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DC High Current Circuit Breaker Tester BALTO Modular 4,000A to 40,000A BALTO Compact 4,000 A User Guide...
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Megger Ltd reserves the right to alter the specification of its products from time to time without notice. Although every effort is made to ensure the accuracy of the information contained within this document it is not warranted or represented by Megger Ltd. to be a complete and up - to - date description.
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Directive 2014/53/EU. Other equipment manufactured by Megger Instruments Limited described in this user guide is in compliance with Directives 2014/30/EU and 2014/35/EU where they apply. The full text of Megger Instruments EU declarations of conformity are available at the following internet address: megger.com/company/about-us/eu-dofc www.megger.com...
Packing and Shipping..........................6 3. Principles of operation General characteristics ..........................7 General diagram ............................8 Testing modes ............................8 4. BALTO Modular hardware Support Carriage ............................10 Emergency Stop Device ...........................12 Supply, Fuses and Charge Connector .....................13 Power Connections ..........................13 Sockets for the DC Current Generators ....................14 The Control Unit (Incl.
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Charging the current generators ......................26 How to use the Power Flex-cables......................28 Connecting the High-speed DC Circuit Breaker..................29 Assembly of the BALTO Modular on site ....................30 Assembly of the BALTO Compact 4000 on site ..................32 9. Operation Test procedures............................34 9.1.1 To determine the release threshold.
BALTO System. The BALTO family consists of 2 models : The BALTO Modular with a capacity of 20,000 A expandable up to 40,000 A in a Master-Slave configuration The BALTO Compact 4000 with a fixed capacity of 4,000 A ...
Tests of electromagnetic contactors (control and main) in tramways and trolley buses The Megger BALTO system can also be used for other applications where very high currents are required e.g. mining, steel factories, marine and solar. Company web site Occasionally an information bulletin may be issued via the Megger web site.
Pinch-point DO NOT hold the Controller cover by the edges: fingers will be pinched in the gap. Earth/Ground Staff Obligations Legal regulations concerning industrial safety – either within the company or imposed by status laws - must be obeyed. www.megger.com...
To prevent the Support Carriage from moving abruptly during system assembly, it is necessary to put the Support Carriage in working position by locking the wheels (applicable to BALTO Modular only). Carefully follow the instructions concerning the assembly of the device, in particular the steps regarding the DC Current Generators and Power Connections.
WARNING : The generated currents can heat the terminals of the DC Current Generators and connection points to levels that may cause burns. Make sure the connections are cool before handling and use protective equipment as necessary WARNING : The BALTO System must be grounded by using the Ground Connection. www.megger.com...
CAUTION : Follow the transport instructions, which are part of the delivery. CAUTION : To avoid damage during the installation and uninstallation, put on the brakes to lock the wheels (BALTO Modular only). DANGER : DANGER :...
The BALTO system is designed to reach currents up to 4,000 A (BALTO Compact 4000) or 20,000 A (BALTO Modular), using DC Current Generator modules of 4,000 A. To reach 40,000 A, a second BALTO Modular system can be connected in a Master/Slave configuration.
Quicktest Mode : high slope during injection Auto Mode : slope of 200 A/s Manual Mode Protection relay mode : steep slope (higher than short circuit slope) Shunt mode : fixed current during maximum 60 seconds. www.megger.com...
Traction DC Power Systems. The Support Carriage provides a transport mode and a fixed-in-place working position mode. Fig 2: BALTO Modular System 20,000 A The DC Current Generators and Control Unit are plug-ins and can be separated from the device. The Support Carriage itself cannot be dismantled for transport purposes.
BALTO Modular hardware Support Carriage The Support Carriage is the mobile part to facilitate the handling of the device on-site. This carriage includes the energy supply, connectors for the DC Current Generators, a Control Unit platform and a work surface.
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BALTO Modular hardware Compartment for the Ultracapacitors The energy storage modules - used as a buffer for the Batteries - are of type 16 V and consist of 6 cells of 3,000 F placed in series. The compartment can hold up to 5 modules of 16 V connected in parallel.
BALTO Modular hardware Emergency Stop Device The Emergency Stop Device physically breaks the circuit and disconnects the DC Current Generators from the energy supply. The Emergency Stop Device is located inside the Support Carriage and the operating lever is mounted on top.
BALTO Modular hardware Supply, Fuses and Charge Connector Fig 5: Support Carriage: Compartment overview. Item Description Item Description Mains supply: 230 VAC / 50 Hz or Charge connector (XLR) for charging the 120 VAC / 60 Hz. DC Current Generators...
Two wheels with inflated tyres. The Control Unit (Incl. Protection Test Module) The Control Unit sits on top of the BALTO Modular and consists of : A touch screen Interface to operate the BALTO An emergency stop, various buttons and connectors (see chapter “Control Panel”) ...
BALTO Modular hardware Item Description Supply Connector Provides the Control Unit with mains power. Carries Support Carriage monitoring signals. Provides protective earth connection. Signal Connector Carries DC Current Generator control signals. Carries DC Current Generator current measurement signals. Power Connector Detects connected DC Current Generators.
Protection Relay module for testing DC Protective Relays and measurements regarding reaction times of High- speed DC Circuit Breakers. Connection socket for the DC Current Generator. Emergency Stop Device. Fig 11: BALTO Compact System: Main Unit. www.megger.com...
This compartment contains the Batteries, placed in a row of 7 cells connected in series, cells being 2 V 25.0 Ah each. Type: Enersys Cyclon 0820-0004. The compartment holds one row DC Current Generator Connection Panel. The connection panel connects the DC Current Generator to the Main Unit. www.megger.com...
Fig 14: Emergency Stop Device. CAUTION : Use the Emergency Stop Device only in case of an emergency. Excessive operation may cause wear and damage to the contacts Supply, Fuses and Charge Connector Fig 15: Supply, fuses and charge connector www.megger.com...
For further information regarding Protective Relay secondary injections, consult the ‘chapter on secondary injection. Item Description Output mA used for secondary injection. Output mV used for secondary injection. Trip Input 1 input for potential-free trip signals. Trip Input 2 input for potential-free trip signals. www.megger.com...
Never abruptly remove the CF (Compact Flash) modules. Software data could be destroyed, lost or damaged. Megger cannot be held responsible for damage caused in this manner. It is not covered by warranty. For more information and precautionary measures regarding battery replacement, consult the appropriate user manual available from the Beckhoff website: www.beckhoff.de...
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Windows operating system and the application software. The handling of the touch screen may only be done with a clean finger or touch screen stylus. If gloves are worn, ensure that they do not contain any sharp particles such as metal shavings or glass shards. www.megger.com...
‘Measurement of the voltage drop’ (mV / µΩ test). Fig 20: Connection terminals The external measurement terminals are also used during system calibration. Consult chapter 12. Calibration on page Communication interfaces Fig 21: Connection interfaces 8. Buzzer Passes auditory alerts through the Control Unit casing. www.megger.com...
The ‘System ready’ indicator is illuminated after a successful system start-up. This means the Control Unit and PLC are operational and the BALTO system is ready for use. Emergency Stop In case of an emergency, press the Emergency Stop Button. www.megger.com...
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Control Panel Fig 23: Emergency Stop Activating the Emergency Stop Button will immediately halt any ongoing Current Injection and prevents further Current Injections in hardware. www.megger.com...
On the rear panel: Fig 25: DC Current Generator: Rear panel. Item Description Power Junction Connectors for energy supply from the energy compartment System Connector for management and control signals. Charge Connector (XLR) for connecting the charge/discharge tool. Cooling fans. www.megger.com...
Do not ship damaged batteries. Charging the current generators Before connecting the DC Current Generator(s) to the Support Carriage (BALTO Modular) or the Connection Panel (BALTO Compact), the DC Current Generator(s) voltage must be charged to match the voltage of the energy compartment.
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The module must be connected to the XLR 5-pin connector on one side and to the XLR 3-pin connector of the DC Current Generator. The XLR-5 connector can be found on the support carriage of the BALTO Modular or on the main unit of the BALTO Compact 4000.
CAUTION : Before connecting the Power Junction Connectors to the DC Current Generators, please ensure that the contact bands - both front and rear - are intact and positioned properly within the connector. The contact bands are important for providing good contact and the least possible impedance. www.megger.com...
Circuit Breaker. These are available as a separate part. Fig 32: Connections using breaker clamps. Connecting the High-speed DC Circuit Breaker. It is imperative to follow these instructions carefully and to follow standard procedures, including performing a risk analysis, before starting. www.megger.com...
13. Press the I/O button on the Control Unit, the BALTO Modular will start booting. The BALTO Modular System 8,000 A / 12,000 A includes only two or three DC Current Generators slots (if no future expansion is planned or desired).
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Installation Fig 33: BALTO Modular System with only two slots. The DC Current Generators have assigned positions on the Support Carriage. When assembling the system, please follow the ordering as indicated. The mechanical positions of the Power Junction Connectors are aligned specifically for the indicated ordering.
Installation Configuration of a BALTO Modular System 20,000 A SLOT SYSTEM CAPACITY Remarks POS. 1 PU 1 4,000 A Position used for Auto-Verification. POS. 2 PU 2 8,000 A POS. 3 PU 3 12,000 A POS. 4 PU 4 16,000 A POS.
Furthermore, the use of inadequate equipment may cause considerable damage to the system. CAUTION : Caution : Proper use of DC Current Generators on BALTO Modular All DC Current Generators connected to the Support Carriage MUST be connected to the DC High Speed Circuit Breaker as well.
For High-speed DC Circuit Breakers on rolling stock, it is advised to additionally perform the following tests: The manual closing/opening time test (Reaction Time Tests) and the proper functioning of the auxiliary contacts (I_Max No - NC). www.megger.com...
NOTE : The reference values in this manual are indicative values for settings and parameters. Consult the device calibration report for the actual parameters. Setting I_ref The I_ref threshold can be modified in the dialog displayed by pressing ‘Set I_ref’. www.megger.com...
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To adjust the duration of the 200 A/s slope, configure the K1 and K2 parameters accordingly in the ‘Auto Mode’ dialog. Starting Point ‘e’ of the 200 A/s slope Ending Point ‘f’ of the 200 A/s slope K1 and K2 are given as a percentage of the specified I_ref. www.megger.com...
The values displayed here only serve as an example. The displayed values will differ depending on the type of test performed. 9.2.2 Background. Under some circumstances, the colour of the background of the dialogs will change: Colour Reason Grey Normal operation Orange Warning Error Yellow Master/Slave WARNING : www.megger.com...
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The reason for the error is displayed in abbreviated form in the status bar. The varying background colours are not displayed on the start dialog. However, error and warning messages will still be displayed in the status bar. Status bar: Error and warning messages. www.megger.com...
9.3.1 Start procedure. Connect the system to the mains supply. The indicator light of the O/I button should illuminate. Pressing the O/I button begins the automated start-up procedure. Several dialogs will be presented on the screen while the system starts up. www.megger.com...
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Operation The ‘TwinCAT’ and ‘BALTO Launcher’ applications will start automatically. ‘TwinCAT’ is activated. ‘BALTO Launcher’ will open the main BALTO application automatically. NOTE : ‘TwinCAT’ is software by Beckhoff for managing the PLC hardware. www.megger.com...
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CAUTION : If the start dialog is not reached, or if the start dialog fails to start the main program - signalling the ‘System ready’ indicator - the system will shut down after 2 minutes. Please wait 20 seconds before attempting to start the system again. If start-up problems are not resolved, please contact customer support. www.megger.com...
Configuration. The BALTO Modular System is configured and calibrated for a Current Range from 4,000 A up to 20,000 A. The Power Range depends on the number of DC Current Generators used in the device (ranging from 1 to 5).
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Battery level optimal for Current Injections. Orange indication: Battery is charging, but Current Injections may still be performed. Red indication: Battery needs time to recharge, Current Injections are blocked. Example: Error display: these messages can be displayed in all dialogs. www.megger.com...
I_Max NO - NC I_ds Reference Quickstart Mode Auto Mode Manual Mode P7/P8 P9/P10 Manuel Manuel Opening Reaction Opening Time DC Protection Closing Reaction Shunt Mode Time Test Test Relay Test Time Test Fig 35: Flow chart Primary BALTO System. www.megger.com...
Menu Bar. Menu option: User. Standard (active by default): Normal user. Administrator: Used by BALTO service staff, only accessible with a password. Menu option: Mode. Dropdown menu: Selection from dropdown menu: Auto-Verification: Self-checking of Power Units. www.megger.com...
Changing the language in this menu will also affect the BALTO Launcher and Calibration programs. Main Menu. The Main Menu contains all the functions required to test a High-speed DC circuit breaker extensively. Press the centre image in the ‘Start Dialog’ to open the Main Menu. www.megger.com...
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Displayed in yellow: contains measurements. ‘Info’ dialog containing system status and information. Opens the ‘Auto-Verification’ dialog: Test function for DC Current Generators. The system battery voltage and charging current at this time. Master/Slave configuration. (Only applicable to BALTO Modular.) www.megger.com...
CAUTION : It is recommended to utilize this function whenever the system must be left unattended for a short period of time or during breaks between Current Injections. Emergency Stop The following symbol is displayed in the ‘Info’ dialog when the Emergency Stop Button is pressed down. www.megger.com...
To open Test Modes, press the ‘Test mode DC High Current Injections’ button 3 in the Main Menu. The ‘Selection Testmode’ dialog will be displayed: This dialog contains the following test modes: Test Modes: Quicktest Mode. Auto Mode (IEC) Manual Mode - MAN Opening Time Test. www.megger.com...
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In order to determine the position of the High-speed DC Circuit Breaker, a current Icheck of 100 A per connected DC Current Generator is injected before and after every test. The test current is represented in the following graph: If the system detects the High-speed DC Circuit Breaker in an incorrect position, the following message is displayed: www.megger.com...
To obtain an estimate of the trip level value in case the exact value is unknown. To quickly determine whether the High-speed DC Circuit Breaker is functioning. In the dialog ‘Selection Testmode’: Select ‘Quicktest Mode’. The following dialog will be displayed: www.megger.com...
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The value can be customized further by pressing ‘XXXX ms’: The slope duration can be customized to any duration between 600 and 2,000 ms. NOTE : The obtained result in the Quicktest Mode is automatically used as the reference for Auto Mode. www.megger.com...
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If the found trip level in the Quicktest Mode is due to the high rate of current rise, it will not elicit a trip in the Auto Mode test. To start the test, press the ‘Start’ button. www.megger.com...
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If the High-speed DC Circuit Breaker does not trip during the current injection, the following dialog is displayed: This could mean that the main circuit or over-current release mechanism of the High-speed DC Circuit Breaker malfunctioned, or that the I was simply not reached by the injected current. www.megger.com...
I_ref < 0.75 * 4,0000 * (number of power units) If I_ref > 75% of the maximum current capacity of the BALTO Modular, K1 and K2 are restricted. E.g. for 5 power units K1 will always be 99% and K2 will be 101% To start the test, press ‘Start’.
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1,000 ms. For high current injections, 500 ms is used to conserve battery power. k1 = Point e, start of the measurement interval. Measured release current. k2 = Point f, end of the measurement interval. t3 = The test duration, depends on the e and f values and applied current rise. www.megger.com...
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The following screens will be displayed when the trip occurs before point e : When selecting the graph-button, the following screen will be displayed : Perform a new AUTO-test, with the new I_ref value, until the breaker trips in the 200A/s interval. www.megger.com...
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The obtained results should be consistent and within the e - f measurement interval. Inconsistency in the measured values could indicate a malfunction of the High-speed DC Circuit Breaker opening mechanism. Also see the ‘Opening Time Test’. If no trip occurs, the following dialog is displayed: www.megger.com...
Reaction Time Tests (if supported by the system). 9.10.3.1 Opening Time Test. This test determines the mechanical response time of the High-speed DC Circuit Breaker. The mechanical response time is only part of the total electrical interruption time during a real overcurrent event, as www.megger.com...
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: Current direct setting di/dt Initial current rate of rise Rated voltage Ûarc Maximum arc voltage Total break time Time-constant of the circuit Mechanical response time Select ‘Opening Time Test’ in the ‘Manual Mode’ menu. The following dialog is displayed: www.megger.com...
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High-speed DC Circuit Breakers with an inductive shunt (di/dt sensitive) may trip during the rising slope of the injection. For this reason, the 60% to 110% option is available to avoid a trip during the rising slope. To start the test, press the ‘Start’ button. www.megger.com...
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Il and Ih. Otherwise, the High- speed DC Circuit Breaker may not trip, or may trip too soon. Result: If the measured trip falls outside of the range t2 ➝ t4, (200ms) the measurement is considered invalid. www.megger.com...
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Operation Measurement results. The test result is displayed in the following dialog: To store the result into the current report file, press the ‘Save’ button. The graph button opens the graph dialog illustrating the performed measurement. www.megger.com...
(e.g. a shunt) must be included in the circuit of the Primary Injection. Depending on the configuration, the complete response chain can be verified, as well as the thresholds of the DC Protective Relay parameters. Select ‘DC Protection Relay Test’ in ‘Manual Mode’ menu. The following dialog is displayed. www.megger.com...
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Bias current used for simulating a starting condition. Fixed at 100 A per connected DC Current Generator. Specified current increase by the user (dI). di / dt = Specified current slope by the user (dI / dt). dt = Calculated automatically based on the specified current increase and slope. www.megger.com...
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Relay. The tripping of the Protective Relay can be measured directly if it provides a voltage-free ‘NO’ (Normally Open) trip output contact. This contact can be connected to the ‘trip’ terminals of the ‘PROTECTION TEST’ hardware. Trip detections will typically also display on the Protective Relay itself. www.megger.com...
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If the time constant is unknown, a theoretical calculation can be made based on the line characteristics. Press ‘Parameters’ to open the time constant calculator. The following dialog is displayed: In this dialog, the line characteristics can be provided. To calculate the time constant, press ‘Calculate’. Press ‘Apply’ to use the calculated time constant. Example: www.megger.com...
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➝ Icc/τ ➝ U/L. Measurement results. The test result is displayed in the following dialog: To store the result into the current report file, press the ‘Save’ button. The graph button opens the graph dialog illustrating the performed measurement. www.megger.com...
‘Trip’ input (3) of the ‘PROTECTION TEST’ interface. Fig 36: PROTECTION TEST Modular PROTECTION TEST COMPACT 4000 Measuring reaction time. Manual closing. Select ‘Manual Closing Reaction Time’ in the ‘Manual Mode’ menu. The High-speed DC Circuit Breaker must be in the open position. www.megger.com...
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The generated current is corrected within a few milliseconds. Measurement results The test result is displayed in the following dialog: The graph button opens the graph dialog illustrating the performed measurement. www.megger.com...
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If an error code is displayed, please check for the following: Faulty connections of the measurement cables. Incorrect connection of the command button. Faulty connections on the High-speed DC Circuit Breaker. The time-out is exceeded. www.megger.com...
When started, the system will begin sending the test current. The resulting reaction time is the time between the command input and the measured interruption of current. Measurement results The test result is displayed in the following dialog: The graph button opens the graph dialog illustrating the performed measurement. www.megger.com...
This function is used for performing a Current Injection at a constant specified current. It can be used for calibrating current monitoring systems. Select ‘Shunt Mode’ in the ‘Manual Mode’ menu. The maximum allowed duration of the Current Injection is limited to 60 seconds. However, if the battery level becomes too low, the test will stop automatically. www.megger.com...
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(These values should be more or less identical.) Measurement principle. The desired test current Itest is injected during the configured duration t test. During the first and last 250 ms, the change in current is applied gradually. These durations are fixed. www.megger.com...
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To start the test, press the ‘Start’ button. The following dialog is displayed: Running time of the ongoing Current Injection. (2) The remaining time until the next injection. (1) The Current Injection can be terminated early by pressing the ‘Stop’ button. www.megger.com...
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1. The following dialog is displayed if the test current is set too low: 2. The following dialog is displayed if the test current is set too high: Measurement results. The test result is displayed in the following dialog: www.megger.com...
Please consult the technical specifications of the manufacturer of the device before proceeding. Establishing the connection for the measurement between the following devices: Fig 37: Control Panel: µOhm measurement connection. 1. The Control Unit - External measurement. 2. The High-speed DC Circuit Breaker main contact. www.megger.com...
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Operation Fig 38: Test object: Measurement connection. NOTE : Please disconnect the voltage drop test leads after the voltage drop measurement has been completed. Making a measurement Select ‘mV’ in the ‘Selection Testmode’ menu. The following dialog is displayed: www.megger.com...
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= I_ref (selected test current). Several samples are measured between 500 ms and 600 ms; the average value is displayed in the result. The measured voltage is converted to resistance using Ohm’s law. Example: Testing with 2,000 A: www.megger.com...
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The test result is displayed in the following dialog: NOTE : For information regarding the tolerable voltage drop values and testing procedure, please consult the technical specifications provided by the device manufacturer. The graph button opens the graph dialog illustrating the performed measurement. Error message. www.megger.com...
Contact NO - Trip 2 (4) Fig 39: PROTECTION TEST module PROTECTION TEST module of the BALTO Modular of the BALTO COMPACT 4000 Example : Double-contacts switches B Contact NC - Trip 1 (3) - # 2/4 Contact NO - Trip 2 (4) - # 1/3 Double-contact switches E www.megger.com...
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The test current will be determined by the number of Power Units of the BALTO System. The increase of the slope has been fixed to 600 ms and is not changeable. The operating principle is identical to the Quicktest Mode. www.megger.com...
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The indicated values Trip Current /Trip time in the ‘P26_Graph’ dialog are not really relevant as they depend on the I of the breaker and the slope generated by the BALTO. The values are only displayed when the functioning of the contacts NO/NC is correct. www.megger.com...
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Error codes test results. These error codes are test-related and are displayed in the test result dialog. Default error code. Code 100. Close the breaker and try again. Error codes test results I_Max NO - NC Code 111. www.megger.com...
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Check the connections and mechanical state of the NO/NC auxiliary contacts. Code 112 Check the connections and mechanical state of the NO/NC auxiliary contacts. Code 113 Check the connections and mechanical state of the NO/NC auxiliary contacts. www.megger.com...
Pressing an empty field on the screen will open the virtual keyboard for text entry. Report information can be entered at any point during testing. www.megger.com...
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An automatic report name can be selected to use a field’s entered value as the name for the report automatically. NOTE : By selecting a field to use as the automatic report name, the operator must enter the field to save the report. If the field is left blank, the following dialog is displayed: www.megger.com...
This table shows the date and time of the measurement, the measurement parameters and results, and the type of measurement. The measurements table stores up to 20 measurements. The values contained in the measurements table can be saved to a report file by pressing ‘Save’. The following dialog will be displayed: www.megger.com...
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Report files are stored and exported in BALTOWin format, CSV format and PDF format (which includes the measurement injection graphs). To clear all report files stored in the system, press the ‘Delete’ button. Confirm by pressing ‘Yes’ in the displayed pop- up window: www.megger.com...
DC Current Generators, and use the bottom slot for testing each DC Current Generator one by one for the BALTO Modular. For the BALTO COMPACT 4000, there is only one slot. The indicators on the left-hand side indicate which slots are currently connected to a DC Current Generator.
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The results are displayed in the table as follows: Current differences that exceed 5% of Iout are shown in red, indicating a problem with the DC Current Generator or system calibration: Pressing ‘RESET’ will clear the results table for performing another test. www.megger.com...
Operation 9.13 Info dialog The information dialog is opened by pressing the ‘Info’ button in the Main Menu. The following dialog is displayed: Press ‘OK’ to confirm any active warnings or alarms. www.megger.com...
2. Press the ‘Back’ button in the Main Menu to return to the ‘Start Dialog’. 3. Press the ‘EXIT’ button. 4. To shut down the system, confirm by pressing ‘Yes’ in the displayed pop-up window: 5. Please wait for the system to shut down safely. This may take up to a minute. www.megger.com...
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In this dialog, press ‘SHUTDOWN WINDOWS’ to begin shutting down the system. ATTENTION : If the BALTO System is being shut down and disassembled for transportation, it is highly recommended to discharge the DC Current Generators using the charge/discharge tool. www.megger.com...
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Operation Fig 40: Discharging a DC Current Generator. www.megger.com...
40,000 A. The Control Units must be fitted with Master/Slave connectors to do this. 10.1 System Assembly. Each BALTO Modular comes with a fully equipped energy compartment, i.e. with 4 rows of batteries and 5 ultracapacitors. 3 versions are available : BALTO Modular 24000-40 with 6 current generators ...
Male connector for system cable. Slave Control Unit. Fig 42: Control Unit: Slave. Female connector for system cable. 10.2 Start-up master/slave. Boot up both BALTO Modular systems independently. When both systems are ready connect the cable between the two Control units. www.megger.com...
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Fig 43: BALTO Master/Slave connexion with system cable. Plug the connectors 1 and 2 of the system cable on the respective control units (for control and commands), and de BNC connectors 3 (for PWM). The following images are displayed on both Control Units: Master Control Unit. www.megger.com...
10.2.1 Operating Master/Slave. The operation of the Master/Slave versions remains identical to all other versions. The only difference is that a maximum current of 24.00 0A, 32.000 A or 40.000 A can be injected depending on the model. Example: www.megger.com...
By activating the ‘Master/Slave’ button 8 the following information is available: Information on the voltage and charging current 7 of the Batteries from both BALTO Modular systems is displayed. When pressing button 8 without the two BALTO Modular systems connected together, the following screen will be displayed : www.megger.com...
The following information is displayed: The extra line - position 11 - gives the information on the Master/Slave Status. The connected Slave BALTO System has no Power Units (Current Generators) placed in the Support Carriage. All tests are blocked. www.megger.com...
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A difference of 1 Power Unit is allowed, for example: Master 3 - Slave 2 Master 3 - Slave 4 However, use of an asymmetrical amount of Power Units may have an effect on the lifetime of the batteries. www.megger.com...
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The Slave BALTO System is in an Error Status. To have a view on the nature of the warning, please consult the display of the Slave BALTO System. All tests are blocked. There is no connection between the Master and the Slave. ‘OK’ - With this button confirm warnings and alarms. www.megger.com...
Master/Slave version. 10.4 Stop master/slave. To stop the master/slave application, go back to the main menu on the Master and disconnect the cable between the two systems. www.megger.com...
BALTO PROTECTION TEST module. In this way the BALTO can register the trip command of the protective relay. On the next page it is depicted how the protective relay is connected in a live environment and in conjunction with the BALTO PROTECTION TEST module. www.megger.com...
Secondary Injection. Fig 44: Connection with PROTECTION TEST Connection with PROTECTION TEST module of BALTO Modular. module of the BALTO COMPACT 4000 11.3 DC Protective Relay Interface. The PROTECTION TEST module is equipped with outputs for testing DC protective relays.
Cable 1 is required to provide the power to the Control Unit. It is possible to use the Control Unit without a connection to the BALTO Modular. In that case a specific power cable is required (available as an accessory). The cable is depicted below.
Secondary Injection. 11.5 Main Menu. From the ‘Start Dialog’, the application for the test modes will be activated by touching the image. The ‘Main Menu’ will be displayed … In this Main Menu, several sub-menus can be selected: www.megger.com...
+ 7.500 A - 7.500 A + 7.500 A As feedback - trip contact - an auxiliary contact from the DC Protection Relay is utilized, select between: NC - Normal Closed or NO - Normal Open. www.megger.com - 20 mA...
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The output voltage from the BALTO PROTECTION TEST module should be in the same range as expected by the DC Protective Relay. Recalibrate Output. Before executing tests, it is appropriated to recalibrate the output. By activating the corresponding function, the next dialog will be displayed. + 7.500 A www.megger.com...
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Secondary Injection. Fig 46: Connection for recalibrate output. Output - mV (2) connect to the External measurement (5), control with a Volt-meter. www.megger.com + 7.500 A...
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As feedback - trip contact - an auxiliary contact from the DC Protective Relay is utilized, select between: NC - Normal Closed, or NO - Normal Open. The connection to the voltage output is automatically done. Adjust output range Fig 47: Adjust output range. + 7.500 A www.megger.com...
“Protection Relay Test” in Manual mode. The test capabilities available under “Protection Relay Test” are much more elaborate compared to the primary injection tests. www.megger.com + 7.500 A...
To perform tests, the operator needs to enter various values that correspond to the function of the protective relay that needs to be tested. Slope types. Those tests can be configured for a linear or exponential injection. + 7.500 A www.megger.com...
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Flat Part The time to hold the final current after the injection. Principle of measurement. Linear injections, example : Example: The key ‘Preview’ from the dialog displays the dialog ‘P26_Graph’ with a view on the injection graphic. www.megger.com + 7.500 A...
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These values can either be entered directly, or their theoretical values can be computed by the BALTO from line characteristics by activating ‘Calculate Tau’. Enter data in this dialogue and active with the button ‘Calculate’, then ‘Apply’. For an explanation of the parameters, check the description in the primary injection section. + 7.500 A www.megger.com...
Multiple step injections are configured by pressing the ‘Add Step’ button until the desired number of steps is reached. The scrollbar is used to switch between steps. To remove a step, press the ‘Remove Step’ button. To revert to the initial configuration, which contains the default bias step and an empty step, press ‘Reset’. www.megger.com + 7.500 A...
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= 100 ms Step 4: Linear dt = 75 ms I = -4000 A flat part = 100 ms Results of advance configuration. Press the ‘Preview’ button to get a graphical representation. + 7.500 A www.megger.com...
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Test results are displayed in the following dialog: This dialog displays whether the test resulted in a trip. If so, it displays at what time and current level the trip occurred The graph key displays the results of the performed measurements. www.megger.com + 7.500 A...
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This allows a user to simply select a test and run it, rather than entering the parameters manually each time. Reports. From the main menu, activate the sub menu ‘Reports’. The report handling is identical to the report section for primary injections. + 7.500 A www.megger.com...
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From the Main Menu, press the button ‘Info’ to go to the information sub-menu. The following screen will be displayed. A red message means that there is an active alarm that is blocking any further secondary injections. For more information, Consult chapter 15. Troubleshooting. on page 156. www.megger.com + 7.500 A...
A configuration is defined as the number of connected DC Current Generators. There is a calibration set for one connected DC Current Generator, a set for two connected DC Current Generators, and so on. A BALTO Modular System contains up to 5 calibration sets. The BALTO COMPACT 4000 has only 1 calibration set.
If the main BALTO application has already started, it must be closed to reach the launcher dialog. Please consult the chapter ‘Operation’ - section ‘Exiting the BALTO application’. When asked to shut down Windows, press ‘No’. 12.2.2 Operation Access conditions After launching the calibration software application, the following dialog is displayed: www.megger.com...
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Calibration WARNING : The calibration procedure should only be performed by trained personnel. Megger cannot be held responsible for incorrect use of the device or any property damage and/or injuries caused as a result. To accept the calibration software conditions, press the ‘Accept’ checkbox.
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NOTE : The battery voltage and charge current are displayed in the top-right corner of the screen. The colour indicates the battery status: Green: battery voltage is normal, fully charged. Orange: battery voltage is normal, still charging. (I > 5 A) Red: battery voltage is low. (U < 13 V) www.megger.com...
The calibration reports are only created if the operator presses ‘Save Report’ at the end of the calibration. NOTE : Please note that the BALTO System only saves the last calibration report for any given calibration set. Any older calibration reports are overwritten. 12.2.3 Step 1/6 – OFFSET CALIBRATION www.megger.com...
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The offset calibration only tests a limited range for the resulting value (0 - 1,500). The nominal value is around 230. If the offset is not found within this range, the following error dialog is displayed: This error means that the maximum offset value has been reached without measuring current from the calibration sensor. www.megger.com...
The calibration sensor output signal reacts to flowing current. Fig 49: Sensor for calibration. If problems persist, please contact Megger technical assistance. 12.2.4 Step 2/6 - CALIBRATION OF OUTPUT FACTOR This dialog calibrates the output factor. The calibration is performed by injecting 80% of the maximum available current.
Please check the following: The calibration sensor is operational and properly connected to the µΩ input. If problems persist, please contact Megger technical assistance. 12.2.5 Step 3/6 - CALIBRATION OF INPUT FACTOR This dialog calibrates the internal current measurement factor.
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The input factor will be adjusted according to the calibration sensor measurements. When finished, the resulting value is displayed: The nominal value is around 1100. Press OK to confirm, and continue by pressing ‘Next’. Error message: If the input factor cannot be determined within the valid range, the following error dialog is displayed: www.megger.com...
The calibration sensor is operational and properly connected to the µΩ input. If problems persist, please contact Megger technical assistance. 12.2.6 Step 4/6 - LINEARITY ADJUSTMENT I-OUT This dialog adjusts the linear calibration performed earlier for improved output accuracy.
Repeat the procedure until all points are calibrated. Press ‘Next’ to continue. The linearity adjustment can be skipped to perform a faster calibration. However, to obtain maximum accuracy, it is recommended to perform all 6 steps. www.megger.com...
The deviation is displayed as a percentage relative to the output current (Iout) and as a percentage relative to the maximum available current (Inom). To save and apply the new calibration values, press ‘Apply settings to BALTO’. The following dialog is displayed when the new values have been stored successfully: www.megger.com...
In this case, pressing OK will close the calibration program. 12.2.9 Results. The final dialog displays the new calibration values that were applied to the system and provides the creation of a report. The calibration sets overview is displayed at the top of the dialog. www.megger.com...
To save the calibration report, press ‘Save Report’. When the report has been saved successfully, the following dialog is displayed: If a USB stick is connected to the system, the report will automatically be copied to the USB stick after saving. www.megger.com...
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OK to continue. If no change in the system configuration is detected, an error dialog will be displayed allowing the operator to try again or cancel. If all calibration sets have been calibrated, exit the calibration program by pressing ‘Exit’. www.megger.com...
The battery indicator must be green to (warning). continue. 12.3.2 Initialisation warnings. Warning no. Cause: Action: Battery voltage < 13 Please wait for the battery to charge fully before starting the Battery voltage calibration. The battery indicator must be green to continue. critically low. www.megger.com...
Please check the following: The High-speed DC Circuit Breaker is closed. The High-speed DC Circuit Breaker’s configured trip level is sufficiently high. The calibration sensor is connected properly. If the problem persists, please contact Megger technical assistance. www.megger.com...
To start the installation, run the ‘BALTOWin_Setup.exe’ installation file from the USB stick on the desired system. The default installation settings should be suitable for a standard system. After the installation has completed, a shortcut will be placed on the desktop and in the start menu (under ‘Megger’). The BALTOWin program will be started automatically.
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The required licence information can be found in the ‘BALTOWin Licence.txt’ text file included on the USB stick. NOTE : The licence code can be used on multiple systems. Installing a newer version of BALTOWin can be done without having to uninstall the older version. The installed licence is maintained. www.megger.com...
BALTOWin. Shortcuts. The shortcut for opening BALTOWin is available on the desktop as well as in the start menu (under ‘Megger’). 13.3 Communication. Communication with the BALTO System is established through the Ethernet interface. NOTE : The report files can also be downloaded using a USB stick. In this case, configuring the Ethernet connection is not required.
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BALTOWin. Select ‘View network status and tasks’. Click ‘Change adapter settings’. Right-click the ‘Ethernet’ adapter and select ‘Properties’. Select ‘Internet Protocol Version 4 (TCP/IPv4)’ and open ‘Properties’. The following dialog is displayed: www.megger.com...
After configuring the IP settings, the Ethernet connection can be made by connecting the Ethernet cable from the PC or laptop to the BALTO System Ethernet interface - Control Unit position 7. 13.4 Operation. 13.4.1 Starting BALTOWin. Start the BALTOWin program using the ‘BALTOWin’ desktop or start menu shortcut. www.megger.com...
Reinitialises the program. ‘Exit Program’. Closes the program. Menu option - Print Print a screenshot of the currently displayed measurements. For printing the complete report, it is recommended to use ‘Export to PDF’ and printing the PDF file instead. www.megger.com...
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Not used for modern BALTO Systems. BALTO 6000A)’ ‘Start Windows Remote Start Windows Remote Desktop for controlling the BALTO System remotely. Desktop’. Menu option - Language Menu option - ? Information regarding the BALTOWin program version. Report results table. www.megger.com...
The connection status indicator is highlighted in yellow if the connection has been established successfully. To begin downloading the report files, click ‘FTP’ - ‘Download files from BALTO’. The download progress bar will appear. Downloading reports may take a few minutes depending on the amount of stored reports. www.megger.com...
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Press OK to confirm the completed download. The open dialog will be shown automatically. Select the report file to open from the list of downloaded reports: Press ‘Open’ to open the selected report file. The report results will be shown in the results table: www.megger.com...
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Exporting to Excel will only work if Microsoft Excel is installed on the system. To export the report to PDF, click the ‘Export to PDF’ button. The PDF file includes the additional report information and the report graphs. www.megger.com...
Report files saved in BALTO software versions 4.08 and newer include the measurement graphs. If the opened report file includes measurement graphs, the ‘View Graph’ button is enabled when selecting a measurement. Click ‘View Graph’ to open the measurement graph in a new window. www.megger.com...
After performing the measurements and saving the report on the BALTO System, a USB stick can be connected to the USB interface to obtain the report files. The report files consist of: Reports in BALTOWin format. Measurement graphs in PNG format. Reports in PDF format. Status messages: www.megger.com...
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Connect the USB stick to a USB port on the PC or laptop. Select ‘File’ - ‘Open’. Navigate to the USB stick files. Open the ‘Report’ folder. Select the report file to open and click ‘Open’. www.megger.com...
Cleaning off dust can be done using compressed air. The device must be protected adequately when stored. 14.2 Tyres (BALTO Modular only) NOTE : The tyre pressure should be checked regularly. Used tyre pressure: 3 bar (43.5 psi) 14.3 Components 14.3.1 Trained personnel only...
Maintenance 14.3.4 Batteries. The batteries of the BALTO COMPACT 4000 are located in the Main Unit. The batteries of the BALTO Modular are located in the Support Carriage. Replacing the batteries of the BALTO Compact 4000 can only be performed by a Megger Service Centre. It is sufficient to ship the Main Unit.
The embedded PC uses a battery to back up the date and time. It is advised to replace the battery every five years. If the battery is no longer functioning properly, time & date may not be correct. 14.7.2 Ventilation. Ensure that all vents are kept clean and free of dust or particle build-up. www.megger.com...
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Maintenance Fig 53: Control Unit : Vent terminal. Fig 54: Main Unit: Vent. Fig 55: DC Current Generator vents www.megger.com...
The ‘Start Dialog’ awaits the starting of the ‘TwinCAT’ runtime, and automatically starts the main BALTO software. If the ‘TwinCAT’ runtime fails to start, the system will shut down after approximately 2 minutes. If this occurs, please try restarting the system. CAUTION : If start-up issues persist, please contact Megger technical assistance. 15.2 Info dialog status.
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55 °C, an alarm is displayed, and further use is blocked until cooled. OK button. Press the ‘OK’ button to confirm and dismiss system warnings and alarms. Software version. The software version and build date is displayed in the bottom right corner of the ‘Info’ screen. www.megger.com...
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A red status bar indicates that there is an active alarm blocking further use of the BALTO System. Pressing the ‘OK’ button confirms the alarm and returns the operator to the testing menus. Operation of the system is blocked and the background colour is changed to red while the alarm persists. www.megger.com...
If the Emergency Stop lever cannot be switched on/off smoothly any longer, or a deterioration of the injections is perceived, the Emergency Stop may be damaged. CAUTION : If the Emergency Stop Device has suffered damage, please contact Megger technical assistance before performing any further Current Injections.
Depending on the problem, the operator may need to wait for the batteries to charge, connect a DC Current Generator, free up disk space, or wait for the ultracapacitors to cool. If a PLC error has occurred, try restarting the system. Contact Megger technical assistance if the problem persists. Code no. 2 Message: No Power Units available.
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Action: If the Calibration Tool is available, a calibration of the system can be performed. For more information, consult the chapter ‘Calibration’. Contact Megger technical assistance if the problem persists. Code no. 13 Message: Free disk space has reached the warning level. Please delete old log-files.
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Action: Reduce the I-ref value. Code no. 33 Message: The maximum number of tests for one report has been reached: Please insert a report name to close this form. Cause: See code no. 25. Action: See code no. 25. www.megger.com...
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Current value too low. Please raise the value of I-ref (min=… A) Action: Increase the I_ref value. Code no. 51 Reserved for secondary injection Message The system has detected at least one Current Generator. Action Open the DC High-Speed Circuit Breaker and remove all Current Generators. www.megger.com...
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Cancel to abort the deletion procedure. Code no. 204 Message: Invalid password. Cause: The operator has entered an invalid password for a password-protected feature. Action: Please enter the correct password. Code no. 205 Message: Please fill in the “…” field. www.megger.com...
Please fill in the required field in the ‘Info’ tab of the ‘Report’ dialog. Alternatively, change the automatic report name settings by pressing ‘Customise’. 15.4.2 Test result error codes. The following error codes are related to a performed test and are displayed in the test result dialog. www.megger.com...
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Wait for the battery indicator to turn green (battery fully charged) before starting injections. Reduce the impedance of the circuit. Reduce the test current or duration. Contact Megger technical assistance if the problem persists. Code no. 103 Message: Tripped too soon / Imax = … A Cause: A trip has occurred before the valid measurement range in which a trip is expected.
If the battery voltage is below 12 VDC, please wait for the battery to recharge. PLC error. PLC errors regarding the I/O system will prevent further operation. A system restart may be required. Please contact Megger technical assistance if the problem persists Ultracapacitor temperature. ...
Earth cable cross-section: 2.5 mm² Emergency stop lever: Disconnects DC current generators from energy compartment. Control Unit: Functionality: HMI (Human Machine Interface) and CPU Screen Type: TFT touchscreen Screen Diagonal: 145 mm (5.7”) Screen Resolution: 640 x 480 pixels www.megger.com...
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4.5 kg (9 lb) for 2 m, 6.8 kg (14 lb) for 3 m Connectors: DC current generator side: BALTO proprietary. BALTO Modular specific Current consumption: AC 120 V 60 Hz: 7.20 A AC 230 V 50 Hz: 3.50 A Dimensions complete system : 1,200 x 645 x 1,005 mm (47.2 x 25.4 x 39.6”)
3. Pack the instrument carefully to prevent damage in transit. 4. Before the instrument is sent to Megger, freight paid, make sure that the returns label is attached or that the RA number is clearly marked on the outside of the package and on any correspondence. Copies of the original purchase invoice and packing note should be sent simultaneously by airmail to expedite clearance through customs.
19.1 WEEE Directive The crossed out wheeled bin symbol placed on Megger products is a reminder not to dispose of the product at the end of its life with general waste. Megger is registered in the UK as a Producer of Electrical and Electronic Equipment. The Registration No is WEE/ HE0146QT.
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Kent CT17 9EN ENGLAND +44 (0)1 304 502101 +44 (0)1 304 207342 Manufacturing sites Megger Limited Megger GmbH Megger USA - Valley Forge Archcliffe Road Obere Zeil 2 61440 Valley Forge Corporate Center Dover Oberursel, 2621 Van Buren Avenue Kent...
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