Megger BALTO User manual

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SECONDARY INJECTION
DC PROTECTION SYSTEMS
BALTO MODULAR VERSION
User Manual
MAY 2016

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Content
Content 2
Revisions. 4
Introduction. 5
Object of the instruction manual. .............................................................................................................. 5
Safety regulations. .................................................................................................................................... 6
Fundamental rule. ....................................................................................................................... 6
Information and safety symbols. ................................................................................................ 6
Staff Obligations. ........................................................................................................................ 7
Qualification of staff. .................................................................................................................. 7
User manual. ............................................................................................................................... 7
Installation - Maintenance - Handling. ....................................................................................... 7
Prohibition. ................................................................................................................................. 7
Requirements for irrefutable operation. ..................................................................................... 8
Containment. ............................................................................................................................................. 9
Overview. 10
General information. ............................................................................................................................... 10
System Assembly. 11
Control Unit. ........................................................................................................................................... 11
Control Panel. ........................................................................................................................... 11
Connectors. ............................................................................................................................... 15
DC Protection Relay Interface. ................................................................................................. 16
Power Supply. ........................................................................................................................... 17
Integrated CX5130 PC and Interfaces. ..................................................................................... 17
Installation. 19
Safety. ..................................................................................................................................................... 19
Preparation. ............................................................................................................................................. 20
BALTO Modular System. ........................................................................................................ 20
Standalone BALTO Controller System. ................................................................................... 21
Connections. ........................................................................................................................................... 22
Connectors. ............................................................................................................................... 22
Power Supply. ........................................................................................................................... 22
Connection DC Protection Relays. ........................................................................................... 22
Connection BALTO Controller. ............................................................................................... 23
Operating. 24
Software structure. .................................................................................................................................. 25
General information. ................................................................................................................. 25
Background. .............................................................................................................................. 27

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Management of messages. ........................................................................................................ 29
Boot up the BALTO System. .................................................................................................................. 30
Start procedure. ......................................................................................................................... 30
Flow sheet secondary BALTO System. ................................................................................... 34
Start Dialog. .............................................................................................................................. 35
Main Menu. ............................................................................................................................................. 37
Output configurations. .............................................................................................................. 38
Safety Mode. ........................................................................................................................................... 44
Emergency Stop. ..................................................................................................................................... 45
Testmode. ................................................................................................................................................ 46
Quicktest Mode. ....................................................................................................................... 47
Auto Mode. ............................................................................................................................... 51
Manual Mode. ........................................................................................................................... 54
Reports. ................................................................................................................................................... 71
Identification. ............................................................................................................................ 71
Reading reports. ........................................................................................................................ 73
Info Dialog. ............................................................................................................................................. 76
Exit BALTO application. ........................................................................................................................ 77
BaltoWin 80
System requirements. .............................................................................................................................. 80
Information regarding the BaltoWin files. ............................................................................... 81
Installation. ............................................................................................................................................. 82
Communication. ...................................................................................................................................... 84
PC Configuration. ..................................................................................................................... 84
Connection. ............................................................................................................................................. 87
Preparations. ............................................................................................................................. 87
Operating. ............................................................................................................................................... 88
Starting up and exiting BaltoWin. ............................................................................................ 88
Download. ................................................................................................................................ 92
Downloading graphs. ................................................................................................................ 97
USB Interface. .......................................................................................................................... 98
Maintenance. 100
Control Unit. ......................................................................................................................................... 100
Control Panel. ......................................................................................................................... 100
Control Electronics. ................................................................................................................ 100
Troubleshooting. 101
Boot-up the BALTO System. ............................................................................................................... 101
Start-up procedure. ................................................................................................................. 101
Status Info dialog. ................................................................................................................................. 103
Codes index. .......................................................................................................................................... 105
Operation codes. ..................................................................................................................... 105
Error codes test results. ........................................................................................................... 118
Appendix 1 120
Concise technical specifications. .......................................................................................................... 120
Appendix 2 123
References technical assistances. .......................................................................................................... 123

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Revisions.
Information about the history of this document
Archive photography: Tommy Ravache – www.I2527.be
Copyright © April 2013 STEVO Electric
Revision
Date
Description
[1]
01
15-05-2016
Initial version
[2]
02
15-12-2016
BaltoWin
Version v1.8b
[3]
03
15-06-2017
Update
Version v1.12
[4]
04
27-12-2017
Update
BaltoWin v1.9
[5]
05
15-02-2020
Update redaction
[6]
06
10-08-2020
Update redaction
DARE
[7]
07

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Introduction.
Object of the instruction manual.
This instruction manual contains information regarding a correct
use and handling in full safety of the BALTO Controller used
from a BALTO Modular System version.
The BALTO Controller can be used as stand-alone or in
conjunction with a BALTO Modular System (3.000A up to 30.000A
or 4.000A up to 40.000A).
This user Manual must also be available when using the
System.
Please consult the chapter - 'Safety Regulations'. Information
regarding your personal safety is treated there.
Read attentively the following safety regulations before using
this device.
Modifications.
This document is not contractual and the information that it
contains corresponds to the technological status at the time of its
compilation.
STEVO Electric reserves all rights of modification or
improvement of the product which characteristics are described
in this document.

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Safety regulations.
When designing the BALTO Controller part of the BALTO
Modular System, special attention was given to safety, health
and environment.
Fundamental rule.
The BALTO Systems are compliant to nowadays technique and
recognized technical regulations, nevertheless dangers can
emerge.
The BALTO Systems can only be handled under irrefutable technical
requirements and by considering this user manual.
Information and safety symbols.
Danger
indicates a dangerous situation which could lead, when not
considered, to death, serious injuries or health problems.
Warning
Indicates a potentially dangerous situation which could lead,
when not considered, to death, serious injuries or health
problems.
Attention
Indicates a dangerous situation which could lead, when not
considered, to injuries or health problems.
Important
Indicates a situation which could lead to damages of the equipment
or environment.
Indication
Indicates important instructions, which will be able to contribute to a
better process.
EN ISO 7010 W001
To indicate that caution is necessary when operating the device or
control close to where the symbol is placed, or to indicate that the
current situation needs operator awareness or operator action in
order to avoid undesirable consequences.

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Staff Obligations.
The recognized regulations concerning the industrial safety -
within the company or imposed by status laws - must be
considered
The regulations on the improvement of working conditions are
determined by the European directives, which must be
transposed into national law.
Controls and the calibrations are subject to these provisions
which may vary for each country of the European Community.
(Belgian Regulation ARAB & CODEX)
Qualification of staff.
It’s necessary to control if all the people using the BALTO
Controller System are informed of all its characteristics and are
qualified.
All the people using the BALTO Controller System must have
received the instructions necessary relating to connections and
handling of the BALTO Controller System.
Moreover, these people must be informed about the dangers and
risks relating to the system.
User manual.
Make sure each person using the BALTO Controller System has
read and understood this user manual.
Complete documentation must always be available near the
device.
Working with an incomplete copy could lead to serious damage
and injuries.
Installation - Maintenance - Handling.
Make sure that the device will be handled, assembled,
maintained and moved in a qualified way by considering the
important technical standards.
To guarantee the operational safety use always original spare
parts.
Prohibition.
Neglecting any security functions regarding the functional or
technical staff is not permitted.

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Requirements for irrefutable operation.
To ensure that the BALTO Controller System can achieve its
contractual conditions, it’s necessary to consider the following
points:
Only qualified persons are authorized to work with the device,
These persons have read and understood this user manual,
The environmental conditions are considered,
A correct transport, and
A correct storage.
Do not open the Control unit with the power supply connected.
Moreover, read the following safety instructions - available at the
respective websites - attentively. These instructions are also part of
the complete documentation:
Beckhoff et Pulspower
Never connect the Control Unit to a main voltage or Power
Supply that is different to the one specified.
Take the following remarks into account:
When shutting down the device from Operation Mode, handle in
chapter 'Operating - section: Exit BALTO System' in the
following cases:
To clean the BALTO System, use a wet rag. Do not use liquid
detergent products or aerosols.
It’s not allowed to throw water or other liquids on the BALTO
System.
If it is necessary to return the BALTO System to the factory -
either for repair or for control - please uses the original
packaging or a resistant one. If not, the equipment may be
damaged during transport.
Caution!
Follow the transport instructions which are part of the delivery.
Caution!
Do not connect the BALTO Controller System to a DC Protection
Relay before starting-up of the software, and the High Speed DC
Circuit Breaker should be in OFF position, isolated and
grounded.
In case of enclosed DC switchgears, the draw-out part should be
in test- or service position.

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Containment.
The BALTO Controller System is applicable to any DC Protection
Relay.
Considering the diversity of DC Protection Relays available on
the market today, this manual does not include any instructions
on how to use your DC protection system.
Prior to using the BALTO Controller, consult the manual of your
DC Protection Relay.
Figure 1: Principles of operation.

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Overview.
General information.
The BALTO Controller System can simulate the output of the
shunt or Hall sensor installed in the cubicles of the High-Speed
DC Circuit Breakers.
This simulation contains several fault currents to activate the trip
from DC Protection Relays. The most important section in this
manual to test your DC Protection Relay is the section 'DC
Protection Relay Test' which can be found under 'Testmode' -
'Manual mode' - 'DC Protection Relay Test'.
The other tests, i.e. 'Quicktest Mode' and 'Auto Mode' may not
be relevant to your DC Protection Relay.
In-depth understanding of your DC Protection Relay is required
in order to perform these tests and to understand the relevance.
The secondary injection format is in accordance with IEC railway
standards:
Fixed installations - DC switchgear:
IEC 61992-1/61992-2
The BALTO Controller can be purchased as a stand-alone unit or
as part of a BALTO Modular System (3.000A up to 30.000A,
4.000A up to 40.000A).

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System Assembly.
Control Unit.
The Control Unit consists of the following components:
The Control Panel.
The Control Electronics.
Connectors.
The Control Unit contains all the functions that make it possible to
test DC Protection Relays comfortably.
Control Panel.
Overview.
Figure 2: Control Panel.
1. Control Unit - Display.
2. Push button O/I and signalling PLC
3. Signalling system operational.
4. Emergency Stop.
5. External measurement.
6. USB Interface.
7. RJ45 Interface.
8. Buzzer
These functions are further elaborated below.

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Control Unit - Control Panel Display.
The Touch Screen Display CP6907 is designed for industrial
applications with tactile colour screen of 5.7" with active TFT matrix
(Thin Film Transistor).
With the possibilities given by this Control Panel, the BALTO System
gives an optimal management performance.
Figure 3: Control Unit: Control Panel - HMI
For more information and technical assistance, please consult the
chapter 'Appendix 2' - section 'References technical assistances'.
Specific responsibilities.
Environmental conditions.
Extreme environmental conditions should be avoided!
The necessary measures should be taken against dust, moisture and
heat.
Particularly against the climatological fluctuations - variations of
temperature, or humidity: moisture can condense on or in the device
which may lead to short-circuits.
Do not use direct heat from heaters.
Let the device adapt to the ambient temperature before putting in
operation.
A waiting period of about 12 hours is recommended.
The Control Panel should not be opened by the user.
For more information and technical assistance, please consult the
chapter 'Appendix 2' - section 'References technical assistances'

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Switching ON and OFF Power Supply.
The Control Panel does not have its own switch.
Switching ON and OFF the control panel is carried out by the PLC.
Do not disconnect any connection when powered, software data could
be lost or damaged.
Maintenance of the Control Panel.
For the maintenance, please consult the chapter 'Maintenance'.
Operation.
The Control Panel may only be operated by qualified and authorized
operators; furthermore, each operator must be familiar with the
Windows browser and the application software.
The operating of the Touch Screen may only be done with the
finger or a Touch Screen Pencil.
The operator should wear gloves, but they must not contain any
hard particles such as chips, metal shavings, debris or glass
splinters.
Function:
Image management:
Display of the images.
Handling of the various operating processes with data
recording of measurements.
Service supervision.
Report and communication.
External measurement.
Application for the BALTO Modular System.
Remark:
The external measurement is also used for the function ꞌRecalibrate
Outputꞌ.
Please refer to the paragraph ꞌOutput configurationsꞌ - section
'Boot up to the BALTO' - chapter ꞌOperatingꞌ.

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Communication - Buzzer.
Buzzer.
Not in use by software release v4.12
Ethernet Interface.
Communication and operating by PC or Laptop
from the BALTO Win software
Printer with Ethernet connection - addressing
TCP/IP (not available for printing)
•
Interface Ethernet according to EIA/TIA568
TSB-36
• Twisted-Pair cable
• Max length: 100m
USB Interface.
• It is possible to store measurement data on a
USB Stick.
The data can be processed by BALTOWin
• Connection of keyboard.
Push button O/I - PLC Signalling.
Push button/Signalling button 1:
The BALTO System can only be activated
when the indicators are lit up. After which,
you can press the button to start the
operation.
During the operation, this signal will be turned
off and the button will become inactive during
the process. These indicators will light back up
when the operation has been stopped
completely. Afterwards, the BALTO System can
be restarted.
Signalling - System ready :
The green lamp 'System ready' lights up after a successful
start-up process. This means that the Control Unit including the
PLC is operational and the BALTO System start-up was
completed successfully.
Emergency Stop.
In case of an emergency, the Emergency Stop Button has to be
activated.
By activating the emergency stop button operation of the BALTO
System is blocked.
For more information, please consult the chapter 'Operating' -
section 'Emergency Stop'.

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Connectors.
On the Control Unit there are the following connectors:
Figure 4: Control Unit: Connectors.
1. Connector.
Power Supply Control Unit: 230VAC/50Hz or 120VAC/60Hz
Figure 5: Control Unit: Power Supply cable.
2. Connector.
3. Connector.
Remark:
Connectors and : Application for the Modular BALTO System.

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DC Protection Relay Interface.
Protection Test
SUBModul ADP
The Control Unit is equipped with an interface - Submodul ADP -
with outputs for testing DC Protection Relays.
Output: Source of simulation errors input for DC Protection Relay.
mA: - 20mA/+20mA or +4mA/+20mA
mV: Selection between 60mV up to 10VDC
Input - TRIP: Signalling contact form the High-Speed DC Circuit
Breaker or the DC Protection Relay.
Trip → Signalling trip contact.
Trip → Implementation in according the application.
Remark:
By BALTO Modular Systems used for testing High-Speed DC Circuit
Breakers for rolling stock, the second Trip can be implemented for
measuring the interactions of the auxiliary contacts.
Figure 6: Control Unit: Connection DC Protection Relay.

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Power Supply.
Power Supply with primary switch mode SFB technology
PULS Q-Series.
For more information and technical assistance, please consult the
chapter 'Appendix 2' - section 'References technical assistances'.
Integrated CX5130 PC and Interfaces.
General information.
The module CX5130 has an Intel® Atom™ multi-core processor
with a clock rate of 1.75 GHz. Depending on the installed
TwinCAT runtime environment, the CX5130 can be used for
implementing PLC functions with or without monitoring.
Specific responsibilities.
Switching ON or OFF
Never disconnect any connection to the PLC or any peripheral device
when powered, software data could be lost or damaged.
For more information regarding safely turning the device ON or OFF,
refer to the chapter 'Operating'.
Use of the CF (CompactFlash) modules.
Never abruptly remove the CF modules.
Software data could be destroyed, lost or damaged.
In this case STEVO Electric cannot be held responsible for the
suffered damage, and that is not covered by any guarantee.
Replacement of the Battery.
The Battery must be replaced every five years.
A badly inserted Battery, or inserted with incorrect polarity,
can explode and can cause damage.
Only use original Battery types: CR2032 from Sanyo or
Panasonic - Battery Lithium.
The Battery is not rechargeable.
When removing or closing the controller unit cover, care should
be taken to not displace any components or connections.
Concerning the replacement and the precautionary measures
and for more information, please consult the manual CX51x0
Beckhoff available on the website: www.beckhoff.de
For more information and technical assistance, please consult the
chapter 'Appendix 2' - section 'References technical assistances'.

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PLC control management.
The PLC has a number of digital inputs and outputs, as well as
analogy inputs and outputs to carry out the controls and
monitoring for the BALTO Controller System.
These consist of:
Input management:
Measurements of the various currents.
Emergency Stop.
Output management:
Control Unit fan.
Command and control signals.
Generation of power curves.
Monitoring.
Processing of measurements and calculations.

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Installation.
How to use the BALTO Controller System and make it operational
in order to carry out tests on the DC Protection Relays .
Safety.
During the assembly of the various units it’s necessary to read
the warnings concerning the equipment carefully.
All primary tests have to be terminated before removing any
equipment.

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Preparation.
How to prepare the BALTO Controller System?
BALTO Modular System.
For starting the Secondary Injection function, several actions
have to be taken in order to unblock the software program for
performing Secondary Injections.
All primary tests have to be finished and the test object has to
be removed from the Power Units.
On the Control Unit, there are the following connectors:
Figure 7: Control unit: Connectors.
Disconnect the connectors and
The Control Unit is now ready to operate has a BALTO Controller.
Remark:
The Control Unit can also be removed from the Support Carriage
and be used as autonomous system.
The start dialog will indicate that the Secondary Injection
program is running.