Control Module

• Five Main Functions: F1: Battery Discharge, F2: Float
  Charge Optimizer, F3: Charge Optimizer, F4: Step
  Current Testing, F5: 1- and 3-phase AC Load Testing
• Controls one Master Load and up to 31 Slave Loads
• Discharge current 1A-1200A
• Switches loads off when final voltage reached
• Discharge: constant current / power /resistance
• Discharge testing without disconnecting battery
• Predicts charge content
• Measures cell voltages (max. 100 cells)
• Simple to operate with 11 soft keys
• Blue display monitor 58 x 108mm, displays all values
• 0.5 % accuracy
• Acoustic signaling of events
• Displays guidance for correct operation
• Displays warnings and takes proper action
• Light weight control module, 1.2kg
• Saves battery data for later analysis and printing
• Performs on the spot battery analysis
• Windows Battery Analysis Software available

Master Load / Slave Load, LD260, LD60

• Factory set for 0-60V / 150A-, or 0-260V / 70A operation
• Covers wide voltage range 10-600V, series connection
• Covers wide current range 1-1200A, parallel connection
• Up to 4 loads in series, up to 8 loads in parallel
• LD260: 190-260V, 70A/13kW max. AC- and DC-Load
• LD60: 40-60V, 150A max. AC- and DC-Load
• Light weight: 8.5kg; universal 90V-240V supply
• Reverse polarity protection; Rise time = 50us
• Slave Loads: can be series- or parallel connected to Master Load

Master Load / Slave Load, LD100

• Factory set for 0-100V / 100A / 800W operation
• Up to 8 loads in parallel
• Single cell discharge at 100A per load
• Light weight: 8kg; universal 90V-240V supply
• Reverse polarity protection; Rise time = 50us
• Analog input for transient testing
• Analog output for transient current

Introduction

The Infratek DC27 Loads offer the user versatility, flexibility, lightweight, and sturdy design, combined with precise measurement technique to obtain complete battery information, or UPS- and generator characteristic. Three load types are available: LD260 and LD60 are DC- as well as AC-Loads for up to 600V, 1200A, 100kW; LD100 is a DC-Load for 1V / 100A up to 100V/8A.

Versatile Battery Load Unit

Battery Load Units measure capacity of back-up batteries by means of a discharge test. Premature capacity decrease, weak blocks, or weak cells are detected. Periodic tests assure crucial equipment to run in case of power failure.

Infratek DC27 Battery Load Units LD260 and LD60 discharge batteries in the voltage range 10V to 600V at currents from 1A up to 1200A. The DC27 consists of a control module and a programmable high current load. Its versatility is almost unlimited; it performs tasks such as battery discharge without detaching battery, precise measurements of battery parameters and cell voltages versus discharge, charge estimation which makes a total discharge unnecessary, on the spot battery analysis, battery data storing for later analysis on a PC, and finally the DC27 control module analyzes battery systems under float charge, determines discharging - charging efficiency, and performs step current tests on DC power supplies.

The DC27 control module drives one master load and up to 31 slave loads. The programmable loads are factory set for 10V-60V/150A -, or 10V to 260V/70A operation. The weight of a load is only 8.5kg. To discharge high voltage batteries, loads can be series connected. High current discharge results by parallel connecting slave loads. Load LD100 can discharge single cells, low voltage batteries, fuel cells, or DC-power supplies up to 100A. It operates in the voltage range 1V to 100V, 800W maximum. Loads can be connected in parallel but not in series. Analog input and analog output is provided for transient testing or load profile testing.

Versatile 50Hz / 60Hz Load

One master load and one slave load can be connected to form a 50Hz, 60Hz single phase resistive load for 230V/113A - or 400V/65A operation. The load current is set in the SETUP menu of the control module. The load characteristic is constant current, constant power, or constant resistance. Three phase loads, star - or delta connected, can be configured using one master load and five slave loads. Maximum power for a basic 3-phase load is 78kW. By parallel connecting slave loads, power can be increased to a maximum of 390kW.

Easy To Use

The DC27 load bank in its minimal configuration consists of the control module and a master load. To start a discharge test you simply connect the control cables to the load, energize the load, set in the SETUP menu of the control module the desired discharge current, number of cells, and final cell voltage. Also, select the discharge function F1. Connect the master load to the battery, connect the voltage measuring cable from the control module to the battery poles, and press the START key. The monitor displays discharge current, voltage at the battery poles, charge, energy, time, cell voltage, and in a reserved text field presents status, warnings, or errors.

The current will rise to its preset value and will be kept constant until the final voltage is reached. At that time the control module stops the measurement, issues an alarm and holds all battery data for storage in nonvolatile memory.

If you need to discharge a 48V Telecom battery at 300A, for example, you connect one slave load in parallel to the master load. The procedures to use the functions F2 through F5 is similar to the one described above. The control module is operated using 6 menu soft keys M1 through M6 and five cursor soft keys. The user is menu guided, all operations are self-explanatory. In addition, the display monitor with backlight can easily be read in dark rooms.

High Performance

With only three different load types the user can discharge batteries in the whole voltage range up to 600V. Series connected loads can discharge high voltage batteries. Very large currents are obtained by parallel connection. The control module commands all load types and does the controlling based on the programmed criteria constant current,- power,- resistance. It performs precision measure-ments of discharge current, (no current clamps are needed) battery voltage, charge, energy, elapsed time, and cell- or block voltages. Battery data are accumulated and can be saved in nonvolatile memory. During discharge you have the option to read cell - or block voltages into the control module memory. Values of up to 100 cells can be entered.

A unique feature of the control module gives you a conservative estimation of charge after approximately 20 % of total discharge time. With reasonable certainty you can use this estimate as a guide to either terminate or continue discharge. This saves you time, energy, and eventually money. If you discharge to the final voltage you can display the battery discharge characteristic.

Using the 260V loads single- and three phase AC generating systems (UPS, generators) can be tested. Star- and delta connected loads up to 390kW can be formed. All loads are steered by just one single control module.
Depending on the type of Control module, you can make use of up to 5 different functions F1, F2, F3, F4, and F5. F1: Battery Discharge, F2: Float Charge Optimizer, F3: Charge Optimizer, F4: Step current testing on large DC power supplies, and F5: Load Testing of single- and three phase AC-supplies.

DC27 DC- and AC-Loads

Product	Description
DC27-CM0	Control Module, incl. measurement function F1, data storage, charge estimation, graphics and tables, 5m control cable to load, set of voltage test leads with clips, and carrying case. No clamp input, no cell voltage measurement, no RS-232 interface.
DC27-CM1	Control Module, incl. measurement function F1, F2, F3, data storage, charge estimation, graphics and tables, clamp input (permits discharge without detaching battery), cell voltage measurement, 5m control cable to load, set of voltage test leads, 0-200A current clamp, supply and carrying case.
DC27-CM2	Control Module, incl. measurement function F1, F2, F3, F4, F5, data storage, charge estimation, graphics and tables, clamp input (permits discharge without detaching battery), cell voltage measurement, 5m control cable to load, set of voltage test leads, 0-200A current clamp, supply and carrying case.
DC27-LD260M	Master Load 260V / 70A / 13kW / 8.5kg for DC- and AC-operation, carrying strip. (Please order desired high current cable set separately).
DC27-LD260S	Slave Load 260V / 70A / 13kW / 8.5kg for DC- and AC-operation, 1m control cables, carrying strip. (Please order desired high current cable set separately).
DC27-LD60M	Master Load 60V / 150A / 13kW / 8.5kg for DC- and AC-operation, carrying strip. (Please order desired high current cable set separately).
DC27-LD60S	Slave Load 60V / 150A / 13kW / 8.5kg for DC- and AC-operation, 1m control cables, carrying strip. (Please order desired high current cable set separately).
DC27-LD100M	Master Load 100V / 100A / 800W / 6.5kg for DC-operation, carrying strip. (Please order desired high current cable set separately).
DC27-LD100S	Slave Load 100V / 100A / 800W / 6.5kg for DC-operation, carrying strip. (Please order desired high current cable set separately).

Options

Option	Description
Opt-01	RS-232 interface incl. PC-Windows Battery Analysis Software, reeds stored data from Control Module, analyses battery data and cell data, generates and plot graphics (Windows 95,98,NT,ME,2000,XP)

Accessories

Accessory	Description
DC27-ACS1	Cable set 2x3m, 16mm². One side with selve locking plug to connect to load or current junction, other side clamp to connect to battery.
DC27-ACS2	Cable set 2x1m, 16mm². Both ends with selve locking plugs for parallel or series connecting loads, or connection to current junction.
DC27-ACS3	Current junction for parallel connection of up to 4 loads or up to 4 series combinations of loads. Two M10 screw terminals allow connection of cables with lugs to battery.
DC27-ACS4	Cable set 2x3m, 70mm², 300A with M10 cable lugs on both sides.