Kongter K-3980 User manual

K-3980 Battery Load Bank
User Manual
K-191211-V2.7

K-3980 Battery Load Bank
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Catalogue
1. INTRODUCTION............................................................................. 4
1.1 Accessories…………………………………………………..………4
1.2 Safety Information…………………..……….………………………6
1.3 Operating Precautions……………………………………………....7
2. OVERVIEW................................................................................... 10
2.1 About K-3980………………………………...……………………..10
2.2 Display and Keypad……..…………………………………..……..10
2.3 Features……………………………………………………….…….11
2.4 Specification………………………………...…………………..….12
2.5 Measurement Flowchart………………………………………..…14
2.6 Definition of Abbreviation………………………………………….15
3. MEASUREMENT PREPARATION................................................ 16
3.1 Connection…………………………………………………….……16
3.1.1 Check Conditions ..............................................................16
3.1.2 Connection of Cables........................................................16
3.1.3 Connect with DAC.............................................................20
3.1.4 Connect with Computer.....................................................26
3.2 Disconnection of Cables……………………………………..……26
3.3 Power On……………………………………………………………27
4. MEASUREMENT .......................................................................... 27
4.1 Battery String Discharge…………………………………………..27
4.1.1 Discharge Test................................................................... 27
4.1.2 Discharge for Strings in Parallel Connection .....................32
4.1.3 Continued Discharge.........................................................34
4.1.4 Parallel Load Test..............................................................35
4.2 Other Tests………………………………………………………….37
4.2.1 Assistant Discharge...........................................................37
4.2.2 External test ......................................................................39
4.2.3 Charge Monitor.................................................................. 41
4.3 Data Management………………………………………………….43

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4.3.1 Read Data Results ............................................................43
4.3.2 Load to USB Drive.............................................................44
4.3.3 Delete Data Results...........................................................44
4.3.4 Data Format ......................................................................44
4.4 System Management………………………………………………45
4.4.1 Time Setting ...................................................................... 45
4.4.2 Parameter Management....................................................46
4.4.3 Function Setting ................................................................50
4.5 Firmware Update…………………………………………………...51
5. SERVICE AND MAINTENANCE................................................... 51
5.1 Cleaning……………………………………………………………..51
5.2 Storage………………………………………………………………52
5.3 Trouble-shooting……………………………………………………52
6 ANALYZING SOFTWARE.............................................................. 53
6.1 Operation Environment……………………………………...…….53
6.2 Installation………………………………………………………......53
6.3 Start The System……………………………………………...……54
6.4 Data Management………………………………………………….55
6.4.1 Battery Setting...................................................................55
6.4.2 Manage Data Structure......................................................56
6.4.3 Upload Measurement Data................................................57
6.4.4 View Data & Generate Test Report....................................57
6.5 Real Time Monitor………………………………………………….58
6.5.1 Wifi Setting........................................................................58
6.5.2 Monitor .............................................................................. 59
7. CONTACT KONGTER .................................................................. 60

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1. INTRODUCTION
This Users Manual gives full information on how to use K-3980 Battery
Load Bank safely and effectively. It applies to all K-3980 models.
Please read the manual carefully so as to obtain maximum
performance of the load bank and its accessories.
Warning: Read this manual completely before connecting and
powering on the load bank to avoid possible damage caused by
improper use of this instrument.
1.1 Accessories
After receiving the K-3980 unit, please ensure that no damage
occurred during transportation. Upon any damage or failure of
operation based on this instrument, please contact your supplier
immediately. And make sure you have each items below. Amount of
some accessories may vary based on different K-3980 models.
♦K-3980 main unit (1)
♦Carrying Case (1) 1
♦Data Acquisition Case (DAC)2
♦Data Acquisition Leads 2
♦Antenna for main unit (1)
♦USB drive (1)
♦Load Cables (1 black and 1 red) 3
♦Voltage test lead with two clamps (1)
♦AC Power Cord (1)
♦Users Manual (1)
♦Serial cable (1,optional)4
♦Current clamp (1, optional)
♦Grounding line (1)

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NOTE:
1) For bigger load bank models like 220V 200A, there is no carrying
case. For convenient use, they will use rolling wheel at the main
unit bottom. And for transportation, they will have wooden case
and pallet.
2) DAC (Data Acquisition Case) is optional for logging voltage of
each cell in K-3980 series load banks, amount of DAC and DAC
serial cables may vary in different models. In some basic load unit,
there is no DAC and relevant cables. For detailed connection of
DAC, please refer to 3.1.3 Connect with DAC.
3) For load bank model with max current higher than 400A, there are
2 sets of load cable.
4) Serial cable is only used for parallel load. It will come only when
requested.
K-3980 with Carrying
Case*
DAC (Optional)
DAC serial cable, 7-lead
(Optional with DAC)
DAC serial cable, 3-lead
(Optional with DAC)
Antenna
(for main body)
USB drive

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Red Load Cable
Black Load Cable Voltage test lead
AC220 Power Cord
User Manual
Serial port cable
Current clamp
(Optional )
Grounding line
*NOTE: For convenient transportation, models with size of XL or bigger
will be made with rolling wheel at main unit bottom and packed with
wooden case instead of carrying case. For detailed configuration,
please refer to 2.4 Specification.
1.2 Safety Information
When you read this user manual, please carefully observe all warnings,
precautions and instructions for effective operation of K-3980.
WARNING:Servicing described in this manual is to be done only by
qualified personnel. To avoid electrical shock, do not service the

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instrument unless you are qualified enough under Kongter’s
instruction.
DANGER Safety testing has been done on this instrument
thoroughly before shipment. However,
mishandling during use could result in injury or
other bad consequences, as well as damage to
the instrument. Make sure that you understand
the instructions and precautions in the manual
before use. We disclaim any responsibility for
accidents or injuries not resulted directly from
instrument defects.
Safety Symbols
Description of symbols used in this manual.
WARNING Indicates correct operat
ion to prevent a
significant hazard that could result in serious
injury or other bad consequences to users or the
product.
NOTE Indicates advisory items related to performance
or correct operation of the instrument.
1.3 Operating Precautions
WARNING:
♦The electrical voltage and current used in battery testing is
potentially lethal.
♦Ensure that the AC supply is isolated and any battery under test is
disconnected before attempting any cleaning or maintenance of
K-3980.
♦Do not connect or disconnect any of the cables unless the circuit
breaker is turned off.
♦Connection and disconnection procedures are extremely

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important. Be sure to follow the instructions faithfully.
♦Do not touch conducting parts of the load cables or the voltage
cables when they are connected to K-3980.
♦Explosion risk when using K-3980 (all models)
♦When a lead acid battery is charged or discharged i.e. when there
is a current flow through the battery it is always a risk that the
battery can explode.
♦For new open (vented) batteries the risk is medium to low but in
old VRLA (sealed) batteries the risk is medium to high.
♦If there is a bad connection inside the battery and there is a
current flow - the connection will burn off and there will be an arc,
which will ignite the oxyhydrogen gas in the battery.
♦To minimize the risk for personnel injuries: Always place K-3980
as far away from the battery as possible - use long load cables
and do not stand close to a battery during charge or discharge.
♦Too high discharge current applied on a battery can cause the
battery to explode or get over-heated. And may also over-wear the
batteries. Be sure to not set too high current.
♦If the external current measurement is interrupted or giving false
values during the test, the current will rise to a higher level than
the set value before the test is shut down. If the battery is too small
for this current or in a bad condition - it may explode.
♦If you see any spark from batteries, testing cables or K-3980 main
body, please switch off the unit and disconnect all cables for
further inspection.
IMPORTANT:
To use K-3980 efficiently and avoid electrical shock, fire or any
damage to the K-3980 or its accessories, please do read these
precautions carefully before using K-3980:
♦Except as explained in this manual, do not attempt to service this
equipment yourself.

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♦To avoid frequency interference, please do not run two K-3980
simultaneously in the same location within 100 meters if it is not
parallel connection. If you really have to, please contact Kongter
for presetting.
♦Before use, check to see if the nominal voltage ranges on the
K-3980 matches the batteries that you are going to test. Do not
apply K-3980 of lower voltage in higher voltage. For example, if
K-3980 nominal voltage is 48V, do not connect the unit with
batteries of 220V. Otherwise, some parts inside K-3980 main body
may get damaged.
♦Do not operate the K-3980 around explosive gas or vapor.
♦Use only insulated load cables and test leads supplied with the
load bank.
♦Before use, please inspect the load bank, load cables, test leads
and accessories for mechanical damage and replace them when
they are damaged. Pay special attention to the insulation
surrounding the connectors.
♦If you have more than one K-3980, please use them separately,
do not mix them up. Their accessories may not compromise with
each other.
♦Remove all clamps, test leads and accessories that are not in use.
♦Make sure that the mains voltage and frequency fit the local AC
power supply. Do not apply the unit to voltages that are above the
rated mains of the instrument.
♦Ensure that the equipment is provided with adequate ventilation.
Do not block equipment ventilation openings.
♦Proper installation is essential to the correct functioning of your
analyzing software CD. If you have any questions about
installation, please contact your supplier for assistance.
♦After discharging batteries for some hours, please keep the main
body powered on for at least 10 minutes. This will help cool down
the resistors and other electronics inside the main body and

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prevent it from over wearing.
♦If you need to discharge the next battery string right after the first
string, please wait for at least 30 minutes to let the unit cool down
also.
2. OVERVIEW
2.1 About K-3980
K-3980 series Battery Load Bank are for battery discharge experiment,
capacity test, battery string maintenance, project checkup and
acceptance, and DC power load test. For battery maintenance, it is
periodic examination (e.g. once a year). It is used to judge the capacity
of cells to see whether cells are weak to remove or renew. Users judge
its capacity by the way of discharge in one string or more strings.
The wireless communication technology enables it continuously
monitor and display the real-time discharging process of all individual
cells on PC software.
The measurement data can be read on the instrument screen directly.
It can also be uploaded to a personal computer via a USB driver. With
the analyzing software, you could have an all-rounded analyzing for the
testing result and status of batteries.
2.2 Display and Keypad
The 6-button keypad enables you for quick navigation through the
screen display or menu.

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Fig.2.2. Keys Operation
Keys Functions
▼▲Move up and down to highlight the selecting options
◄►1. Change the numbers
2. Move back and forth to highlight the selecting
options
Confirm the selection or number input
Return to the previous menu
2.3 Features
♦Rugged, compact and portable unit with carrying case
♦Wireless communication for convenient discharge monitoring in
PC
♦It sets 4 conditions for auto shut-down of discharge:
discharge time, discharged capacity, cell cut-off voltage and total
cut-off voltage
♦Continued discharge available when certain cells voltage reach
cut-off value
♦Parallel connection of two units for mass discharge
♦Real-time display of voltage for each cell
♦Accurate data results and vivid waveforms
♦Powerful management system for data analyzing
ENT
ESC

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♦Auto sorting for lag-out batteries during discharging
♦Optional AC & DC power supply modes for different needs
♦Integrated functions for displaying, controlling and discharging
♦Safe circuits avoids damage to battery when testing
♦Direct USB drive for convenient data transfer to PC
♦Warning info, dynamic discharge and static discharge data
auto-saving
♦It covers different types of batteries for a wide range of
discharging like 24V, 48V, 110V, 220V and 380V in different
models
2.4 Specification
Power Supply AC 220V/110V
or DC (from battery, optional), 50/60Hz
Discharging
Current Accuracy: 1% Resolution: 0.1A or 0.5%
Discharge
voltage range 48V: 10-55.2V 110V: 10V-126.5V* 220V: 10-253V 380V: 10-437V
Voltage
Accuracy 0.5% Sampling Interval 5s--1min
LCD Display 128*64 pixel Communication USB
Temperature 0℃～40℃
5%～90% Relative humidity
CE marking EMC standard:
EN55022:2006
EN55024:1998+A1:2001+A2:2003
EN61000-3-2: 2006
EN61000-3-3:1995+A1:2001+A2:2005
Dimension
(main unit)* 400*177*280 mm (Size: S) 520*202*355 mm (Size: M)
555*225*435 mm (Size: L)

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603*400*740 mm (Size: XL)
Weight (main
unit)* 11kg(S) 16kg(M) 21Kg (L) 43Kg (XL)
NOTE*:
1) In some countries, 110VDC is replaced by 125VDC with range of
10-143V, and 220V is replaced by 240V (10-288V).
2) Dimension and weight depend on different models; more
customized models may differ in some aspects.
2.5 K-3980 Models
Currently Kongter offers the following frequent-used models for
international markets. All models come with necessary parts and
software. Amount of DAC depends on different models. “W/O DAC”
means that the model is basic load unit without data logging for each
cell.
Kongter also offers customized load banks and separate units for
testing 1.2V batteries. For details, please contact our sales
representatives.
Model Discharge Range Code DAC
24V/48V 200A Current: 0-200A
Voltage: 10V-55.2V
LB-2482 With DAC
LB-2482-1 W/O DAC
24V/48V 300A Current: 0-300A
Voltage: 10V-55.2V
LB-2483 With DAC
LB-2483-1 W/O DAC
48V/110V
100A
Current: 0-100A
Voltage:10V-55.2V(nom:48V)
10V-126.5V (nom:110V)
LB-4811 With DAC
LB-4811-1 W/O DAC
48V/220V
100A
Current: 0-100A
Voltage: 10V-55.2V(nom:48V)
10V-253V (nom:220V)
LB-4821 With DAC
LB-4821-1 W/O DAC

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110V/220V
100A
Current: 0-100A
Voltage: 10V-126.5V (nom:110V)
10V-253V (nom:220V)
LB-1121 With DAC
LB-1121-1 W/O DAC
380V 100A Current:0-100A
Voltage:10-437V
LB-3810 With DAC
LB-3810-1 W/O DAC
380V 50A Current: 0-50A
Voltage: 10V-437V
LB-3850 With DAC
LB-3850-1 W/O DAC
48V 300A Current: 0-300A
Voltage: 10V-55.2V LB-4830 With DAC
LB-4830-1 W/O DAC
110V 100A Current: 0-100A
Voltage: 10V-126.5V
LB-1110 With DAC
LB-1110-1 W/O DAC
2.5 Measurement Flowchart
The measurement workflow is described as below
Measurement Preparation 1. Wear necessary protective clothing
2. Connect the AC power cord (if
power supply is from AC)
3. Connect the testing leads
4. Turn the power on
Start Measurement
1. Select measuring mode
2. Read displaying results

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Ending of Measurement
1. Disconnect the test leads from the
subject of measurement
2. Turn off the power
3. Disconnect the power cord
Data uploading
Measurement of data
1. Us a USB drive to load the testing
data and transfer the data to PC
2. Data management on PC
WARNING: There are high voltage and current in cells and the load
bank components. Only qualified personnel can perform all the
measuring procedure. Pay special attention to precautions of electrical
and chemical safety when removing cells, installing cells, connecting
leads and making measurements.
2.6 Definition of Abbreviation
Below are the definitions of abbreviated words used in K-3980
firmware menu:
Abbreviation Full name Abbreviation Full name
avg average I current
DIS discharge Paral Parallel
C capacity param parameter

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calib calibration strg/stg string
Case acquisition case syst system
CHG charge T time
comm communication tot total
EX exit U voltage
3. MEASUREMENT PREPARATION
This section describes how to connect all the testing leads and cables
in correct way and sequence. It is very important for the whole process
of operation. For the safety of equipments and operators, please read it
carefully.
3.1 Connection
3.1.1 Check Conditions
Before any connection, make sure that:
1). The battery strings are not working and cut off from power supply.
2). There is enough space for testing. Do not test the unit around
explosive gas or vapor.
3). The nominal voltage of the load bank matches that of the battery
strings.
3.1.2 Connection of Cables
IMPORTANT: Power supply and control on-off (circuit breaker) should
be turned off before all wire connections. To ensure the safety, please
turn on the control on-off ONLY when all the other connections are
finished.
All switches and cable sockets are at the back of the main unit. Pleases
see blow for the back panel of K-3980.

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Fig 3.1.2
A. Connection of load cables
Connect one end (round socket) of the black load cable with the
black port of the load bank and the other end (with clamp) with the
negative pole of battery string.
Connect one end of the red load cable with the red port of the load
bank and the other end with the positive pole of battery string.
WARNING: Make sure they are correctly and tightly connected to
avoid electrical fire and short circuit. The black and red load cables
should be firstly connected with load bank main unit with power off, and
then with batteries. If you firstly connect them with batteries and the
other two ends accidentally get connected with each other, there will be
return circuit. Thus load cables and their clamps may get burned.
In the same way, after the testing is done, please first turn off the power,
disconnect the load cables from batteries and then disconnect them
from K-3980 main unit.

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Fig.3.1.2.A1 Fig. 3.1.2.A2 Fig. 3.1.2.C
B. Connection of voltage testing lead
Connect one end (round connector) of the voltage testing lead to the
voltage socket of the K-3980, and the other two clamps with two poles
of battery string. The red clamp is connected with the positive pole and
the black with the negative of battery string.
C. Connect the antenna to the antenna socket of the load bank like Fig.
3.1.2.C. Kongter only has one type of antenna for all main unit of
battery load.
D. When power supply is from AC, connect the load bank to an
appropriate AC power source with the AC power cord. And turn the
power switch at the back of load bank to AC 220 (or 110V mains).
When power supply is from batteries, turn the mains switch to DC. In
that case, power will be supplied via the two load cables.
E. In the following 3 auxiliary testing functions, you will need a current
clamp:
1) External discharge.
In this function, K-3980 only serves the function to display the
voltage (by DAC) and current values of external load.

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If you do not need to test current value of external load, current
clamp is not needed.
2) Reparation discharge (assistant discharge)
For example, if external loads discharge 10Amps from the
batteries and but your target is to discharge 25Amps, you could
use K-3980 reparation discharge to handle the rest 15Amps.
A current clamp is needed to monitor the external current value. If
external value is changed (e.g. 13Amps), reparation discharge
value will change (12Amps) accordingly so as to make total
discharge current (25Amps) unchanged.
Current clamp range is accordant with external load.
3) Charge monitor
K-3980 also only serves the function to display the voltage (by
DAC) and current values as the batteries are charged. If you do
not need to monitor current value or you have other way to monitor
current value, then optional current clamp not needed.
So no matter which way it takes, current clamp range should be
accordant with external loads or chargers. For details, please refer to
4.2 Other Test.
WARNING: Make sure the black load cable is connected to the
negative pole, and the red one to the positive, otherwise it may cause
significant damage to the load bank.
Other way of load cable connection
In some high power model of load bank, clamp of load cable is bigger
and harder to open. Therefore, in these models of load bank package,
the clamps are separated from cables like Fig 3.1.2.1. For different
situation, you could use load cable connected directly with battery
posts like Fig. 3.1.2.2. Or you could fix the clamp on load cable and
connect with battery like Fig 3.1.2.3.
:

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Fig 3.1.2.1 Fig 3.1.2.2
Fig. 3.1.2.3
3.1.3 Connect with DAC
Reminder: Below are introduction of DAC and instruction for its
connection with batteries.
This info is for the new DAC with insulation-protected case only. For
introduction and connection ways of old model (black metal case) of
DAC, please refer to previous version.
Fig.3.1.3.1 DAC Fig. 3.1.3.2 Magnetic bolts at bottom