TORKEL 900-series

Battery Load Unit

User’s Manual

WWW.MEGGER.COM

Art No. ZP-CS01E Doc. CS033663FE V06a 2019

 TORKEL 900-series

Battery Load Unit


User’s Manual

NOTICE OF COPYRIGHT & PROPRIETARY RIGHTS

© 2016-2019, Megger Sweden AB. All rights reserved.
The contents of this manual are the property of Megger Sweden AB. No part of this work may be reproduced or transmitted in any form or
by any means, except as permitted in written license agreement with Megger Sweden AB. Megger Sweden AB has made every reasonable
attempt to ensure the completeness and accuracy of this document. However, the information contained in this manual is subject to change
without notice, and does not represent a commitment on the part of Megger Sweden AB. Any attached hardware schematics and technical
descriptions, or software listings that disclose source code, are for informational purposes only. Reproduction in whole or in part to create
working hardware or software for other than Megger Sweden AB products is strictly prohibited, except as permitted by written license
agreement with Megger Sweden AB.
This device contains software that is licensed under the General Public License (GPL). If requested, a copy of the source code licensed under
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of the source code can be answered. You may be charged a fee covering the costs of sending you the source code.
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document are trademarks or registered trademarks of their respective companies.
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Postal address: Visiting address:

Megger Sweden AB Megger Sweden AB
Box 724 Rinkebyvägen 19
SE-182 17 DANDERYD SE-182 36 DANDERYD
SWEDEN SWEDEN
T +46 8 510 195 00
E [email protected] www.megger.com

CS033663FE ZP-CS01E TORKEL 900-series 3



Contents

1 Introduction Preparations...................................................... 23
.............................................................. 6 Select "Test Method"........................................ 23
1.1 Product description.............................................. 6 Starting the test................................................. 23
1.2 Features and benefits........................................... 6 Pausing the test................................................. 23
Ending the test.................................................. 23
1.3 Receiving instructions........................................... 7
5.3 Test at constant power....................................... 24
1.4 Warranty............................................................. 7
Preparations...................................................... 24
Warranty repair.................................................... 7
Configuring TORKEL for constant power............ 24
2 Safety Select "Test Method"........................................ 24
.............................................................. 8 Starting the test................................................. 24
2.1 Symbols on the instrument.................................. 8 Pausing the test................................................. 24
Information duty regarding substances on Ending the test.................................................. 25
REACH article 33, SVHC-list ................................ 8
5.4 Test at constant resistance.................................. 25
2.2 Safety instructions................................................ 8
Preparations...................................................... 25
Protection system................................................ 9
Select "Test Method"........................................ 25
3 Instrument description and Starting the test................................................. 25
Accessories........................................ 10 Pausing the test................................................. 25
3.1 Top panel........................................................... 10 Ending the test.................................................. 25
3.2 Side panel.......................................................... 11 5.5 Testing with a load profile.................................. 26
3.3 Included accessories........................................... 11 Preparations...................................................... 26
TORKEL 910...................................................... 11 Select "Test Method"........................................ 26
TORKEL 930/950............................................... 11 Starting the test................................................. 27
TORKEL Viewer.................................................. 11 Pausing the test................................................. 27
3.4 Optional accessories........................................... 12 Ending the test.................................................. 27
TXL extra loads.................................................. 12 5.6 V Logger............................................................ 27
BVM - Battery Voltage Monitoring..................... 12 Starting "V Logger" directly after a discharge
Sensing leads..................................................... 12 test.................................................................... 27
Clamp-on-probe................................................ 12 Starting "V Logger" as a separate test............... 27
Ending the test.................................................. 27
4 Menu system
5.7 Viewing results and reporting............................ 28
............................................................ 14
Viewing the results............................................ 28
4.1 Main menu........................................................ 14
REPORT............................................................. 28
Screen buttons.................................................. 14
TEST menu........................................................ 14 6 External current measurement........... 30
Test configuration.............................................. 15 6.1 General.............................................................. 30
GRAPH.............................................................. 18 6.2 Setting up external current measurement........... 31
RESULT.............................................................. 18 DC clamp-on current probe............................... 31
REPORT............................................................. 19 Troubleshooting................................................. 31
CELLS (optional BVM)........................................ 19 6.3 TORKEL used together with TXL Extra Load........ 32
4.2 TORKEL Viewer.................................................. 20 Multiple units used together.............................. 32
5 Making a test Constant current, regular load connected.......... 33
............................................................ 22 7 Alarm function
5.1 Preparations for testing...................................... 22 ............................................................ 34
Connecting the current cables to the battery..... 22 7.1 Description........................................................ 34
5.2 Test at constant current...................................... 23 Resetting the alarm............................................ 34

4 TORKEL 900-series ZP-CS01E CS033663FE

 

8 How to obtain the desired current..... 36

8.1 When a single TORKEL isn’t enough................... 36
TXL connected to TORKEL ................................. 36
How many units are needed?............................ 36
TORKEL 910...................................................... 37
TORKEL 950....................................................... 38

9 Optional equipment
............................................................ 40
9.1 TXL830/850/865/870/890 (Extra Loads) .............. 40
Panel................................................................. 40
Using the TXL.................................................... 41
Testing............................................................... 41
9.2 BVM - Battery Voltage Monitor.......................... 42
Power & signal connector unit........................... 42
Test with BVM – without TORKEL....................... 45
Optional BVM equipment.................................. 45

10 Troubleshooting
............................................................ 46
11 Calibration
............................................................ 48
11.1 General............................................................ 48
11.2 How to calibrate.............................................. 48

12 Specifications
............................................................ 50
Index........................................................ 54

CS033663FE ZP-CS01E TORKEL 900-series 5

1 Introduction

1 Introduction

1.1 Product description 1.2 Features and benefits

This manual explains how to use TORKEL 900-series of Model overview
battery load units, and it also covers the optional TXL TORKEL 910 930 950
(extra load units) and the BVM (Battery Voltage Moni- Current (max) 110 A 220 A 220 A
tor) system. Voltage (max) 300 V 300 V 500 V
The instrument is designed mainly for capacity tests. BVM functionality No Yes Yes
The unit can be programmed to test a battery bank at Charging measurement No Yes Yes
constant current, constant power, constant resistance Full report functionality No Yes Yes
or using a user-defined load profile. TORKEL can also
be used for testing battery chargers and other electri-
cal equipment that require resistive load testing.
The BVM (Battery Voltage Monitor) is a battery voltage
measurement device that is used for monitoring of cell
voltages and battery blocks in battery banks com-
monly found in electrical power sub-stations, telecom
facilities and computer data center UPS systems.

6 TORKEL 900-series ZP-CS01E CS033663FE

 1 Introduction

1.3 Receiving instructions 1.4 Warranty

▪▪Check the equipment received against the packing list to Products supplied by Megger are warranted against
ensure that all materials are present. Notify Megger of any defects in material and workmanship for a period of
shortage. one year following shipment.
▪▪Examine the instrument for damage received in transit. If Our liability is specifically limited to replacing or repair-
damage is discovered, file a claim with the carrier at once ing, at our option, defective equipment.
and notify Megger, giving a detailed description of the
damage. This warranty does not include batteries, lamps or
other expendable items, where the original manufac-
▪▪This instrument has been thoroughly tested and inspected
turer’s warranty shall apply.
to meet rigid specifications before being shipped. It
is ready for use when set up as indicated in this user We make no other warranty. The warranty is void
manual. in the event of negligence abuse (failure to follow
recommended operating procedures) or failure by the
customer to perform specific maintenance as indi-
cated in this manual.

Warranty repair
Equipment returned to the factory for repair must be
shipped prepaid and insured.
Contact your Megger representative for instructions
and a return authorization (RA) number.
Please indicate all pertinent information, including
problem symptoms.
Also specify the serial number and the catalog num-
ber of the unit.

CS033663FE ZP-CS01E TORKEL 900-series 7

2 Safety

2 Safety

2.1 Symbols on the 2.2 Safety instructions

instrument ▪▪All safety and operating instructions must be read before
using TORKEL.
Caution, refer to accompanying docu-
▪▪All safety and operating instructions for TORKEL must be
ments.
followed.
▪▪All safety and operating instructions must be retained for
Caution, risk of electric shock. future reference.

WARNING
Hot, do not cover
1. The electrical voltage and current used in battery
testing is potentially lethal.
Protective conductor terminal. Ensure that the AC supply is disconnected and any
battery under test is disconnected before attempt-
ing any cleaning or maintenance of TORKEL.
2. Connection and disconnection procedures are
WEEE, Waste Electronic Equipment. extremely important. Be sure to follow the
Please utilize your local WEEE collec- instructions carefully..
tion facilities in the disposition of this 3. Do not touch conducting parts of the clamps on
product and otherwise observe all the current cables or the voltage sensing cables
applicable requirements. when they are connected to TORKEL.
The unit can also be returned to 4. Never connect a TORKEL to a voltage higher
Megger at any time at no charge for than specified.
the disposal. 5. Always connect protective earth (ground).
6. Misuse of TORKEL can be extremely dangerous.
Information duty regarding 7. Inspect cable connections to make sure there is
substances on REACH article 33, no short circuit.
SVHC-list 8. Use an easily accessible power outlet. This will
This product contains a coin cell battery which con- ensure that you can disconnect the power
tains 1,2- dimethoxyethane (CAS 110-71-4) above quickly in case of a problem.
0.1% by weight. 9. When a lead acid battery is charged or dis-
charged i.e. when there is a current flow
through the battery it is always a risk that the
battery can explode.
If there is a bad connection inside the battery
and there is a current flow - the connection will
burn off and there will be an arc, which will
ignite the oxyhydrogen gas in the battery.
For new open (vented) batteries the risk is me-
dium to low but in old VRLA (sealed) batteries
the risk is medium to high.

8 TORKEL 900-series ZP-CS01E CS033663FE

 2 Safety

10. To minimize the risk for personnel injuries: 3. If TORKEL has been stored below freezing for
Always place TORKEL/TXL as far away from the an extended period of time, you must allow 3
battery as possible. Never stand close to a bat- hours for it to adapt to room temperature.
tery during charge/discharge. 4. At high ambient temperatures and high loads,
11. Too high discharge current applied on a battery TORKEL will employ a heat reduction discharge
can cause the battery to explode or get over- scheme that under certain circumstances might
heated. Be sure to not set too high current. induce a high frequency audible noise. This is
12. If the external current measurement is inter- normal, but can be taken as an indication that
rupted or giving false values during the test, the TORKEL is working close to its temperature
current will rise to a higher level than the set limits.
value before the test is shut down. If the battery
is too small for this current or in a bad condition Protection system
- it may explode.
The unit has built-in protection system against over-
13. Never use the TORKEL/TXL Extra Load in an explo-
heating and malfunctioning cooling fans. A built-in
sive environment. Never put the TORKEL/TXL Extra circuit breaker is an important component in the
Load where it can be reached by battery gas. safety system. If the temperature will be too high and/
14. Improperly connected cables carrying high cur- or the cooling fans malfunction, the circuit breaker
rent can cause fire. Make sure that the cables are will trip. There is also a melting fuse connected in
not twisted in such a way that could cause them series with the circuit breaker.
to turn and come loose from the connector.
Always follow the safety instructions in section 2.2.
15. Make sure that there is no dust or dirt in or
around the cooling fans before starting a
discharge test. After starting a discharge test,
check that the fans are running properly and
that the airflow is good. Make sure no hair or
clothing is sucked into the fans.
16. Position TORKEL/TXL Extra Load where air flow
is unobstructed and where it does not come into
contact with any flammable or heat-sensitive
material. Keep a free distance of 1.5 m (5 ft)
to the vertical sides of TORKEL/TXL and 2.0 m
(6.5 ft) above TORKEL/TXL.
17. Do not place TORKEL a) near another TORKEL,
a TXL Extra Load or any other heat source or b)
where the cooling airflow can be blocked. TORKEL
will overheat if there is insufficient cooling.
18. External current shunt may not be used above
300 V DC
19. Do not use any other equipment other than
what is provided or specified.

Important
1. When using the external current measurement
function:

▪▪Always replace the CT internal battery before a

test or use the 9 V DC out from TORKEL.
▪▪Set the correct current ratio in the external current
measurement menu.
2. Do not use liquid detergents or aero-sols when
cleaning TORKEL or TXL units. Use a damp
cloth.

CS033663FE ZP-CS01E TORKEL 900-series 9

3 Instrument description and Accessories

3 Instrument description and

Accessories
3.1 Top panel

1 2 6 7
5 8
3 4 9

12
10 11 13

1. TXL STOP 10. EMERGENCY STOP

Output used for stop discharging from an external Push to stop.
device (TXL). Galvanically isolated. The connection to the test object (battery bank) is
2. SERVICE interrupted in the same way as if mains would fail.
Connector for service purposes only. In addition, a separate signal will stop the electron-
3. ALARM ics and the discharge process stops.
Output equipped with a relay contact for trigger- The emergency stop works even if the electronics
ing an external alarm device. fail.
4. DC OUT Reset the button by turning it right
9 V output for external current clamp. 11. Control knob
5. I EXT ≤ 1 V For entering settings etc. Press to confirm a set-
Input used to measure current in an external path ting.
by means of a DC clamp-on current probe or a cur- 12. Buzzer
rent shunt. For alarms.
6. Display 13. ON/OFF switch
Touch screen 7"
7. BVM1, BVM2
USB connections for BVM units.
8. USB connection
For USB memory stick.
The USB memory stick must be FAT32 formatted.
9. Ethernet connection
For service of the instrument.

10 TORKEL 900-series ZP-CS01E CS033663FE

 3 Instrument description and Accessories

3.2 Side panel 3.3 Included accessories

14 15
TORKEL 910
Cable set
Cable set, 2 x 3 m, 25 mm2 (10 ft), for connecting
TORKEL to the battery.

16 17 18 Cable set (GA-00550)

14.
Protective conductor terminal TORKEL 930/950
15. MAINS
Connector for mains supply. Cable set
Cable set, 2 x 3 m, 70 mm2 (10 ft), for connecting
16. + TORKEL to the battery.
Connection terminal (+) for the battery (or other
DC source)
17. VOLTAGE SENSE
Input for sensing voltage at the battery terminals.
Impedance to the battery current terminals is
>1 MΩ

18. –
Connection terminal (-) for the battery (or other
DC source).

Cable set (GA-09550)

TORKEL Viewer

TORKEL Viewer can be used to edit and print out reports

CS033663FE ZP-CS01E TORKEL 900-series 11

3 Instrument description and Accessories

3.4 Optional accessories Extension cables

Extension for GA-00550, 2 x 3 m, 25 mm2, male / female.
TXL extra loads
See chapter "9 Optional equipment" on page 38

BVM - Battery Voltage Monitoring

Enables automatic battery cell voltage logging during
capacity tests. Up to 2x120 units can be used (Daisy-
chain).
For complete information see the BVM data sheet. Extension cable set (GA-00552)

Extension for GA-09550, 2 x 3 m, 70 mm2, male / fe-

male.

Sensing leads
For measuring voltage at battery terminals. 2 x 5 m Extension cable set, high rating (GA-09552)
(16.4 ft).

Sensing lead set (GA-00210)

Clamp-on-probe
Clamp-on probe, 1000 A DC.
To measure current in external circuit.

Clamp-on-probe (XA-12991)

12 TORKEL 900-series ZP-CS01E CS033663FE

 4 Menu system

CS033663FE ZP-CS01E TORKEL 900-series 13

4 Menu system

4 Menu system

4.1 Main menu TEST menu

Screen buttons
Confirm

Exit without changes

Run

Pause the test to make any cor-

rections/changes in the settings*)

Stop

Temperature compensation Test method

Shown when compensation is A test can be made in six test methods, "Constant I"
enabled is default.

Quick guide
1] Press the button and select test method.
▪▪Constant I (current)
Open test file library ▪▪Constant P (power)

New test ▪▪Constant R (resistance)

▪▪Profile I (current profile)
Test configuration
▪▪Profile P (power profile)
Information bar ▪▪V Logger (Current with monitoring during charge)
Shows messages and is used for
acknowledge alarms
A] For Constant I, P or R you press the numeric
field and make the settings for the parameter
Information field using the On-screen keyboard or the control
Shows voltage and current knob.
*) The pause time has limitations regulated by inter-
For Profile I or Profile P a new tab will be
national standards. If the pause time is too long the
battery may have to be recharged before a new test is
shown on top of the screen together with a win-
done. dow for the settings.

14 TORKEL 900-series ZP-CS01E CS033663FE

 4 Menu system

Here you configure your profile and press to

start the test or press TEST SETTI to return to the test
menu.
For V Logger the voltage will be logged during
charge. You can set time values for warning and stop.

Warning and stop limit parameters

You can set TORKEL to issue a warning and/or to stop:

▪▪When the voltage has reached a certain level.

▪▪When a certain amount of capacity is discharged.
▪▪After a specified time. Note This means that the discharge is stopped and
▪▪When a cell voltage has reached a certain level (if BVM is you can change parameters and continue the
used, see section "9.2 BVM - Battery Voltage Monitor" on test or press to close the test.
page 40).
When BVM stop limit is set and a BVM gets
The warning and stop limits can be set and changed
loose during test, the test stops.
during a test.
The settings for the warning and stop levels are inde- Procedure for ignoring erroneous cells and,
pendent of each other. for example, connections that give mislead-
ing voltage drops is described under "CELLS
See also chapter "7 Alarm function" (optional BVM)" on page 19
Warning limit Setting the limit parameters
When a "Warning" limit is reached, the "information 1] Press the numeric field and make the settings
bar" turns yellow and the warning cause is displayed. for the limit parameter using the On-screen
The alarm buzzer sounds as well. keyboard or using the control knob (press to
confirm).
2] Enable the limit by touching the checkbox.
3] Go on with the desired parameters.

Test configuration
1] Press

ID Labels

The warning is confirmed by pressing the "informa-

tion bar" and the alarm buzzer stops to sound.

Note The test will continue.

Stop limit
When a "Stop" criteria is reached, the "information
bar" turns red and the cause of stop is displayed.

2] Click the label fields and enter the informa-

tion as desired.

CS033663FE ZP-CS01E TORKEL 900-series 15

4 Menu system

Settings

In this example 200 A is set as nominal current. The

temperature is set to 35 degrees.
It gives a compensated current discharge level on
215.1 A.

▪▪Select Internal (prefault) or External.

For external current clamp / current shunt set the Ratio,
see section"6.2 Setting up external current measurement"
on page 31.
▪▪If desired enable temperature compensation.
▪▪If desired enable cell numbering from plus (default
numbering is from minus).

Temperature compensation

Nominal capacity calculated on 200 A => nominal

capacity 33 Ah

Time Correction
Setting of nominal time will give a compensated time
depending on temperature selected. However tests
has to be stopped manually or by any stop limits
selected.

If temperature compensation is enabled, see above, a

button will be shown in TEST menu.

Note The activation of temperature compensation

in settings remains active until deactivation
occurs. The activation forces the user to
always enter a temperature before starting a
new test.

1] Press to make settings for the tempera-

ture compensated test.
Note Time correction is also possible after comple-
2] Select Rate or Time correction. tion of the test.
You can select according to IEEE and IEC
standards or Manual setting:

Rate Correction
The rate compensation is for capacity tests up to 1
hour. Depending on the set temperature the nominal
current will change.
It will be reflected in the “TEST SETTING” menu.

16 TORKEL 900-series ZP-CS01E CS033663FE

 4 Menu system

Language 4] When the start menu appears, tap on the

space bar and select “Connected”
After a short while, the button gets
activated. From here a discharge test simula-
tion with BVM can be performed.
5] When the TORKEL has been turned off,
the simulator mode will be disabled when
TORKEL is turned on again.

Calibration
See section "11.2 How to calibrate" on page 46.

Test Manager
▪▪Manage language files for the internal software and select
U or V as the symbol for voltage. The database can store up to 30 tests.
1] Press
About
When an USB stick with a license file is inserted in
one of the USB ports, the “License file” button will be
highlighted in blue.

▪▪Information about software version etc.

▪▪Upgrade License.
A license file is to be copied to TORKEL
Upgrade can be performed to TORKEL 930/950.

How to upgrade
1] Press the “License file” button and select the
license file from the menu that appears.
The upgrade will be performed directly. 2] Select a test by marking the checkbox.
System 3] You can use the buttons at the bottom for
actions described below:

to open a test

to put test in the trash can

to undelete all tests

to save test on USB stick for use in PC

to import data from USB

to save a test in TORKEL Win format
wich makes it possible to open it in
▪▪Select external keyboard. TORKEL Win

▪▪Set the time Note Downloading and opening files in TORKEL

may take some time depending on the size of
▪▪Simulator mode the files.
Using simulator mode you are can simulate a test
without a battery and BVM connected.
1] Enable "Simulator available".
2] Shut down and restart TORKEL.
3] During start of TORKEL select the “BVM
Simulator “ button and “Simulator”.

CS033663FE ZP-CS01E TORKEL 900-series 17

4 Menu system

GRAPH

1] In the RESULT and BATTERY tabs you can add

information by pressing the "Edit" button.
Graph settings
1] Press

By pressing in the diagram, test data for the selected time

will be shown in the table.

The specific time interval can also be examined by

zooming the time axle.
Make settings for the axis. Above is an example of a
setting that will show the voltage curve. 1] Press in the diagram were you want to exam-
ine details on the voltage curve.
Zoom
2] Press the control knob shortly and turn it
1] Press to zoom the graph clockwise to zoom. Tap on the diagram and
to scroll the cursor for this time interval.
3] To return to the full test, press the control
knob shortly and turn it counterclockwise.

REPORT
4] The saved tests can be stored on an USB
memory stick and transferred to a PC or
transferred using FTP communication. The
included PC software TORKEL Viewer can
be used to edit and print out reports. Edited
reports can be transferred back to TORKEL
i.e. you can design the test and settings in
TORKEL Viewer.
2] Set scale for y-axis and set the offset value or Note The USB memory stick must be FAT32 format-
select Auto scale. ted.

RESULT
After ending a test you can go into the different tabs
to se the result.

18 TORKEL 900-series ZP-CS01E CS033663FE

 4 Menu system

CELLS (optional BVM)

When using the optional BVM equipment you get
information of the cell voltages, see also section "9.2
BVM - Battery Voltage Monitor" on page 40.

Connection change if there is a voltage drop in the intercon-

nection.

Diagram shows voltage per cell during the test. Numbering

of cells depends on cell direction (cell 1 "+" or "-"). Informa-
tion on cell numbering and direction are displayed on the
screen.

▪▪The LIVE voltage means the present voltage

▪▪The FLOAT voltage means the voltage read prior to
removing the battery charger.
▪▪The START voltage is when the discharge tests start.
1] By pressing a cell bar, readings can be seen in Connection change when a battery cell voltage drops below
the table as the "Sel" value. set limit. Faulty battery is disconnected but the BVM should
The cell direction can be selected either from remain in the loop.
plus to minus or opposite (cell 1 "+" or "-")

Stop limit on cell voltage

If a cell reach the stop limit during a test it is possible
to ignore the cell for future stop.
1] Press the status bar to silent the alarm
2] Shoot out or disconnect the failing cell/cells.
The BVM should be kept in the loop.
3] Press to continue the test

Note All BVMs that read 0V when restarted will be

ignored for future cell voltage stop.

How to ignore voltage drop in long

interconnections in battery strings
If there is a long interconnection in a battery string the
voltage drop during a discharge test will affect the cell
voltage value. This voltage drop can be cancelled by
connecting a BVM on each side of the interconnec-
tion. It will be a 0 V bar, displayed as a gap in the bar
graph. When the test starts all 0 V bars will be ignored
and removed from the bar graph, in the data collec-
tion and in the report.

CS033663FE ZP-CS01E TORKEL 900-series 19

4 Menu system

4.2 TORKEL Viewer ▪▪The “Plot” tab gives you the possibility to check the
battery measurements or the BVM voltages diagram.
TORKEL Viewer is delivered together with TORKEL By right click and drag on the y-scale of resp. entity the
(not with TORKEL 910) on a USB stick. diagram lines can be modified.
The time scale can also be adjusted by right click and drag
TORKEL Viewer runs under MS windows 7,8 and 10. the scale.
1] Double click the: By placing the cursor in the diagram and scrolling with
mouse, zooming of the time scale will be done.
“TORKEL Viewer Setup.msi” file.
Clicking the “Auto zoom” will reset the diagram to the
2] Follow instructions and the TORKEL Viewer default appearance.
will be installed on your computer. Clicking the “Export Plot” button will export the diagram
in a .png format.
Note After installation you can find a demo file at The BVM measurements can also be examined by
C:\Program Files (x86)\Megger\Torkel Viewer\ selecting the BVM voltage diagram in the “Choose plot to
Reporting. display”.
The diagram can be moved by right click and drag.
3] Click to open the program.
Each voltage cell can be checked by clicking on the cell
bar. Float, start and end values are presented.
▪▪The “Preview” tab is simply a way of checking the report
after modification, prior saving or print out of the report.
▪▪The "TorkelCalc" tab is used for calculating how many
TORKELs and TXLs are needed.
▪▪The "Settings" tab contains, among other things,
language setting.
▪▪The cell bar diagrams shows numbering of cells and
whether it has + or - cell direction.

▪▪The "Report " tab includes several settings and options

on how to set up the test report.
With the “Save test file” button a test can be prepared in
advance with information of the test object.
Cell voltage reading with possibility of 7 percentage
intervals applies to relevant standards and a possibility for
user-defined choice.

Show user defined time stamps

20 TORKEL 900-series ZP-CS01E CS033663FE

 5 Making a test

CS033663FE ZP-CS01E TORKEL 900-series 21

5 Making a test

5 Making a test

5.1 Preparations for testing Tip

To get a more accurate voltage reading
when current cables are long and the
WARNING discharge current is high.
See the chapter "2.2 Safety instructions"
Connect the voltage sensing cables
on page 8.
between the “VOLTAGE SENSE” input on
TORKEL and the battery terminals.
1] Connect TORKEL to the mains voltage.
2] Switch on TORKEL.
The display will show the following after a
short time:

Connecting the current cables to The sensing cables (dotted lines) are normally not needed.
the battery
Note TORKEL automatically selects the voltage
Important range when voltage is applied to the high-
Connection and disconnection procedures current terminals.
are extremely important. Be sure to fol-
low the instructions. If load polarity is incorrect the load will not
be connected internally. On the display the
”space bar” will be red and an alarm will
Use the cables supplied with TORKEL or other cables sound. This is true for both the battery and
of suitable size. Follow the numbered steps that are voltage sense terminals.
set forth below. Inspect each connection to make sure
it is securely fitted. You can start a test in any of the menus.
While test is running you can go into any tab
1] Connect one end of the first cable to the
and pause the test and make changes and
negative (-) terminal on TORKEL.
continue the test.
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.

22 TORKEL 900-series ZP-CS01E CS033663FE

 5 Making a test

Emergency stop button 5.2 Test at constant current

The button is intended to be used if a fault occur in
the test object and/or the external testing cables. Preparations
1] Press the button to immediately inter- Follow the safety precautions set forth in section "2.2
rupt discharging. Safety instructions" on page 8 and the prepara-
TORKEL will still have power and the cooling tions for testing in section "5.1 Preparations for test-
fans will run at maximum speed. ing" on page 22.
2] Reset the stop button by turning it right.
If you consider it safe to continue the test Select "Test Method"
you can start the test again. 1] Press "Constant I"
2] Set the desired current by pressing the nu-
meric field and make the settings for current
using the On-screen keyboard.
3] Make settings for warning and stop limits,
see section "Warning and stop limit param-
eters" on page 15.

Tip
You can change the settings for current
and limits at any time in "TEST".

Starting the test

1] Wait for "Connected ready" to be displayed
on the information bar and the control knob
is lit.
2] Press
The current value (A) will be displayed and
the control knob lamp will start blinking.

Pausing the test

1] Press
2] Restart by pressing
Note Any TXL Loads connected to TORKEL must be
restarted manually.

Ending the test

WARNING
Do not disconnect any cables until the test
is completed and stopped

1] Press

CS033663FE ZP-CS01E TORKEL 900-series 23

5 Making a test

5.3 Test at 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.

Preparations
2] Press "Yes"
Follow the safety precautions set forth in section "2.2
3] Disconnect the cables in reverse order that Safety instructions" on page 8 and the prepara-
they were connected. tions for testing in section "5.1 Preparations for test-
ing" on page 22.
WARNING
Do not connect a discharged battery to a Configuring TORKEL for constant
battery that has not been discharged. The
batteries must be charged to the same
power
potential (voltage) before they are con- 1] Calculate the current at the end of the test
nected together. (divide the power by the voltage).
2] Then make sure that the total current does
For viewing results and report see section "5.7 View- not exceed 2999 A and that the TORKEL and
ing results and reporting" on page 28. TXL units can load with the required current
throughout the test.

Select "Test Method"

1] Press "Constant P"
2] Set the desired Power by pressing the nu-
meric field and make the settings for power
using the On-screen keyboard.
3] Make settings for warning and stop limits,
see section "Warning and stop limit param-
eters" on page 15.

Tip
You can change the settings for power
and limits at any time in "TEST".

Starting the test

4] Press
The power value (kW) will be displayed and
the control knob lamp will blink.

Pausing the test

1] Press
2] Restart by pressing
Note Any TXL Loads connected to TORKEL must be
restarted manually.

24 TORKEL 900-series ZP-CS01E CS033663FE

 5 Making a test

Ending the test 5.4 Test at constant

WARNING resistance
Do not disconnect any cables until the test TORKEL can be used to conduct a discharge test at
is completed and stopped constant resistance instead of constant current. All
procedures are the same except that you must set
1] Press TORKEL differently before starting – you set the resist-
ance instead of the current.

Preparations
Follow the safety precautions set forth in section "2.2
Safety instructions" on page 8 and the prepara-
tions for testing in section "5.1 Preparations for test-
ing" on page 22.

2] Press "Yes" Select "Test Method"

1] Press "Constant R"
3] Disconnect the cables in reverse order as
described in section "Connecting the current 2] Set the desired Resistance by pressing the nu-
cables to the battery" on page 22 meric field and make the settings for resist-
ance using the On-screen keyboard.
WARNING 3] Make settings for warning and stop limits,
Do not connect a discharged battery to a see section "Warning and stop limit param-
battery that has not been discharged. The eters" on page 15.
batteries must be charged to the same
potential (voltage) before they are con- Tip
nected together. You can change the settings for resistance
and limits at any time in "TEST".
For viewing results and report see section "5.7 View-
ing results and reporting" on page 28. Starting the test
4] Press
The resistance value (Ohm) will be displayed
and the control knob lamp will blink.

Pausing the test

1] Press
2] Restart by pressing
Note Any TXL Loads connected to TORKEL must be
restarted manually.

Ending the test

WARNING
Do not disconnect any cables until the test
is completed and stopped

1] Press

CS033663FE ZP-CS01E TORKEL 900-series 25

5 Making a test

5.5 Testing with a load

profile
TORKEL can be used to conduct a test that incorpo-
rates a current profile or power profile. A profile can
consist of up to 20 time intervals. The duration and
the magnitude of the load can be specified for each
interval.
2] Press "Yes" If you want step or steps to be repeated you enable
the "Auto Loop".
3] Disconnect the cables in reverse order as
described in section "Connecting the current
Note Using more than 20 steps will slow the sys-
cables to the battery" on page 22 tem.

WARNING
Do not connect a discharged battery to a
Preparations
battery that has not been discharged. The Follow the safety precautions set forth in section "2.2
batteries must be charged to the same Safety instructions" on page 8 and the prepara-
potential (voltage) before they are con- tions for testing in section "5.1 Preparations for test-
nected together. ing" on page 22.

For viewing results and report see section "5.7 View- Select "Test Method"
ing results and reporting" on page 28. 1] Press "Profile I" or "Profile P"

2] Set the desired "Duration" by pressing the

numeric field and make the settings for dura-
tion using the On-screen keyboard.
3] Set the desired current or power by pressing
the numeric field and make the settings for
current using the On-screen keyboard.
4] Make settings for warning and stop limits,
see section "Warning and stop limit param-
eters" on page 15.

Tip
You can change the settings for current/
power and limits at any time in "TEST".

26 TORKEL 900-series ZP-CS01E CS033663FE

 5 Making a test

Starting the test 5.6 V Logger

5] Press TORKEL can log the voltage during charging of the
The current value (A) or power (kW) will be
batteries.
displayed and the control knob lamp will
blink.
Starting "V Logger" directly after a
Pausing the test discharge test
1] Press Tip
2] Restart by pressing You can select to make the charging test
immediately after a discharging test and
Note Any TXL Loads connected to TORKEL must be keep all connection as they are.
restarted manually.
1] Press"Save and start V logger".
This will be a separate new test.
Ending the test
2] Press
WARNING 3] Start charging the batteries.
Do not disconnect any cables until the test 4] You can change the Warning and Stop limits
is completed and stopped. during the test.

1] Press
Starting "V Logger" as a separate
test
Preparations
Follow the safety precautions set forth in section "2.2
Safety instructions" on page 8 and the prepara-
tions for testing in section "5.1 Preparations for test-
ing" on page 22.
2] Press "Yes".
3] Disconnect the cables in reverse order as Select "Test Method"
described in section "Connecting the current 1] Press "V Logger" button.
cables to the battery" on page 22 2] Make settings for warning and stop time, see
section "Warning and stop limit parameters"
WARNING on page 15.
Do not connect a discharged battery to a
3] Press
battery that has not been discharged. The
batteries must be charged to the same 4] Start charging the batteries.
potential (voltage) before they are con-
nected together. Ending the test

Tip WARNING
You can select to make the charging test Do not disconnect any cables until the test
immediately after a discharging test and is completed and stopped.
keep all connection as they are.
1] Press
For viewing results and report see section "5.7 View-
ing results and reporting" on page 28.

CS033663FE ZP-CS01E TORKEL 900-series 27

5 Making a test

2] Press "Yes". 5.7 Viewing results and

3] Disconnect the cables in reverse order as
described in section "Connecting the current reporting
cables to the battery" on page 22
Viewing the results
WARNING 1] Select the "RESULT" tab to view the test
Do not connect a discharged battery to a results
battery that has not been discharged. The
2] In the RESULT and BATTERY tabs you can add
batteries must be charged to the same
information by pressing the "Edit" button.
potential (voltage) before they are con-
nected together. Float voltage The voltage value prior the charger is
removed.
Open voltage The value prior start of discharge
test.
Start voltage The value given after the first initial
decrease of the battery bank at a
start of a discharge test.
End voltage The value at the end of discharge test

REPORT
The saved test can be stored on an USB memory stick
and transferred to a PC. The included PC software
TORKEL Viewer can be used to edit and print out
reports, see paragraph "4.2 TORKEL Viewer" on page
20.

28 TORKEL 900-series ZP-CS01E CS033663FE

 6 External current measurement

CS033663FE ZP-CS01E TORKEL 900-series 29

6 External current measurement

6 External current
measurement
6.1 General Tip
For tests where it is important to obtain
External current measurement must be used when: the desired current within a few seconds
▪▪TORKEL is working together with TXL Loads. or less it is better to use internal current
measurement since it provides faster
▪▪Testing without disconnecting the regular load.
regulation.
Since total current is measured, TORKEL can compensate
for changes attributable to the regular load. The total
current from the battery is then kept at a constant value.
This ensures accurate test results.
The external current measurement function enables
TORKEL to measure the total current in an external
path and base regulation on this measurement.
A DC clamp-on current probe (optional accessory) has
to be used for this measurement. It can be applied at
one of the battery terminals or at an inter-cell con-
nector. The DC clamp-on current probe must measure
the total current, including that which passes through
TORKEL.
A current shunt can also be used, but this requires
opening the current path and connecting the shunt
in series. The current shunt must be connected to the
negative side of the battery.

WARNING
External current shunt may not be used
above 300 V DC

Important
Always activate the warning and stop
limit functions when using external cur-
rent measurement. This will protect your
batteries if the DC clamp-on current probe
will malfunction.

Important
If a current shunt is used it must be con-
nected on the negative side of the bat-
tery.

30 TORKEL 900-series ZP-CS01E CS033663FE

 6 External current measurement

6] Activate the warning and stop limit func-

6.2 Setting up external tions.
current measurement 7] Connect the DC clamp-on current probe to
input I EXT ≤ 1 V. Best results are obtained if
WARNING the cables running from the DC clamp-on
See the chapter "2.2 Safety instructions" current probe are twisted.
on page 8.
Note If the DC clamp-on current probe has an
adapter for using external power supply. Use
the power supply from TORKEL (DC Out) con-
DC clamp-on current probe nector, that gives 9 V.
Preparation and requirements of the DC clamp-on
current probe to be used.
Important
▪▪The DC clamp-on current probe output voltage must not The DC clamp-on current probe must
exceed 1 V. always be applied in such a way that cur-
▪▪Make sure that the DC clamp-on current probe has fresh rent through TORKEL is included in the
batteries. The batteries must last throughout the entire measurement.
test.
▪▪The DC clamp-on current probe must be accurate and 8] Apply the DC clamp-on current probe to the
calibrated and it must be able to carry a load of 600 kΩ. conductor.
Please note that a DC clamp-on current probe is usually
9] Turn on the power switch on the DC clamp-
less accurate in the lowest part of its measurement range.
on current probe.
Resetting the output voltage 10] Make the setup for preferred test mode.
1] Place the DC clamp-on current probe as far as
possible from any magnetic field Troubleshooting
2] Connect a DC voltmeter (set to 2 V full scale) 1] Check that the DC clamp-on current probe is
to the DC clamp-on current probe. properly connected to TORKEL.
3] Switch on the DC clamp-on current probe 2] Check that the DC clamp-on current probe is
and adjust its zero knob to set the output to switched on.
0.0 V
3] Check that the DC clamp-on current probe
has fresh batteries.
4] Check the following settings in “TEST SET-
TINGS”, "Settings":
• “I measurement” must be set to “External”.
• The mV/A ratio must match the ratio that
appears on the DC clamp-on current probe
itself.

The mV/A ratio for the input can be set to a value

between 0.1 mV/A and 100 mV/A.
1] In "TEST" press
2] Press "Settings".
3] Select "External" for "Current measure-
ment".
4] Press the numeric field to set the "Ratio" for
the current clamp to be used
5] Press

CS033663FE ZP-CS01E TORKEL 900-series 31

6 External current measurement

3] Set max current on TORKEL 2.

6.3 TORKEL used together
4] Set warning limits only on TORKEL 1.
with TXL Extra Load
5] Set the stop limits. The voltage and test
period (time) can be set on each individual
TORKEL. Stopping after a certain capac-
ity (Ah) is reached can only be activated on
TORKEL 1.

Note Only TORKEL No. 1 is to control the TXLs.

6] Set switch <F1> to the upper (ON) position

on the TXLs.
7] Then start the TORKEL that has the highest
number (when numbered as set forth above).
Now start the TORKEL with the second
highest number, then the third highest, etc.
Finally, start TORKEL 1.
Starting the TORKELs in this order prevents
the current from being higher than desired
at the beginning of the test.

A current shunt can also be used, but this requires opening Two or more TORKEL and TXL units
the current path and connecting the shunt in series.
TORKEL 1 Measures the entire battery current.
Multiple units used together TORKEL 2 Measures all current except the current
through TORKEL 1.
One TORKEL control TORKEL 3 Measures all current except the currents
through TORKEL 2 and TORKEL 1 (and so
forth).
The last Measures only the current through itself
TORKEL and the TXLs.

The first TORKEL regulate the TXLs.

1] Apply the clamp-on-probes as illustrated

above.
2] Set the desired total current on TORKEL 1.
32 TORKEL 900-series ZP-CS01E CS033663FE
 6 External current measurement

the current from being higher than desired

at the beginning of the test.

Constant current, regular load

connected

Example with two TORKELs. The first TORKEL regulate the TXLs
and the second TORKEL contributes in the total regulation.
A current shunt can be used instead of the DC clamp-on
1] Apply the clamp-on-probes as illustrated current probe but this requires opening the current path
above. and connecting the shunt in series.
2] Set the desired total current (same value) on
both (all) TORKEL units.
As a result, the maximum regulation capabil-
ity of all TORKEL units will be used. You do
not need to pay any attention to the mes-
sage reading “Cannot regulate” as long as it
does not appear on TORKEL No. 1.
3] Set warning limits only on TORKEL No. 1.
4] Set the stop limits. The voltage and test
period (time) can be set on each individual
TORKEL. Stopping after a certain capac-
ity (Ah) is reached can only be activated on
TORKEL No. 1.

Note Only TORKEL No. 1 is to control the TXLs.

Only TORKEL No. 1 is to be connected to the
PC.

5] Set switch <F1> to the upper (ON) position

on the TXLs.
6] Then start the TORKEL that has the highest
number (when numbered as set forth above).
Now start the TORKEL with the second
highest number, then the third highest, etc.
Finally, start TORKEL No. 1.
Starting the TORKELs in this order prevents

CS033663FE ZP-CS01E TORKEL 900-series 33

7 Alarm function

7 Alarm function

7.1 Description
The TORKEL alarm function is provided by a buzzer
and a relay connected to the <ALARM> - connector.
An external alarm device can be connected to this
connector if desired.
Devices higher than Cat II must not be attached to the
alarm connector.

Relay contact
8 A / 28 V DC
0.28 A / 250 V DC (resistive load only)
8 A / 240 V AC

Connector insulation
Voltage to ground must not exceed 250 V.

The following events can cause an alarm to

be issued
▪▪Warning level is passed.
▪▪Discharging is stopped because a stop level is reached.
▪▪TORKEL can not regulate the current to the desired level.
▪▪Thermal protection device trips or a fan does not rotate as
expected.
▪▪The connection to the battery is broken.
▪▪Other fault situations such as battery voltage too high or
too low or excessive current through TORKEL.

Note TORKEL will safely interrupt the discharge and

issue an alarm if any of the internal tempera-
tures should exceed the safe operating limits.

Resetting the alarm

1] You can reset the alarm by pressing the infor-
mation bar.

34 TORKEL 900-series ZP-CS01E CS033663FE

 8 How to obtain the desired current

CS033663FE ZP-CS01E TORKEL 900-series 35

8 How to obtain the desired current

8 How to obtain the desired

current
8.1 When a single TORKEL How many units are needed?
isn’t enough Automatic calculation - TorkelCalc
TORKEL regulates current by lowering its internal re- In TORKEL Viewer (not included with TORKEL 910)
sistance as the voltage drops. However, the resistance you can use TorkelCalc to figure out how many
elements built into TORKEL impose a limit beneath TORKEL and TXL are needed.
which further lowering is impossible. See"4.2 TORKEL Viewer" on page 20.

▪▪You must make some simple calculations before starting

a test to find out whether or not TORKEL will be able to
provide the desired load current.
▪▪You must also make certain that TORKEL will be able to
sustain this current until the test ends.
When a single TORKEL cannot provide the current you
need, you can:

▪▪Connect one or more TXL Extra Loads to TORKEL.

▪▪Connect two or more TORKELs in parallel.
▪▪Connect two or more TORKELs and two or more TXL
Extra Loads into a single system.
When two or more TORKELs are connected into a sin-
gle system, you will normally use the “External current
measurement” function. Manual calculation
1. Number of TXLs – Current flowing
TXL connected to TORKEL through TXL(s) at beginning of a test
TXLs are resistive loads which are unable to provide At the beginning of the test, as high a percentage as
any sort of regulation. Regulation is provided by possible of the current must flow through the TXLs,
TORKEL which measures the total current and keeps it thereby providing the TORKEL(s) with as much reserve
constant. See the chapter headed "2.2 Safety instruc- regulation capability as possible. However, the current
tions" on page 8 which shows how to connect through the TXLs must not, of course, exceed, the
the TXL(s) and TORKEL(s). desired current value (A).

When TXL Extra Loads are connected to TORKEL, you

Tip
must check:
Remember that the internal resistances of
▪▪That the current flowing through the TXLs when the test the TXLs can be set manually. For accurate
is started is not higher than intended. calculation, add the cable resistance to
▪▪That TORKEL has enough regulation capability a) to the internal resistance.
compensate for the drop in current through the TXLs at
the end of the test and b) to set the current to the correct ▪▪ The current in an individual TXL can be obtained by dividing
value at the beginning of the test. the voltage at the beginning of the test by the internal
resistance of the TXL in question (see tables below).
▪▪Calculate the number of TXLs that you can connect
without exceeding the desired total current.

36 TORKEL 900-series ZP-CS01E CS033663FE

 8 How to obtain the desired current

2. Current flowing through TXL(s) at final Systems TORKEL 910 and TXL 870 (Pos 1)
voltage 220 V battery (108 cells)
▪▪Multiply the total current through the TXL(s) which you Max constant current No. of TORKEL 910 No. of TXL 870
obtained in step 1 above by the final voltage, and then 112 A 1 1
divide by the voltage at the beginning of the test. 156 A 1 2
195 A 1 3
3. Number of TORKELs – for the current 235 A 1 4
regulation 313 A 2 4
The TORKEL or TORKELs in the system must regulate
the current to the desired value and compensate for TORKEL 930
the drop in current through the TXL(s) that occurs at
Systems TORKEL 930 and TXL 830 (Pos 3)
the final voltage.
12V battery (6 cells)
▪▪The amount of regulation needed can be obtained by Max constant current No. of TORKEL 930 No. of TXL 830
subtracting the current value (A) obtained in step 2 above 183 A 1 1
from the desired current. 299 A 1 2
414 A 1 3
▪▪Calculate the number of TORKELs required for the current
regulation. 24V battery (12 cells)
Max constant current No. of TORKEL 930 No. of TXL 830
4. Are all of the TXLs needed? 384 A 1 1
If the total load-providing capability of the TORKEL(s) 615 A 1 2
846 A 1 3
exceeds the amount of regulation needed by a wide
margin (as set fort in step 3 above), you can perhaps
Systems TORKEL 930 and TXL 850 (Pos 3)
conduct the test with fewer TXLs. If this margin is
wider than the current through one of the TXLs at the 48 V battery (24 cells)
Max constant current No. of TORKEL 930 No. of TXL 850
final voltage, this TXL is not needed.
452 A 1 1
685 A 1 2
Note Discharge is from 2.15 V to 1.8 V per cell
918 A 1 3
1151 A 1 4
TORKEL 910
Systems TORKEL 930 and TXL 870 (Pos 3)
Systems TORKEL 910 and TXL 830 (Pos 2) 110 V battery (54 cells)
12 V battery (6 cells) Max constant current No. of TORKEL 930 No. of TXL 870
Max constant current No. of TORKEL 910 No. of TXL 830 225 A 1 1
144 A 1 1 314 A 1 2
221 A 1 2 392 A 1 3
298 A 1 3 470 A 1 4
376 A 1 4 628 A 2 4
443 A 2 4
24 V battery (12 cells) Systems TORKEL 930 and TXL 870 (Pos 1)
Max constant current(A) No. of TORKEL 910 No. of TXL 830
220 V battery (108 cells)
264 A 1 1
Max constant current No. of TORKEL 930 No. of TXL 870
419 A 1 2
112 A 1 1
574 A 1 3
156 A 1 2
195 A 1 3
Systems TORKEL 910 and TXL 850 (Pos 3) 235 A 1 4
48 V battery (24 cells) 313 A 2 4
Max constant current No. of TORKEL 910 No. of TXL 850
342 A 1 1
575 A 1 2 TORKEL 950
Systems TORKEL 910 and TXL 870 (Pos 3) Systems TORKEL 950 and TXL 890 (Pos 1)
110 V battery (54 cells) 480 V battery (240 cells)
Max constant current No. of TORKEL 910 No. of TXL 870 Max constant current No. of TORKEL 950 No. of TXL 890
188 A 1 1 65 A 1 1
266 A 1 2 70 A 1 2
344 A 1 3 90 A 1 2
422 A 1 4 100 A 1 3
532 A 2 4 120 A 2 2

CS033663FE ZP-CS01E TORKEL 900-series 37

9 Optional equipment

9 Optional equipment

9.1 TXL830/850/865/870/890 1. Selector switch

Switch used to set the desired voltage range and/
(Extra Loads) or resistance value.
The TXL830, TXL850, TXL865, TXL870, and TXL890
Extra Loads comprise resistive loads. They can be used WARNING
together with TORKEL Load Units to increase loading Do not exceed maximum voltage.
capability. The TXL Extra Loads can not provide regula- 2. Control
tion by themselves but TORKEL measures total current CONTROL IN
from the battery and regulates the load characteristic. Input for control signal from TORKEL-unit. Gal-
When TORKEL is stopped it sends a stop signal to the vanically isolated.
TXL Extra Load. CONTROL OUT
Output used for the control signal sent from
▪▪TXL830 28 V
TORKEL to the adjacent TXL-unit. Galvanically
▪▪TXL850 56 V isolated.
▪▪TXL865 260 V 3. Circuit breaker
F1
▪▪TXL870 280 V
Voltage-controlled circuit breaker that connects
▪▪TXL890 480 V the resistors in the TXL Extra Load to the battery.
Note F1 will not latch or remain at upper (ON)
Panel position unless the mains switch is turned on and
The panels for the TXL models differ somewhat but a control signal from TORKEL is present at the
the functionality is the same. “CONTROL IN” input..

WARNING
The circuit breaker F1 is an important com-
ponent in the safety system. If the tempera-
ture will be too high and/or the cooling fans
malfunction, the F1 will trip. It is important
to never operate the unit if there is any dam-
age or malfunction to the circuit breaker or
if any damage or malfunction is suspected.
4. Mains inlet
MAINS
1
Connector used for mains supply, equipped with
ON/OFF switch.
5. Connection terminals for the battery
+ (Terminal)
2
Positive (+) current connection for battery or
other DC source, being tested.
– (Terminal)
3
Negative (-) current connection for battery or
4
other DC source, being tested.
Insulation voltage to ground: 2200 V
5

38 TORKEL 900-series ZP-CS01E CS033663FE

 9 Optional equipment

Using the TXL 3] When TORKEL is stopped, manually or by any

stop condition, the TXL will also shut off the
When an extra load is to be used, you must use the
discharge current.
external current measurement function (see the chap-
ter headed "6.2 Setting up external current measure-
ment" on page 31).
1] Set the range selector switch to the desired
position.
2] Connect as shown below.

3] Connect the control wires between the TXL

CTRL output on TORKEL and the CONTROL
IN input on the TXL.
If two or more TXLs are to be used, provide
a connection between the CONTROL OUT
output on the first TXL and the CONTROL IN
input on the second TXL, etc.
4] Connect the TXL to the mains voltage
5] Switch on the TXL.

Testing
WARNING
See the chapter "2.2 Safety instructions"
on page 8. for safety precautions.

1] Proceed in the same way as set forth in the

chapter headed "5.1 Preparations for test-
ing" on page 22 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

CS033663FE ZP-CS01E TORKEL 900-series 39

9 Optional equipment

9.2 BVM - Battery Voltage

Monitor
The BVM (Battery Voltage Monitor) is a battery volt-
age measurement device that is used for monitoring
of cell voltages and battery blocks in battery banks
commonly found in electrical power sub-stations, tel-
ecom facilities and computer data center UPS systems.
In conjunction the TORKEL unit, and test data man-
agement software, such as PowerDB or TORKEL Win,
the BVM enables a completely automated battery The other parts of the BVM system: AC Adapter, Power and
bank capacity test to be performed. Signal Connector and cables.
BVM is available in three kits:

▪▪BVM150 with 16 BVM units

Power & signal connector unit
The BVM units require external 24 DC power and RS-
▪▪BVM300 with 31 BVM units 485 data communications for operation. These func-
▪▪BVM600 with 61 BVM units tions are provided by a combination of an external DC
power supply and a Power & signal connector unit”.
The Power & signal connector conversion is performed
within a single moulded plug that connects directly to
the laptop computer or other data acquisition device.
The Power & signal connector has an RJ-45 connector
1 that provides a connection to the first BVM unit in the
chain, and this connection provides RS-485 data and
2 power to all BVM units in the BVM string.
3

1. Control cable – Output socket

2. Control cable – Input socket
3. Battery sense – Dolphin clip
The BVM is designed in modular form where one BVM
device is used for each battery or “jar” in the string
to be tested. It measures the voltage for each battery
cell and each unit can handle up to 20 V. The BVMs
connects to the batteries in a “daisy-chain” fashion,
thereby providing easy and economical expandability
to meet the testing requirements for small-to-large
battery bank systems. Up to 240 BVMs can be daisy-
chained in a single battery bank under test.
The included dolphin-style battery clamp can be easily
removed and exchanged with different styles of stand-
ard banana plug clamps and/or extension cables to
accommodate any battery connection requirement.
There is an Activity LED on the BVM that flashes when-
ever an individual BVM transmits data back to the data
acquisition host computer. This LED activity is useful for
indicating that the device is functioning properly.

Note The BVM readings are continuously ongoing.

A typical reading from a battery bank is
around 30 seconds. Depending on the num-
ber of cells/BVM’s connected.

40 TORKEL 900-series ZP-CS01E CS033663FE

 9 Optional equipment

Test with BVM and TORKEL

WARNING
See the chapter "Safety" for safety pre-
cautions.

1] Connect the BVM units as shown in the con-

nection diagram, see below.
Each BVM is identical and can be connected
in any battery test position. Up to 120 BVMs
can be daisy-chained in a single battery bank
under test.
If you need more than 120 BVMs they must
be connected in two loops, see connection
diagram on next page.

Note The BVM units must be connected following

the battery cell sequence order. The BVM
connected to the “To 1:st BVM unit” port of
the Power and Signal connector must be con-
nected to the most Negative pole of the bat-
tery. The red dolphin clip shall be connected
to the most Positive pole of the battery. The
connection is the same regardless of the cell
numbering selected in TORKEL.
If more than 61 BVM units are connected
an extra cable is needed. See the connection
diagrams.

Fig.9.1 The BVM units must be connected following the

battery cell sequence order. The red dolphin clip shall be
connected to the most Positive pole of the battery.

CS033663FE ZP-CS01E TORKEL 900-series 41

9 Optional equipment

Fig.9.2 When the battery bank exceeds 120 cells, this connection with 2 BVM loops shall be used.
Connect the first loop to the BVM1 connector on TORKEL and the second loop to the BVM2 connector on TORKEL.

Fig.9.3 The connection shown above must be used when the battery bank voltage is between 300 V and 500 V.
It includes two opto couplers and two ungrounded power supplies.

4] Start TORKEL 900

Warning
A BVM control cable must never be connected The BVM “Auto Discovery” feature enables the host
directly to a computer network inlet. device to automatically determine the number of bat-
When battery string voltage is over 300 V an teries under test and provide sequential identification
opto coupler must be used, see Fig. 9.3. of each BVM in the test string.
2] A. Battery string voltage max 300 V Note The cell numbering can be done from minus
Connect the cable from "Power & signal to plus or reversed and shall correspond to the
connector" to BVM1 / BVM2 terminals on setting in TORKEL. The red BVM conected to
TORKEL 900. plus is not included in the numbering.
B. Battery string voltage max 500 V When “Cell number from plus” is selected
Connect the cable from "Power & signal con- in TORKEL settings, the most positive cell is
nector" to Opto Coupler (UH401-2kV). Cell 1, when this setting is not selected, then
the most negative cell is Cell 1.
3] A. Battery string voltage max 300 V
Connect to a grounded Power Supply The initialization time for the BVMs depends on how
B. Battery string voltage max 500 V many BVMs are connected. E.g. with 2 loops and
Connect to a ungrounded Power Supply 240 BVMs, it is about 3 to 4 minutes. With 1 loop
and 12 BVMs, some seconds. The connected cells are
Warning
shown under tab “CELLS”.
Do not use any other Power Supply than the
original delivered together with BVM.

42 TORKEL 900-series ZP-CS01E CS033663FE

 9 Optional equipment

Loose BVM unit detection

If BVM unit 1 comes loose during test, the first bar in
the bar graph indicates and a beep sounds.
If the BVM unit between 2 and 3 cell becomes loose,
the staple bars for cell 2 and 3 indicates.
If the last BVM unit is loose, the last staple in the sta-
ple bar diagram indicates.

Test with BVM – without TORKEL

BVM can handle battery voltage upp to 600 V, but
then without TORKEL 900. With this connection, only
the voltage can be monitored.

Fig.9.4 The connection is made the same as in example

above (Fig9.3) but without TORKEL 900.

Optional BVM equipment

BVM Cal Kit
Calibration system for BVM units.
Instructions for calibration included with the
BVM Ca Kit.

Extension cables
The BVM cables (USB) may be extended 2 x 5 m with
an Opto Coupler (e.g. B&B UH401 2 kV) in between.

Cable 5 m Cable 5 m

Note "Active" USB cables does not work.

CS033663FE ZP-CS01E TORKEL 900-series 43

10 Troubleshooting

10 Troubleshooting

Problem Cause Remedy

BVM connected to TORKEL
Problem with the connection to
BVM does not get initialized Check/verify BVM connector on TORKEL
BVM port
Check cables, BVM units and Power
supply to the BVM units.
Check/replace the Power & Signal con-
Communication lost with BVM
Cable/power fault verter.
units
If more than 60 BVM units connected,
extra cable needed. See the connection
diagram.
External measurement with current probe
Current probe ratio not set Set ratio in “Configuration” “Settings
No readings Current probe not activated Turn on current probe
Battery/power failure Check battery/power supply
Faulty readings Zero adjustment not done Zero adjust
Other
Impossible to switch on the cir- Control cable from TORKEL to
Check the connection
cuit breaker F1 on the TXL unit TXL not connected properly
No voltage measurement in
Bad connections Check battery connectors
TORKEL
Emergency Stop button pressed Release emergency stop button
TORKEL fans revs up
Fans blocked Remove blocking objects from fan

44 TORKEL 900-series ZP-CS01E CS033663FE

 11 Calibration

CS033663FE ZP-CS01E TORKEL 900-series 45

11 Calibration

11 Calibration

11.1 General 11.2 How to calibrate

By using the internal calibration program TORKEL will 1] Switch on TORKEL.
be calibrated on internal/external current and internal/
external voltage. However, external instruments must
2] Press button to enter the configura-
tion menu.
be used.
3] Press “Calibration” tab.
▪▪Stable voltage power supply (vary less than 1% per
second) with capability up to 200 V DC. 4] Press “Start” and follow on-screen instruc-
tions.
▪▪Current source (vary less than 1% per second) supplying
upp to 100 A DC at a voltage between 10 and
30 V DC, e.g. a 12 V car battery can be used. WARNING
▪▪Accurate reference instrument, e.g. HP 34401A, must be Follow the instructions carefully. Battery
used. connectors may have dangerous voltage

▪▪A current shunt with accuracy class 0.1% for connection

in series with the current source. Note You can press “Skip” to continue to the next
calibration step. No value will be added.
Press “Previous” to redo a calibration point.

5] Press "Store" to save the calibration values.

Note If the “Skip” button is pressed the calibration
values will not be saved.

6] Connect an USB stick to save a copy of the

calibration report that can be opened with
Excel.
7] Press "Stop" to stop the calibration and leave
the calibration routine.
The fans will start and run for about 10 sec-
onds.
8] Press to save and close the calibra-
tion.

46 TORKEL 900-series ZP-CS01E CS033663FE

 12 Specifications

CS033663FE ZP-CS01E TORKEL 900-series 47

12 Specifications

12 Specifications

SPECIFICATIONS Internal current measurement

TORKEL 900-SERIES Range
Specifications are valid at nominal input voltage and an ambient TORKEL 910 0 to 110 A
temperature of +25°C, (77°F). Specifications are subject to change TORKEL 930 / 950 0 to 220 A
without notice. Input for clamp-on probe
Environment Range 0 to 1000 mV DC
Application field The instrument is intended for use in high- mV/A-ratio 0.30 mV/A to 100.00 mV/A
voltage substations and industrial environ- Input impedance >1 MΩ
ments. Voltage measurement
Temperature Voltage 0 to 500 V DC
Operating 0°C to +50°C (32°F to +122°F) Inaccuracy ±(0.5% of reading +0.1 V DC)
Power derating at temperatures over +35°C
(+95°F) Resolution 0.1 V
Storage & -40°C to +70°C (-40°F to +158°F) Sample rate 10 Hz, Values are saved when change is >10 mV
transport Time measurement
Humidity 5% – 95% RH, non-condensing Inaccuracy ±0.1% of reading ±1 digit
Shock/Vibration/Fall Load section
Instrument only ETSI EN 300 019-2-7 class 7M2 Battery voltage 7.5 V to 300 V1) / 500 V2)
Instrument in ISTA 2A Power 15 kW (max)
transport case Load patterns Constant current, constant power, constant
Altitude resistance, current or power profile
Operating 3000 m (10000 ft)
Storage 10000 m (33000 ft)
Encapsulation IP20
class
CE-marking
LVD 2014/35/EU
EMC 2014/30/EU
RoHS 2011/65/EU
General
Mains voltage 100 – 240 V AC, 50 / 60 Hz
Power 200 W (max)
consumption
Power 40 ms (max)
interruption
Protection Thermal cut-outs, Automatic overload pro-
tection, Emergency stop button
Dimensions 519 x 315 x 375 mm, (20.5” x 12.4” x 14.7”) Constant I
Weight 19.5 kg (43.0 lbs) instrument Range
31.9 kg (70.3 lbs) incl. standard transport case
37 kg (82 lbs) incl. large transport case TORKEL 910 0 to 110.0 A
Display 7" LCD, Capacitive touch screen TORKEL 930 / 950 0 to 220.0 A
Available Czech, English, French, German, Romanian, Inaccuracy ±(0.5% +0.2 A)
languages Russian, Spanish, Swedish Resolution 0.1 A
Number of test 30 (max) Ripple max 0.5 A peak
files Constant R
Test time 240 h (max) Range 300 mΩ to 3 kΩ
Measurement section Inaccuracy ±1% typical
Current measurement Resolution 100 mΩ
Display range 0.0 to 2999.0 A Constant P
Basic inaccuracy ±(0.5% of reading +0.1 A) Range 0 to 15 kW
Resolution 0.1 A Inaccuracy ±1% typical
Resolution 10 W

48 TORKEL 900-series ZP-CS01E CS033663FE

 12 Specifications

Inputs Load section

+ 7.5 to 300 V.1) 7.5 to 500 V.2) Voltage (DC) Current Power max.
– 0V max. max.
I EXT ≤ 1 V 1 V DC, 300 V DC to ground TXL830 28 V 300 A 8.3 kW
VOLTAGE Impedance to the current terminals is >1 MΩ TXL850 56 V 300 A 16.4 kW
SENSE TXL865 260 V (98 A max) 117 A 25.5 kW
Outputs TXL870 280 V (56 A max) 112 A 15.8 kW
ALARM TXL890 480 V (32 A max) 62 A 15.4 kW
Relay contact 28 V DC, 8 A, 240 V AC, 8 A Internal resistance, 3-position selector
Devices higher than Cat II must not be at-
Position 1 Position 2 Position 3
tached
TXL STOP TXL830 0.275 Ω 0.138 Ω 0.092 Ω
Relay contact 250 V DC, 0.28 A, 28 V DC, 8 A, 250 V AC, 8 A TXL850 0.55 Ω 0.275 Ω 0.184 Ω
9 V DC 9 V DC, ±7% max 100 mA TXL865 2.65 Ω 5.05 Ω 0.12 Ω
Communication ports TXL870 4.95 Ω 2.48 Ω 1.24 Ω
BVM1 BVM2 USB connection for BVM units TXL890 14.10 Ω 7.05 Ω 3.52 Ω
USB connection for USB memory
Maximal currents, 3-position selector 1)
Position 1
SERVICE For service of the instrument
1) TORKEL 910 and 930 Current Voltage Cells Cell voltage
2) TORKEL 950 TXL830 100 A 27.6 V 12 2.3 V
28 V max 78.5 A 21.6 V 12 1.8 V
SPECIFICATIONS TXL850 100 A 55.2 V 24 2.3 V
56 V max 78.5 A 43.2 V 24 1.8 V
TXL 830 / 850 / 865 / 870 / 890
Specifications are valid at nominal input voltage and an ambient
TXL865 93.7 A 248.4 V 108 2.3 V
260 V max 73.4 A 194.4 V 108 1.8 V
temperature of +25°C, (77°F). Specifications are subject to change
without notice. TXL870 50.1 A 248.4 V 108 2.3 V
Environment 280 V max 39.2 A 194.4 V 108 1.8 V
Application field The instrument is intended for use in high- TXL890 32.3 A 469.2 V 204 2.3 V
voltage substations and industrial environ- 480 V max 26.0 A 367.2 V 204 1.8 V
ments.
Position 2
Temperature
Operating 0°C to +40°C (32°F to +104°F)
Current Voltage Cells Cell voltage
Storage & -40°C to +70°C (-40°F to +158°F) TXL830 200 A 27.6 V 12 2.3 V
transport 28 V max 156 A 21.6 V 12 1.8 V
Humidity 5% – 95% RH, non-condensing TXL850 200 A 55.2 V 24 2.3 V
56 V max 156 A 43.2 V 24 1.8 V
CE-marking
TXL865 49.2 A 248.4 V 108 2.3 V
LVD 2014/35/EU
260 V max 38.5 A 194.4 V 108 1.8 V
EMC 2014/30/EU
TXL870 50.1 A 124.2 V 54 2.3 V
RoHS 2011/65/EU
280 V max 39.2 A 97.2 V 54 1.8 V
General
TXL890 35.2 A 248.4 V 108 2.3 V
Mains voltage 100 – 240 V AC, 50 / 60 Hz 480 V max 27.8 A 194.4 V 108 1.8 V
Power 75 W (max)
consumption Position 3
Protection Thermal cut-outs, automatic overload Current Voltage Cells Cell voltage
protection TXL830 300 A 27.6 V 12 2.3 V
Dimensions 28 V max 235 A 21.6 V 12 1.8 V
Instrument 210 x 353 x 600 mm (8.3” x 13.9” x 23.6”) TXL850 300 A 55.2 V 24 2.3 V
Transport case 265 x 460 x 750 mm (10.4” x 18.1” x 29.5”) 56 V max 235 A 43.2 V 24 1.8 V
Weight 13 kg (29 lbs) 21.4 kg (47 lbs) with trans- TXL865 115 A 13.8 V 6 2.3 V
port case 14 V max 90 A 10.8 V 6 1.8 V
Cable sets
TXL870 100 A 124.2 V 54 2.3 V
for 2 x 3 m (9.8 ft), 70 mm2, 270 A, with fe- 140 V max 74.8 A 97.2 V 54 1.8 V
TXL830 / 850 male  plug / clamp. Max. 100 V. 5 kg (11 lbs)
TXL890 70.5 A 248.4 V 108 2.3 V
for 2 x 3 m (9.8 ft), 25 mm2, 110 A, with fe-
250 V max 55.2 A 194.4 V 108 1.8 V
TXL865 / 870 / 890 male plug / lug. Max. 480 V. 3 kg (6.6 lbs)
1) The data examples apply to lead batteries.

CS033663FE ZP-CS01E TORKEL 900-series 49

12 Specifications

SPECIFICATIONS BVM
Specifications are valid at an ambient temperature of +25°C,
(77°F). Specifications are subject to change without notice.
Environment
Application field The instrument is intended for use in
medium-voltage substations and industrial
environments.
Altitude <2000 m (6500 ft) above sea level.
Temperature
Operating 0°C to +50°C (32°F to +122°F)
Storage & -20°C to +70°C (-4°F to +158°F)
transport
Humidity 5% – 95% RH, non-condensing
CE-marking
LVD 2014/35/EU
EMC 2014/30/EU
RoHS 2011/65/EU
General
Power supply
Mains voltage 100 – 240 V AC, 50 / 60  Hz
Power 50 VA (max)
consumption
Protection Over voltage, reverse voltage, voltage
transients, ESD
Dimensions
BVM unit 75 x 64 x 25 mm (3” x 2.5” x 1”)
Carrying case 575 x 470 x 205 mm (22.6” x 18.5” x 8.1”)
Weight
BVM unit 0.07 kg (0.15 lbs)
With accessories BVM system of 16 units 7 kg (15 lbs)
and carrying case BVM system of 31 units 8.8 kg (19 lbs)
BVM system of 61 units 12.5 kg (27 lbs)
Measurement section
Maximum number 2 x 120
of BVM
Voltage ranges 0-5 V DC and 0-20 V DC
Resolution 1 mV both ranges
Inaccuracy < 0.1% of full scale ±0.01 V DC
Battery string 300 V DC (max)
voltage
Measurement 1 MΩ
input impedance

50 TORKEL 900-series ZP-CS01E CS033663FE

 

CS033663FE ZP-CS01E TORKEL 900-series 51

Index

Index

A Multiple units.................................................. 32
Alarm function................................................ 34 O
B Optional accessories...................................... 12
Battery Voltage Monitor.................................. 42 Optional equipment........................................ 40
BVM................................................................ 42 P
BVM Cal Kit.................................................... 45
Pausing the test.............................................. 23
C Product description........................................... 6
Calibration...................................................... 48 Protection system............................................. 9
Clamp-on-probe............................................. 12 R
Conducting a test........................................... 22
Regular load................................................... 33
Constant current............................................. 23
Regulate current............................................. 36
Constant power.............................................. 24
Resetting the alarm........................................ 34
Constant resistance........................................ 25
Current cables................................................ 22 S
Current, regulate............................................ 36 Safety............................................................... 8
Current shunt.................................................. 30 Safety instructions............................................ 8
Screen buttons............................................... 14
D
Side panel...................................................... 11
Desired current............................................... 36
Specifications................................................. 50
E Starting the test.............................................. 23
EMERGENCY STOP...................................... 10 Stop button..................................................... 23
Emergency stop button.................................. 23 Stop limit......................................................... 15
Ending the test............................................... 23 Symbols on the instrumentI.............................. 8
Extension cables............................................ 12 T
External current measurement....................... 30
Temperature compensation............................ 16
Extra Loads.................................................... 40
Test at constant current.................................. 23
G Test configuration........................................... 15
GRAPH........................................................... 18 TEST menu.................................................... 14
Test method.................................................... 14
I Top panel........................................................ 10
ID Labels........................................................ 15 TORKEL Viewer............................................. 20
Included accessories...................................... 11 TORKEL Win software................................... 42
Introduction....................................................... 6 Troubleshooting.............................................. 46
L TXL................................................................. 40
TXL Extra Loads............................................. 36
License........................................................... 17
Load profile..................................................... 26 U
Load-providing capability................................ 37 Upgrade License............................................ 17
M V
Main menu...................................................... 14 Voltage range................................................. 22
Menu system.................................................. 14
52 TORKEL 900-series ZP-CS01E CS033663FE
 Index

W
Warning limit................................................... 15
Warranty........................................................... 7
Warranty repair................................................. 7

Z
Zoom.............................................................. 18

CS033663FE ZP-CS01E TORKEL 900-series 53

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Subject to change without notice. Printed matter No. ZP-CS01E Doc. CS033663FE V06a 2019