increased and exceeded the range You can continue the test but TORKEL will choose a higher voltage range and rear range the internal resistors Note The current rating for the new range is prob ably lower than the previous range see chapter headed Specifications Input voltage too low The battery voltage is too low less than 10 V which is frequent on defective batteries for safe operation with TORKEL Calibrate Programma Electric AB ZP BSOGE R101 TORKEL 820 840 860 A calibration is recommended TORKEL is now using calculated and standardised calibration values Checksum error Switch off Read error in TORKEL s control memory e Switch off TORKEL and switch on again If the message remains it might be necessary to perform the reset procedure in the chapter Calibration Power failure TORKEL has lost the mains power for a whi
36. etreived later from a file e Voltage curve e Voltage current and capacity in tabular form Commands that can be issued to TORKEL e Set the test method e Set the load current power or resistance Programma Electric AB ZP BSO6E R101 e Set current or power profile e Set warning and stop limits e Start the test e Pause the test e Restart the test e Reset the alarm e Lock unlock TORKEL panel e Set current measurement e Set sample rate Reporting e Fill in report e Copy voltage curve to clipboard Other commands e Transfer voltage curve from TORKEL e Load a new language into TORKEL TORKEL Win is delivered with every TORKEL However a software key must be loaded into the TORKEL in order to make it able to communicate with TORKEL Win This key can be purchased from Programma You can evaluate the program without the key since a file containing test data is included Select Files Open and double click demo Note You do not need a software key for load ing a new language into TORKEL Programma Electric AB ZP BSOGE R101 TORKEL 820 840 860 Installing TORKEL Win The TORKEL Win software package consists of e One diskette containing the TORKEL Win program Provided that you have ordered TORKEL Win the diskette also contains a software key e One CD containing TORKEL Win and other languages than English e Serial cable Requirements on your PC e PC with Pentium processor
37. fter designated P1 and P2 Recommendation Calibrate P1 at 12 V and P2 close to the top of the range or close to the highest voltage at which TORKEL is to be used Ranges TORKEL 820 0 60 V TORKEL 840 0 288 V TORKEL 860 0 480 V 3 Connecta stable variable voltage source to the battery current terminals on TORKEL 4 Connect the same voltage source to the VOLT AGE SENSE input 5 Connect an accurate reference instrument volt meter across the voltage source 6 Adjust the voltage source to the first point P1 at which the voltage measurement is to be cali brated Recommended voltage 12 V 47 TORKEL 820 840 860 7 Press ENTER Message reading Please wait 20sec Switch on F1 Press ENTER 8 Set switch F1 to its upper ON position 9 Press ENTER Message reading P1 Input 012 00V 10 Change the voltage shown on the display to the value read from the reference instrument volt meter 11 Press ENTER Note If a message reading Error Input too low appears check that the voltage source is connected properly to the VOLTAGE SENSE input and also the terminals used for the battery current Message reading P2 max 480V Input 450 00V 12 Adjust the voltage source to the value to be used for point 2 P2 Note The P2 value suggested by TORKEL is dif ferent for TORKEL 820 TORKEL 840 and TORKEL 860 Change the voltage shown on the TORKEL display to the value read from the
38. g a test for safety precautions and how to prepare the test 1 Proceed in the same way as set forth in the chapter headed Conducting a test but before you start TORKEL you must set switch F1 to upper ON position on the TXL You must do this manu ally 2 Start TORKEL by pressing ENTER Cc TORKEL TORKEL with one TXL 41 TORKEL 820 840 860 Cables Cable set 2 x 3 m 10 ft for connecting TORKEL to the battery 70 mm 270 A cable for TORKEL 820 25 mm 110 A cable for TORKEL 840 and TORKEL 860 e Cables for controlling a TXL Extra Load from TORKEL e Sensing leads 2 x 5 m 16 ft used to measure voltage at the battery terminals e Extension cable 2 x 3 m 10 ft 25 mm 110 A Clamp on DC ammeter e 200A clamp on DC ammeter e 1000 A clamp on DC ammeter Software e TORKEL Win software Other Transport case e TXL Extra Loads The TXL830 is for up to 24 V batteries the TXL850 for up to 48 V batteries and the TXL870 for up to 240 V batteries e TMC2001d Data Logger e TMC4001 Multi Channel Data Logger 42 Programma Electric AB ZP BSO6E R101 TORKEL 820 840 860 Programma Electric AB ZP BSO6E R101 43 TORKEL 820 840 860 Display on TORKEL is dark e Check that the mains cable is prop erly plugged in e Check the mains voltage Impossible to switch on the circuit breaker F1 It is only possible to switch on F1 in the Test battery submenu Furthermore you
39. he circuit breaker F1 is in the lower OFF position Do not touch conducting parts of the clamps on the current cables or the volt age sensing cables when they are con nected to TORKEL 1 Switch on TORKEL 2 In the MAIN MENU select BASIC SETTINGS 3 Set I MEASUREMENT to INTERNAL 4 Switch off TORKEL 5 Press the Esc and Stop keys simultaneously while switching on TORKEL Calibrating zero levels 1 Message reading Press ENTER to calibrate 2 Press lt ENTER gt Message reading Short circuit inputs 3 Short circuit the inputs a EXTERNAL CURRENT MEASUREMENT b Positive and negative terminals for bat tery current c VOLTAGE SENSE 4 Message reading Switch on F1 Press ENTER 5 Set switch F1 to its upper ON position Programma Electric AB ZP BSO6E R101 6 Press ENTER Message reading Calibrating Zero levels F1 will trip 7 Remove all short circuits see step 3 2 Calibrating internal cur rent 1 Message reading CALIBRATE Int No 2 Change to Yes using the vertical arrow keys v or 4 3 Connectthe current source two car batteries in series for example to the battery current termi nals on TORKEL Note The current source must be able to supply a high stable current 4 Connect an accurate current measurement refer ence instrument for instance a current shunt with a voltmeter in series with the batteries 5 Press ENTER
40. 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 Programma Electric AB ZP BSO6E R101 When using the external current measurement func tion 1 Check that the CT is connected in the right cur rent direction 2 Always replace the CT internal battery before a test 3 Set the correct current ratio in the external current measurement menu Never use the TORKEL TXL Extra Load in an explo sive environment Never put the TORKEL TXL Extra Load where it can be reached by battery gas 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 Position TORKEL TXL Extra Load where air flow is unobstructed and where it does not come into con tact with any flammable or heat sensitive material Keep a free distance of 1 5 m 5 ft to the verti cal sides of TORKEL TXL and 2 0 m 6 5 ft above TORKEL TXL 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 over heat if there is insufficient cooling External current shunt may not be used above 300 V DC Important Make sure that the clamp on ammeter is properly connected and that its battery lasts throughout the entire test If external current m
41. le when a test was in progress TORKEL displays the values when the test was interrupted You can choose to continue or end the test 8x0 You need to restore Torkel follow instructions below 1 Connect Torkel to the PC and start Torkel Press ESC to enter the main menu 2 Run the file restore exe and select the file xxxxxxx set contact our Customer Service if you do not have the file 3 Click the icon TORKEL Restore and select the Com port 4 When the message Restoring com plete is shown click OK 5 Calibrate Torkel 45 TORKEL 820 840 860 Calibration procedure TORKEL has four circuits used for testing that require calibration e Internal current e Internal voltage e External voltage e External current The calibration procedure has four main steps 1 Calibrating zero levels 2 Calibrating internal current Int I 3 Calibrating internal and external voltage V 4 Calibrating external current Ext I For main steps 2 3 and 4 you can decide whether or not to perform them Note Calibrate once a year to maintain proper accuracy Stable voltage and current sources which vary less than 196 per second and accurate reference instruments must be used The current source must be able to supply high current at a voltage between 10 and 30 V One or two 12 V batteries can be used here 46 How to calibrate Warning Do not connect or disconnect any of the cables unless t
42. nd stopping discharging from an external device Galvanically isolated TXL Output used for control of TXL Extra Loads Galvani cally isolated SERIAL Serial port used for connection to a PC or other con trolling equipment Mains MAINS Connector for mains supply equipped with ON OFF switch 6 Connection terminals for the battery Terminal Positive current connection for battery being tested Terminal Negative current connection for battery being tested Insulation voltage to ground 2200 V VOLTAGE SENSE Input for sensing voltage at the battery terminals Impedance to the battery current terminals is gt 1 Mohm Programma Electric AB ZP BSOGE R101 TORKEL 820 840 860 TORKEL 820 840 860 Test at constant current Safety precautions mmm EE NEM NEMO NEMO GENES ENS NEN Warning Do not connect or disconnect any of the cables unless the circuit breaker F1 is in the lower OFF position Never use TORKEL TXL Extra Load in an explosive environment Never put TORKEL TXL Extra Load in direct contact with battery gas Position TORKEL TXL Extra Load so that the air flow is unobstructed and free from contact with any flammable or heat sensi tive material Do not place TORKEL near another TORKEL a TXL Extra Load or any other heat source TORKEL will overheat if there is insufficient cooling Inspect cable connections to make sure there is no short circuit Preparati
43. ns power was cut off Resetting the alarm You can reset the alarm by pressing any key Programma Electric AB ZP BSO6E R101 TORKEL 820 840 860 Programma Electric AB ZP BSO6E R101 25 TORKEL 820 840 860 Invoking the auto limits function The auto limits function automatically calculates and sets the limit values Here you must specify the volt age per cell at which you want a warning to be issued and the voltage per cell at which you want TORKEL to stop discharging the battery When you start the test TORKEL asks you to enter number of cells and then sets the limits automatically This function can also be used to simplify the task of setting capacity and time limits 26 Activating auto limits 1 Press ESC repeatedly until you see the MAIN MENU 2 Select Auto limits using the vertical arrow keys and press ENTER Warning Vmin No 1 85V cell 3 Use the vertical arrow keys Vv or to activate the auto limits function Yes so that it will issue voltage warnings 4 Set the voltage value cell value 5 Press lt ENTER gt Stop Vmin No 1 80 V cell 6 Use the vertical arrow keys Y or to activate the auto limits function so that it will provide voltage stops 7 Set the voltage value cell value 8 Press ENTER Using the same procedure as that set forth above you can set TORKEL to e Issue a warning when say 50 of the test period time has elapsed e Stop discha
44. nt A Number of units TORKEL 840 860 Number of units TXL870 194 278 363 473 557 642 726 810 895 979 MlIl MmIinMIin MIinlm MIiniBRP TR Ir OlLOINIDI OI HRIWIwWwlrm r 220 V battery 108 cells Maximum con stant current A Discharge from 2 15 to 1 8 V cell Number of units TORKEL 840 860 Number of units TXL870 94 153 188 227 266 306 345 384 423 463 MPM P_LM ITM LM PLM MLM efje OlLOI NID OMI IW rm rmftr Programma Electric AB ZP BSO6E R101 Test conducted using a system comprising TORKEL and TXL units One of the TORKEL units we shall call it TORKEL No 1 is to measure the entire battery current TORKEL No 2 measures all current except the current through TORKEL No 1 TORKEL No 3 measures all current ex cept the currents through TORKEL No 2 and TORKEL No 1 and so forth The last TORKEL measures only the current through itself and the TXLs TORKEL 1 Cc TORKEL Example of a system comprising TORKEL and TXL units Hookup and settings me Warning The chapter headed Conducting a test presents safety precautions and explains how to prepare for testing Be sure to comply with what is set forth in this chap ter 1 Apply the clamp on ammeters as illustrated above Programma Electric AB ZP BSOGE R101 TORKEL 820 840 860 2 Se
45. ogramma Electric AB ZP BSOGE R101 TORKEL 820 840 860 TORKEL 820 840 860 General This manual explains how to use TORKEL 820 TORKEL 840 and TORKEL 860 Battery Load Units and it also covers the TXL830 TXL850 and TXL870 Extra Loads Although performance differs from one model to the next all models are used in the same way Unless otherwise specified what is set forth in this manual applies to all models TORKEL 820 840 860 These Battery Load Units are sophisticated instru ments designed mainly for capacity tests All three units can be programmed to test a battery bank at constant current constant power or using a user de fined load profile TORKEL can also be used for testing battery chargers and other electrical equipment that require resistive load testing The three models have different maximum voltage ratings TORKEL 820 60 V DC TORKEL 840 288 V DC TORKEL 860 480 V DC TORKEL has a number of functions that facilitate its use Examples include e Warning and automatic stop functions for time discharged capacity and low battery voltage e 9 memories where settings can be stored e Voltage curve can be stored for later transfer to a PC using the TORKEL Win program e Discharging can be started stopped from ex ternal equipment e Testing can be carried out without discon necting the regular load TXL830 850 870 Extra Loads The TXL830 TXL850 and TXL870 Extra Loads com prise resistive load
46. ollowing test methods constant current constant power constant resistance current profile or power profile When you start a profile test you will be asked for the number of steps the test duration time and the load value for each step Programma Electric AB ZP BSO6E R101 TORKEL 820 840 860 Programma Electric AB ZP BSO6E R101 11 TORKEL 820 840 860 AURIS Adina m Omron mem m I armar I I o 1 mones Ot i i e On I 1 Y Oh i 1 I E vel i EJ s i i 2 Em i Ta m fa i v l _ losse sounsstene eee ine pe em I e GI E mF c LU om _ TOE I I I I 6 N I e ies D Operator control Display Display settings during programming and measured values during operation Keys lt LIMITS gt key Press to enter the LIMITS MENU lt ESC gt key Press to exit from a function without changing any data or to go backwards in the menu system Horizontal and vertical arrow keys gt wv Used to select data and to change values lt SET LOAD gt key Press to change the load ENTER key Press to select and confirm parameters lt START gt key Press to start discharging STOP key Press to stop pause discharging Lamps OPERATING a LED will glow steadily while TORKEL is discharging b LED will flash when the current or power can not be regulated to the desired value Vmin V a LED will glow steadily after TO
47. ons for testing 1 Connect TORKEL to the mains voltage 2 Switch on TORKEL The following display will appear for a short time TORKEL 840 R01A It will then change to MAIN MENU Test battery and then Connect battery Note Press ESC if you want to access the main menu mm EE NEM M REMO NES ED SES Important Connection and disconnection proce dures are extremely important Be sure to follow the the instructions faithfully Connecting the current cables to the battery 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 fittted C TORKEL Pea maka o n ele 2 Connecting TORKEL to a battery 1 Connect one end of the first cable to the nega tive 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 Tip To get a more accurate voltage read ing Connect the voltage sensing cables between the VOLTAGE SENSE input on TORKEL and the battery terminals Programma Electric AB ZP BSO6E R101 Warning A Do not disconnect any of the above cables until the test is completed and the circuit breaker F1 is in the lower OFF position Note TORKEL
48. reference instrument voltmeter 13 Press ENTER Message reading Disconnect Battery 14 Disconnect TORKEL from the voltage source F1 will trip 4 Calibrating of external current 1 Message reading CALIBRATE Ext I No 2 Change to Yes using the vertical arrow keys v or 4 Calibration must be done at two points called P1 and P2 48 3 Press ENTER Message reading P1 10mV Input 010 00mV 4 Connect the voltage source to the EXTERNAL CURRENT MEASUREMENT input Adjust the voltage source to the value to be used for point 1 P1 Measure the voltage with a reference instrument Change the voltage shown on the TORKEL display to the value read from the reference instrument voltmeter 5 Press ENTER Message reading P2 900mV Input 900 00mV 6 Adjust the voltage source to the value to be used for point 2 P2 Change the voltage shown on the TORKEL display to the value read from the reference instrument voltmeter 7 Press ENTER Message reading PRESS ENTER TO STORE CALIB DATA 8 Press ENTER Message reading MAIN MENU Test battery Connect Battery Calibration is now completed Programma Electric AB ZP BSO6E R101 TORKEL 820 840 860 Resetting TORKEL General This procedure has two purposes e Tosetthe calibration values to calculated standardized values useful if the calibration has become invalid or is lost Torestore the contents of the control
49. rging when say 100 of the test period time has elapsed e Issue a warning when say 50 of the rated capacity is discharged e Stop discharging when say 100 of rated capacity is discharged When you start the test TORKEL will ask you to enter the number of cells the length of the test period time and the rated capacity Programma Electric AB ZP BSO6E R101 TORKEL 820 840 860 Programma Electric AB ZP BSO6E R101 27 TORKEL 820 840 860 General TORKEL can be connected to a PC and controlled by the TORKEL Win program TORKEL also supports communication with the TMC95 program that was created to conduct capacity tests together with the TMC4001 Multi Channel Data Logger 28 TORKEL Win program The TORKEL Win program builds up a voltage curve on the screen while the test is running and presents the current voltage and capacity values in a scrol lable table Moreover you can control TORKEL from TORKEL Win during the test print out a report and store the measured values in a text file which can be imported easily into Microsoft EXCEL Because TORKEL always stores the total voltage curve during the test one curve can be stored you can also connect TORKEL to a PC after the test transfer the voltage curve examine it and store it as a file using TORKEL Win errore H asa cra yoy LLLI vow tna one Example of a discharge voltage curve Displayed while test is running or r
50. rning and stop limit functions when using external cur rent measurement This will protect your batteries if the DC clamp on ammeter were to malfunction Connections NEN i o I OI NENNEN E Warning Make sure the polarity is correct 1 Connect the clamp on ammeter to the EXTERNAL CURRENT MEASUREMENT input Best results are obtained if the cables running from the clamp on ammeter are twisted 2 Apply the clamp on ammeter to the conductor See the figures in the section headed Applica tions Note The arrow on the clamp on ammeter must point in the same direction as the current flow Note The clamp on ammeter must always be ap plied in such a way that current through TORKEL is included in the measurement 3 Turnon the power switch on the clamp on am meter 22 Troubleshooting If the following message appears when you start the test Error External I 1 Checkthat the clamp on ammeter is properly connected to TORKEL Also check the polarity 2 Checkthat the clamp on ammeter is switched on 3 Check that the clamp on ammeter has fresh bat teries 4 Make sure that the clamp on ammeter is clamped in the correct direction A DC clamp on ammeter normally has an arrow which should point in the direction which current flows through the conductor 5 Check the folowing settings in Basic setting submenu e measurement must be set to External The mV A ratio must match the ratio that
51. s TORKEL regulates cur rent 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 34 TORKEL load capacity The following tables present the TORKEL built in cur rent limitation Imax and also the resistance of the built in resistance elements for the different voltage ranges TORKEL 820 Range Max Internal Lowest volt current resistance age at which Imax nominal Imax can be obtained 10 276 V 270A 0 069 Q 21 3V 10 55 2V 270A 0 138 39 9V 1 Requires use of two standard cables 3 m 10 ft 7Omm2 1 5 mA TORKEL 840 860 Range Max Internal Lowest volt current resistance age at which Imax nominal Imax can be obtained 10 276V 110A 0 165 Q 20 8V 10 55 2V 110A 0 275 Q 32 9V 10 144V 110A 0 550 Q 63 1V 10 288V 55A 3 3Q 184V 2 Requires use of two standard cables 3 m 10 ft 25 mm 4 MO Calculating current Programma Electric AB ZP BSO6E R101 Imax Check that the desired current load is not greater than the Imax for the TORKEL unit in question column 2 in the tables above Max power For the 10 480 V range on TORKEL 860 you must also check to see that current multiplied by maximum voltage does not exceed the 15 kW power limit Final voltage If the final voltage is lower than the value set forth in column 4
52. s They can be used together with TORKEL Load Units to increase loading capability The TXL Extra Loads can not provide regulatation by them selves 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 The three models have different maximum voltage ratings TXL830 28 V TXL850 56 V TXL870 280 V TORKEL Win software op tional The TORKEL Win program which runs on a PC under Windows builds up a voltage curve on the screen in real time and displays the current voltage and capac ity readings You can also use TORKEL Win to control TORKEL during the test The program stores the results in a text file and it can generate reports Programma Electric AB ZP BSO6E R101 TORKEL 820 840 860 Programma Electric AB ZP BSO6E R101 7 TORKEL 820 840 860 Symbols on the instrumentl Caution refer to accompanying docu ments Caution risk of electric shock Hot do not cover D Protective conductor terminal poem WEEE Waste Electrical and Electronic Equipment Please utilize your local WEEE collection facilities in the dispo sition of this product and otherwise observe all applicable requirements Safety instructions E i TV N O I 8 NN Warning The electrical voltage and current used in battery testing is potentially lethal Ensure that the AC supply is isolated and any bat tery under tes
53. t breaker F1 is switched on that the battery is properly connected and that the battery voltage is not less than 10 V Unable to regulate The message appears when TORKEL can not regulate the current or power or resistance to the desired value The TORKEL unit can not regulate because it can not decrease its resistance further e You must decrease the current or connect more TORKEL or TXL units e This is not a fault situation if the actual TORKEL is operating in a system of several TORKEL units and another TORKEL TORKEL nr 1 takes care of the total regulation Error External I The measured external current is less than the inter nal current See also chapter headed External Current Measure ment Programma Electric AB ZP BSO6E R101 1 Check the setting in sub menu Basic setting I measurement 2 Select External if you want to use the input External Current Measure ment 3 Select Internal if you do not want to use External Current Measurement 4 Checkthat the mV A ratio complies with the clamp on ammeter TORKEL is set for External Current Measurement but the clamp on ammeter e is not properly connected e is not switched on e is not correctly applied on the conductor e has bad batteries Overheated The internal thermal protection device has tripped e Check cooling and ambient tem perature A fan may be damaged not rotating or slow e Call for service Overcurr
54. t enough 36 TXL Extra Loads connected to TORKEL 36 Programma Electric AB ZP BSO6E R101 Calculating how many TORKELs and TXLs are Needed i 36 TORKEL TXL system examples 37 Test conducted using a system comprising TORKEL and TXL units reete 39 Hookup and settings 39 14 TXL Extra loads ios aeos 40 1 Selector switch 40 2 Circuit breaker rna 40 3 Connection terminals for the battery 40 AE Mors ire NNMERO RE ERE 40 SES 40 Setting up the extra load 41 TESTING RR rr rr nn rna 41 15 Optional accessories 42 Qv MET 42 Clamp on DC ammeter 42 Sila 42 OaE NERI 42 16 Troubleshooting 44 Messages on display na 44 17 Calibration 46 Calibration procedure 46 How to calibrate aiio cto eoer err dere e oerte 46 1 Calibrating zero levels 46 2 Calibrating internal current 47 3 Calibrating internal and external Wbbm 47 4 Calibrating of external current 48 Resetting TORKEL 49 General BINA RO IRR RA NE RATA 49 Performing ATE ia 49 18 Specifications 50 RZ aac 50 Torkel SAB airline 51 TXL 3307 850 48 FU siii 53 Elia 54 Pr
55. t is disconnected before attempting any cleaning or maintenance of TORKEL Do not connect or disconnect any of the cables unless the circuit breaker F1 is in the lower OFF position Connection and disconnection procedures are ex tremely important Be sure to follow the instructions faithfully Do not touch conducting parts of the clamps on the current cables or the voltage sensing cables when they are connected to TORKEL Explosion risk when using Torkel and TXL all mod els 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 For new open vented batteries the risk is medium to low but in old VRLA sealed batteries the risk is medium to high 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 oxyhy drogen gas in the battery To minimize the risk for personnel injuries Always place Torkel TXL as far away from the bat tery as possible use long current cables and or remote start stop Never stand close to a battery during charge discharge Too high discharge current applied on a battery can cause the battery to explode or get over heated Be sure to not set too high current If the external current measurement is interrupted or giving false values during the test the current will rise to a
56. the Test battery sub menu 40 3 Connection terminals for the battery Terminal Positive current connection for battery being tested Terminal Negative current connection for battery being tested Insulation voltage to ground 2200 V 4 Control CONTROL IN Input for control signal from TORKEL unit Galvani cally isolated CONTROL OUT Output used for the control signal sent from TORKEL to the adjacent TXL unit Galvanically isolated 5 Mains MAINS Connector used for mains supply equipped with ON OFF switch Programma Electric AB ZP BSO6E R101 Setting up the extra load When an extra load is to be used you must use the external current measurement function see the chap ter headed External current measurement mM NEED ED EE EE HH Important Never connect a TXL to a voltage higher than specified for the range in question 1 Set the range selector switch to the desired posi tion 2 Connect as shown in the illustrations 3 Connect the control wires between the TXL output on TORKEL and the CONTROL IN input on the TXL If two or more TXLs are to be used provide a con nection 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 Programma Electric AB ZP BSOGE R101 TORKEL 820 840 860 Testing E HOO OE WARNING See the chapter Conductin
57. ts operating together using the external current measurement function Programma Electric AB ZP BSOGE R101 TORKEL 820 840 860 Setting up external current measurement TORKEL 1 Press lt ESC gt repeatedly until you see the MAIN MENU 2 Select Basic settings using the vertical arrow keys Vv or 4 and press ENTER MAIN MENU Basic settings 3 Press ENTER to obtain I MEASUREMENT Internal 4 Press ENTER 5 Select External using the vertical arrow keys or 4 and press ENTER 6 Setthe mV A value to the value specified on the DC clamp on ammeter and press ENTER I MEASUREMENT Ex 010mV A The mV A ratio for the input can be set to a value between 0 3 mV A and 19 9 mV A Important The clamp on ammeter output voltage must not exceed 1 V DC clamp on ammeter Note Make sure that the clamp on ammeter has fresh batteries The batteries must last throughout the entire test 1 Place the clamp on ammeter as far as possible from any magnetic field 2 Connect a DC voltmeter set to 2 V full scale to the clamp on ammeter 3 Switch on the clamp on ammeter and adjust its zero knob to set the output to 0 0 V Note The clamp on ammeter must be accurate and calibrated and it must be able to carry a load of 600 kQ Please note that a DC clamp on ammeter is usually less accu rate in the lowest part of its measurement range 21 TORKEL 820 840 860 Tip Always activate the wa
58. tthe desired total current same value on 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 Can not regulate as long as it does not appear on TORKEL No 1 3 Set warning limits only on TORKEL No 1 4 Setthe stop limits The voltage and test period time can be set on each individual TORKEL Stop ping 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 Starting discharge 1 Set switch F1 to the upper ON position on the TXLs 2 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 39 TORKEL 820 840 860 1 Selector switch Selector switch used to set the desired voltage range and or resistance value 2 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 Furthermore TORKEL must be in

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