Megger BALTO Modular User manual

DC High Current Circuit
Breaker Tester
BALTO Modular 4,000A to 40,000A
BALTO Compact 4,000 A
User Guide

This document is copyright of:
Megger Limited, Archcliffe Road, Dover, Kent CT17 9EN. ENGLAND
T [phone] F [phone] www.megger.com
Megger Ltd reserves the right to alter the specification of its products from time to time without
notice. Although every effort is made to ensure the accuracy of the information contained within
this document it is not warranted or represented by Megger Ltd. to be a complete and up - to - date
description.
For Patent information about this instrument refer to the following web site:
megger.com/patents
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II

Declaration of Conformity
Hereby, Megger Instruments Limited declares that radio equipment manufactured by Megger Instruments Limited
described in this user guide is in compliance with Directive 2014/53/EU. Other equipment manufactured by Megger
Instruments Limited described in this user guide is in compliance with Directives 2014/30/EU and 2014/35/EU where they
apply.
The full text of Megger Instruments EU declarations of conformity are available at the following internet address:
megger.com/company/about-us/eu-dofc
This manual supersedes all previous issues of this manual. Please ensure that you are using the most recent issue of this
document. Destroy any copies that are of an older issue.
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Contents
1. Introduction 1
1.1 Product description ..................................................................................................................................1
1.2 Features.....................................................................................................................................................1
1.3 Applications ..............................................................................................................................................2
1.4 Company web site ....................................................................................................................................2
2. Safety Warnings and Standards 3
2.1 Fundamental rule ....................................................................................................................................3
2.2 Warnings, Cautions and Notes ................................................................................................................3
2.3 Staff Obligations.......................................................................................................................................4
2.4 User manual..............................................................................................................................................4
2.5 EMC ...........................................................................................................................................................4
2.6 Installation - Maintenance - Handling ....................................................................................................4
2.7 Unauthorised use .....................................................................................................................................5
2.8 Requirements for safe operation ............................................................................................................5
2.9 Packing and Shipping. .............................................................................................................................6
3. Principles of operation 7
3.1 General characteristics .............................................................................................................................7
3.2 General diagram ......................................................................................................................................8
3.3 Testing modes ..........................................................................................................................................8
4. BALTO Modular hardware 9
4.1 Support Carriage ......................................................................................................................................10
4.2 Emergency Stop Device ...........................................................................................................................12
4.3 Supply, Fuses and Charge Connector .....................................................................................................13
4.4 Power Connections ..................................................................................................................................13
4.5 Sockets for the DC Current Generators ..................................................................................................14
4.6 The Control Unit (Incl. Protection Test Module).....................................................................................14
4.7 Work surface cover ..................................................................................................................................15
5. BALTO Compact 4000 Hardware 16
5.1 Main Unit. ................................................................................................................................................16
5.2 DC Current Generator Connection Panel. ..............................................................................................17
5.3 Emergency Stop Device ...........................................................................................................................18
5.4 Supply, Fuses and Charge Connector ......................................................................................................18
5.5 Protection Test Module ............................................................................................................................19
6. Control Panel 20
6.1 Display with embedded PC ......................................................................................................................20
6.2 External measurements ...........................................................................................................................22
6.3 Communication interfaces ......................................................................................................................22
6.4 Start button - System ready indicator ....................................................................................................23
6.5 Emergency Stop .......................................................................................................................................23
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7. DC Current Generator 25
8. Installation 26
8.1 Safety Warnings........................................................................................................................................26
8.2 Preparation : charge the BALTO beforehand ........................................................................................26
8.3 Charging the current generators ............................................................................................................26
8.4 How to use the Power Flex-cables. .........................................................................................................28
8.5 Connecting the High-speed DC Circuit Breaker. ....................................................................................29
8.6 Assembly of the BALTO Modular on site ................................................................................................30
8.7 Assembly of the BALTO Compact 4000 on site.......................................................................................32
9. Operation 33
9.1 Test procedures. .......................................................................................................................................34
9.1.1 To determine the release threshold. ....................................................................................................... 34
9.1.2 To determine the opening time. ............................................................................................................ 34
9.1.3 To determine the voltage drop. .............................................................................................................. 34
9.2 Software structure. ..................................................................................................................................35
9.2.1 General information. ............................................................................................................................. 35
9.2.2 Background. .......................................................................................................................................... 37
9.2.3 Message management. ......................................................................................................................... 39
9.3 Booting up the BALTO System.................................................................................................................39
9.3.1 Start procedure. .................................................................................................................................... 39
9.4 Operating conditions. ..............................................................................................................................42
9.4.1 Power Capacity. .................................................................................................................................... 42
9.5 Flow chart Primary BALTO System. .........................................................................................................44
9.5.1 Start Dialog. .......................................................................................................................................... 45
9.6 Main Menu. ..............................................................................................................................................46
9.7 Information BALTO range........................................................................................................................48
9.8 Safety Mode..............................................................................................................................................48
9.9 Emergency Stop........................................................................................................................................48
9.10 Test mode................................................................................................................................................49
9.10.1 Quicktest Mode. ................................................................................................................................. 51
9.10.2 Auto Mode .......................................................................................................................................... 55
9.10.3 Manual Mode. .................................................................................................................................... 59
9.10.3.1 Opening Time Test. ........................................................................................................................ 59
9.10.3.2 DC Protection Relay Test. ................................................................................................................ 64
9.10.3.3 Reaction Time Tests. ....................................................................................................................... 69
9.10.3.4 Measuring reaction time ................................................................................................................. 72
9.10.3.5 Shunt Mode ................................................................................................................................... 73
9.10.4 Voltage drop Measurement ................................................................................................................. 77
9.10.5 I_Max NO - NC..................................................................................................................................... 81
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9.11 Reports. ...................................................................................................................................................86
9.11.1 Report info. ......................................................................................................................................... 86
9.11.2 Saving and exporting. ......................................................................................................................... 88
9.12 Auto-Verification....................................................................................................................................90
9.13 Info dialog ..............................................................................................................................................92
9.14 Exiting the BALTO application. .............................................................................................................93
10. Master/Slave version. 96
10.1 System Assembly.....................................................................................................................................96
10.1.1 Identification of the Control Units. ....................................................................................................... 96
10.2 Start-up master/slave..............................................................................................................................97
10.2.1 Operating Master/Slave. ....................................................................................................................... 99
10.2.2 Status reporting. .................................................................................................................................. 100
10.3 Info Master/Slave....................................................................................................................................101
10.4 Stop master/slave....................................................................................................................................104
11. Secondary Injection. 105
11.1 Introduction............................................................................................................................................105
11.2 Principle of operation. ...........................................................................................................................105
11.3 DC Protective Relay Interface. ...............................................................................................................106
11.4 Booting up secondary injection.............................................................................................................107
11.5 Main Menu. ............................................................................................................................................108
11.5.1 Tuning the BALTO PROTECTION TEST module for a specific relay. ......................................................... 109
11.6 Testmodes. ..............................................................................................................................................113
11.6.1 Manual Mode. ..................................................................................................................................... 114
11.6.2 Advanced Mode................................................................................................................................... 117
12. Calibration 122
12.1 Preparations............................................................................................................................................122
12.1.1 Calibration sets ................................................................................................................................... 122
12.1.2 Precautions .......................................................................................................................................... 123
12.2 Calibration software .............................................................................................................................123
12.2.1 Accessing the application .................................................................................................................... 123
12.2.2 Operation ........................................................................................................................................... 123
12.2.3 Step 1/6 – OFFSET CALIBRATION ......................................................................................................... 126
12.2.4 Step 2/6 - CALIBRATION OF OUTPUT FACTOR ..................................................................................... 128
12.2.5 Step 3/6 - CALIBRATION OF INPUT FACTOR ......................................................................................... 129
12.2.6 Step 4/6 - LINEARITY ADJUSTMENT I-OUT ........................................................................................... 131
12.2.7 Step 5/6 - LINEARITY ADJUSTMENT I-IN ............................................................................................... 132
12.2.8 Step 6/6 - Verification and application. ................................................................................................ 133
12.2.9 Results. ............................................................................................................................................... 134
12.2.10 Calibration sets overview. .................................................................................................................. 135
12.2.11 Saving the report. .............................................................................................................................. 135
12.3 Message codes. ......................................................................................................................................137
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12.3.1 General messages. .............................................................................................................................. 137
12.3.2 Initialisation warnings. ......................................................................................................................... 137
12.3.3 Initialisation critical errors. ................................................................................................................... 138
12.4 Failed calibration messages. .................................................................................................................138
13. BALTOWin. 139
13.1 System requirements. ............................................................................................................................139
13.1.1 BALTOWin files. ................................................................................................................................... 139
13.2 Installation. ............................................................................................................................................139
13.3 Communication. ....................................................................................................................................141
13.3.1 PC configuration. ................................................................................................................................ 141
13.3.2 Connecting to the BALTO System. ....................................................................................................... 143
13.4 Operation. ..............................................................................................................................................143
13.4.1 Starting BALTOWin. ............................................................................................................................. 143
13.4.2 Dialog information. ............................................................................................................................. 144
13.5 Downloading. ........................................................................................................................................146
13.5.1 Report graphs. .................................................................................................................................... 149
13.5.2 USB downloading. .............................................................................................................................. 150
14. Maintenance 152
14.1 Junction Connectors ..............................................................................................................................152
14.2 Tyres (BALTO Modular only) .................................................................................................................152
14.3 Components ...........................................................................................................................................152
14.3.1 Trained personnel only ........................................................................................................................ 152
14.3.2 Battery Chargers. ................................................................................................................................ 152
14.3.3 Ultracapacitors. ................................................................................................................................... 152
14.3.4 Batteries. ............................................................................................................................................. 153
14.4 Power Connectors. .................................................................................................................................153
14.5 Ventilation. ............................................................................................................................................154
14.6 Control Panel. ........................................................................................................................................154
14.6.1 Screen repairs....................................................................................................................................... 154
14.6.2 Screen maintenance. ........................................................................................................................... 154
14.7 Control Electronics. ................................................................................................................................154
14.7.1 Embedded PC battery. ......................................................................................................................... 154
14.7.2 Ventilation. ......................................................................................................................................... 154
15. Troubleshooting. 156
15.1 Booting up the BALTO System. .............................................................................................................156
15.1.1 Starting procedure. ............................................................................................................................. 156
15.2 Info dialog status. ..................................................................................................................................156
15.3 Emergency Stop Device. ........................................................................................................................159
15.4 Message codes. ......................................................................................................................................160
15.4.1 Operation error codes. ........................................................................................................................ 160
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15.4.2 Test result error codes........................................................................................................................... 165
15.5 Current Injection. ..................................................................................................................................167
16. Appendix 1 168
16.1 Concise technical specifications.............................................................................................................168
17. Appendix 2 170
17.1 References for technical assistance. ......................................................................................................170
18. Calibration, Repair and Warranty 171
18.1 Return procedure ...................................................................................................................................171
19. Decommissioning 172
19.1 WEEE Directive .......................................................................................................................................172
19.2 Battery disposal ......................................................................................................................................172
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VIII

1. Introduction
This instruction manual contains information regarding the correct use and handling of the BALTO in full safety and
should be considered an essential component of the BALTO System.
The BALTO family consists of 2 models :
The BALTO Modular with a capacity of 20,000 A expandable up to 40,000 A in a Master-Slave configuration
The BALTO Compact 4000 with a fixed capacity of 4,000 A
Unless the specific product name is mentioned, the description in this manual applies to both models.
This handbook must be at hand when using the System.
Please ensure to consult the chapter ‘Safety Regulations’. This chapter contains information regarding your personal
safety when using the system.
Read the ensuing safety regulations attentively before using this device.
This document is not contractual and the information that it contains corresponds to the technological status at the
time of its compilation.
Megger reserves all rights of modification or improvement of the product, which is described in this document
resulting from new product requirements.
The responsibility to inform oneself of the conditions and the requirements of the product rests solely with the
customer, regardless of the circumstances.
1.1 Product description
Railway operators involved in the service and maintenance of the railway network are challenged with testing DC
high speed circuit breakers and in particular when it comes to the control and the adjustment of the threshold circuit
breaker trip current, known as lds, and when comparing results to the circuit breaker OEM specification.
The solution is the Megger BALTO. Designed with the user in mind this innovative mobile Megger BALTO system
is useable for up to 40,000 A which meets the challenges of the manufacturers and users of DC high speed circuit
breakers.
The Megger BALTO DC High Current Circuit Breaker Tester was developed to generate very high and precise DC test
currents in order to carry out functional tests on DC high speed circuit breakers. These very high currents are injected
in the main circuit of DC high speed circuit breaker and allow control of the entire circuit including the measurement
elements, current converters and protection relays..
1.2 Features
To meet the needs of the market, Megger provides the innovative Megger BALTO system based on the requirements
of the DC high speed circuit breakers’ manufacturers and from various railway networks managers and users.
Each Megger BALTO system consists of ...
An operator terminal
Current Generator(s), sometime called power unit(s). One unit can generate a maximum current of 4,000 A
Batteries, ultra-cap(s) and battery charger(s).
Cable Set(s) – Connection(s) to the test piece
Both models are modular in design and are easily transportable. The system is easy to setup and straightforward to
connect to the device under test.
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Introduction

User safety is paramount and the Megger BALTO provides the automated monitoring of the system and temperature
guarding of the ultra-caps.
The Megger BALTO provides :
A Quick test to determine the approximate Circuit Breaker Trip Current - Ids.
An Automatic test with current increase slope according to IEC 61992-2 (Traction Power Substations) and IEC
60077-2 (Rolling Stock) for accurate testing of Ids
Measurement of the DC high speed circuit breaker’s opening time
Testing of the DC protection
Voltage drop measurement according to the DC high speed circuit breakers manufacturer’s procedure
Calibration of the external devices
Automatic recognition of the Current Generator(s)
Auto diagnostic – Control and calibration of current measurement per Current Generator
Flexible current increase management
Graphical display of measurement results
1.3 Applications
The Megger BALTO System was developed for specific applications in the railway field, namely:
Tests of DC high speed circuit breakers for substations and their protections
Tests of DC high speed circuit breakers in locomotives, train sets, subways, undergrounds and tramways
Tests of electromagnetic contactors (control and main) in tramways and trolley buses
The Megger BALTO system can also be used for other applications where very high currents are required e.g. mining,
steel factories, marine and solar.
1.4 Company web site
Occasionally an information bulletin may be issued via the Megger web site. This may concern new accessories, new
usage instructions or a software update. Please occasionally check on the Megger web site for anything applicable to
your Megger instruments.
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2
Introduction

2. Safety Warnings and Standards
These safety warnings must be read and understood before the instrument is used. Retain for future reference.
When designing the BALTO System, special attention was given to safety, health and environment.
2.1 Fundamental rule
The BALTO System is designed to international safety standards and meets national safety legislation where it applies.
Nevertheless, those responsible for the operation of this equipment must understand hazards that can arise and
ensure that safe working procedures are in place to protect operators and other personnel.
If this equipment is operated in a manner not specified by the manufacturer, the protection provided by the
equipment may be impaired.
2.2 Warnings, Cautions and Notes
This user guide follows the internationally recognised definition. These instructions must be adhered to at all times.
Description
DANGER :DANGER : Indicates a dangerous situation which, if ignored, could lead to death, serious
injury or health problems.
WARNING : Indicates a potentially dangerous situation which, if ignored, could lead to death, serious
injury or health problems.
ATTENTION : Indicates a dangerous situation which, if ignored, could lead to injuries or health
problems.
CAUTION : Indicates a situation which could lead to damage of the equipment or environment
NOTE : Indicates important instructions to be followed to perform the relevant process safely and
efficiently.
Icon Description
EN ISO 7010 P007
Interference to the operation of or damage to active implanted cardiac devices from this
equipment which generates strong electromagnetic fields.
No access for people with active implanted cardiac devices.
EN ISO 7010 W006
Strong magnetic field present
EN ISO 7010 W001
Consult the user instructions. Caution is necessary when operating the device or control close
to where this symbol is placed, or to indicate that an operation needs operator awareness and
protective action in order to avoid hazardous situations.
High voltage
Risk of electric shock
Pinch-point
DO NOT hold the Controller cover by the edges: fingers will be pinched in the gap.
Earth/Ground
2.3 Staff Obligations
Legal regulations concerning industrial safety – either within the company or imposed by status laws - must be
obeyed.
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Safety Warnings and Standards

Controls are subject to these provisions which may vary for each country of the European Community (for example:
Belgian Regulation ARAB and CODEX).
It is necessary to ensure that those who operate the BALTO System are suitably trained and qualified.
Those using the BALTO System must have received instruction relating to operation, connections and handling of the
BALTO System.
Moreover, these people must be informed about the dangers and risks relating to the system and be provided with
written safe working procedures and protective means as necessary.
2.4 User manual
Make sure each person using the BALTO System has read and understood this instruction manual.
CAUTION : The complete manual must be to hand when operating the equipment. Working with an
incomplete copy could lead to serious damage and injury.
2.5 EMC
This device complies with the emission requirements for IEC 61326-1 and Part 15 of the FCC Rules for a Class B
device: (1) This device may not cause harmful interference, and (2) this device must accept any interference received,
including interference that may cause undesired operation.
The emission limits are designed to provide reasonable protection against harmful interference in an industrial
environment. This equipment generates, uses and can radiate radio frequency energy and, if not installed and used in
accordance with the instructions, is likely to cause harmful interference to radio communications. However, there is
no guarantee that interference will not occur in a particular installation.
In particular, when testing high current DC circuit breakers, electromagnetic interference which may disturb the
operation of nearby equipment is radiated. Before use, make sure that sensitive equipment that may be affected is
switched off or located at least 30 m from the test setup. Medical implants may be affected by high energy pulses;
this equipment must not be operated by or near people with active implanted cardiac devices.
2.6 Installation - Maintenance - Handling
Make sure that the device will be handled, assembled, maintained and moved by personnel that are suitably trained
and qualified.
To guarantee operational safety, use only genuine spare parts provided by the manufacturer.
Before assembly of the various components, it is mandatory to read the warnings concerning the equipment
carefully. The warnings must be obeyed.
The output terminals of the DC Current Generators, the cables and the connection points on the test object may
get hot during Current Injections.
To prevent the Support Carriage from moving abruptly during system assembly, it is necessary to put the Support
Carriage in working position by locking the wheels (applicable to BALTO Modular only).
Carefully follow the instructions concerning the assembly of the device, in particular the steps regarding
the DC Current Generators and Power Connections.
Always use the handle provided to close the Compact Controller cover for transport and to open it for operation.
DO NOT hold the Controller cover by the edges: fingers will be pinched in the gap.
Do not use the Compact Controller cover handle to lift the controller: use the carrying handles on each side:
two-person lift.
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4
Safety Warnings and Standards

2.7 Unauthorised use
Neglecting or overriding any safety functions by the operator or the responsible body is strictly forbidden.
2.8 Requirements for safe operation
To ensure that the BALTO System can operate safely and correctly, it is necessary to consider the following:
Only qualified personnel are authorized to work with the device.
These personnel must have read and understood this instruction manual, and be adequately trained and
qualified.
The equipment must be checked before use.
If any parts are damaged, the equipment must be taken out of service for repair. It must not be used until
repaired by manufacturer-qualified service personnel.
The equipment must be operated only within the environmental conditions specified by the manufacturer.
The device must be transported safely.
Suitable storage, within the environment specified by the manufacturer, must be provided..
WARNING : The voltages and currents generated by the BALTO System can cause serious injury in the
event of incorrect use.
DANGER :DANGER : EN ISO 7010 P007
According to Directive 2013/35/EV, the ELV (Exposure Limit Value) for static magnetic fields in controlled working
conditions is 8 T (Tesla). During an injection, a magnetic field is generated by the Power Flex-cables.
The generated field is much lower than 8 T, even at 1 cm from the cables. However, one should not touch the Power
Flex cables during an injection.
WARNING : Read and understand the instructions on the DC Current Generators before installing or
removing them.
WARNING : If a test connection must be changed, in particular the replacement of the device under test,
make sure that all the current injections are completed. Before replacing the test object it is necessary to
put the Control Panel in Safety Mode before disconnecting any Power Connection.
DANGER :DANGER : Do not open any mains power supply modules: there are no user serviceable parts
WARNING : The generated currents can heat the terminals of the DC Current Generators and connection
points to levels that may cause burns. Make sure the connections are cool before handling and use
protective equipment as necessary
WARNING : The BALTO System must be grounded by using the Ground Connection.
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Safety Warnings and Standards

WARNING : Take the following matters into account:
Always use cables or systems that are rated by the manufacturer for the high currents generated by the
equipment and rated for the environment in which the equipment is operated.
Never connect the BALTO System to a mains voltage or power supply that is different to the one specified on the
system.
Never carry out repairs on the BALTO System. When opening the modules of the equipment, for operator-
maintenance or configuration, dangerous voltages and high electrical energy sources are exposed.
When shutting down the device from Operation Mode, place the Emergency Stop isolating handle in the OFF
position and follow the instructions in chapter: ‘Operating - section: Exit BALTO System’ in the following cases:
The equipment is not in use,
The equipment is not connected,
The equipment is not being monitored,
During storms,
Before carrying out maintenance or cleaning.
To clean the BALTO System, use a damp cloth.
Do not use liquid detergents or aerosols. Make sure the equipment is dry before use.
Do not operate the BALTO System in wet conditions.
Keep water and other liquids away from the equipment. If it is necessary to return the BALTO System to
the factory for repair or calibration, use the original packaging or suitable protective alternative. If not, the
equipment may be damaged during transport.
CAUTION : Follow the transport instructions, which are part of the delivery.
CAUTION : To avoid damage during the installation and uninstallation, put on the brakes to lock the
wheels (BALTO Modular only).
DANGER :DANGER : When connecting the BALTO System to the High-Speed DC Circuit Breaker and during
start-up of the software, the High-Speed DC Circuit Breaker should be isolated, grounded and in
the open position. In case of enclosed DC Switchgears, the draw-out part should be in ‘test’ or
‘service’ position.
2.9 Packing and Shipping.
There are specific instructions relating to the transport and unpacking of the equipment. Read these instructions
before unpacking the equipment.
Check that the equipment and the options which are part of the delivery are in conformity with your order.
Despite the robust construction of the equipment, it is desirable to protect the BALTO System against vibrations and
violent shocks.
It is highly recommended that the original packaging is retained to use for any later transport of the equipment.
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6
Safety Warnings and Standards

3. Principles of operation
3.1 General characteristics
The innovative BALTO System is designed and built to carry out examinations when maintaining, repairing and
adjusting trip levels on High-speed DC Circuit Breakers in Traction DC Power Systems and Rolling Stock.
This system meets the requirements for the use in an industrial environment.
The BALTO system is designed to not rely on an industrial three-phase power supply for the source of energy. Instead,
a standard single-phase mains supply suffices.
The BALTO system is designed to reach currents up to 4,000 A (BALTO Compact 4000) or 20,000 A (BALTO Modular),
using DC Current Generator modules of 4,000 A. To reach 40,000 A, a second BALTO Modular system can be
connected in a Master/Slave configuration.
Current injections can be performed using a current increase of 200 A/s, in accordance with IEC railway standards:
Electric equipment for Rolling Stock: IEC 60077-1/60077-2
Fixed installations - DC switchgear: IEC 61992-1/61992-2
The System has a number of predefined standard functions and can realise a wide array of current injections.
NOTE : The assembly of the BALTO System is easy and fast, moreover the deployment is logically intuitive.
The installation and connections must be realised as described in this manual in order to generate optimal
output as prescribed in the technical specifications.
The BALTO system is available for use with a mains power supply of 230 VAC / 50 Hz or 120 VAC / 60 Hz.
The BALTO System has built-in protection mechanisms, such as :
Monitoring system of ADC III Benning rectifier.
Monitoring of ultracap Maxwell Technologies or equivalent.
Monitoring of battery voltage and charging current.
Standard measured results are accurate to 1.5%. Better accuracies are available upon request.
Moreover, this version perfectly meets the needs of tramway networks, Traction DC Power Systems and Rolling Stock.
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Principles of operation

3.2 General diagram
3
2
1
4
5
6
7
Fig 1: General diagram of the BALTO System.
Item Description Item Description
1Mains Supply: 230 VAC / 50 Hz or
120 VAC / 60 Hz
5 Control Unit
2Battery charger(s) 6 DC Current Generator(s) of 4,000 A each
3Ultracapacitor(s) as buffer for the
batteries -
7 Device under test - High-speed DC
Circuit Breaker
4Batteries
When fully charged, the voltage over the batteries will be approximately 15.6 VDC. When performing an injection,
the output voltage of the Current Generator(s) will not exceed 4.7 VDC.
3.3 Testing modes
Current Injections can be generated in different modes, such as:
Quicktest Mode : high slope during injection
Auto Mode : slope of 200 A/s
Manual Mode
Protection relay mode : steep slope (higher than short circuit slope)
Shunt mode : fixed current during maximum 60 seconds.
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Principles of operation

4. BALTO Modular hardware
The BALTO Modular System consists of:
Support Carriage, including:
Compartment containing the Battery Charger(s).
Compartment containing the ultracap(s) Maxwell Technologies or equivalent
Compartment containing the Enersys Cyclon batteries.
Connectors for up to five DC Current Generators.
Power supply and fuses.
Work surface cover.
DC Current Generator(s) of 4,000 A - combined up to 20,000 A and in Master/Slave configuration up to
40,000 A.
Control Unit including MMI (Man Machine Interface)
Connections for the device under test: Set of Power Flex-cables for each DC Current Generator.
Set of measurement cables for measuring voltage drop.
The equipment is designed for horizontal mobility, and special attention was given to providing mobility for moving
between cells in Traction DC Power Systems.
The Support Carriage provides a transport mode and a fixed-in-place working position mode.
Fig 2: BALTO Modular System 20,000 A
The DC Current Generators and Control Unit are plug-ins and can be separated from the device. The Support
Carriage itself cannot be dismantled for transport purposes.
The contents and total weight of the Support Carriage depends on the system power configuration.
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BALTO Modular hardware

4.1 Support Carriage
The Support Carriage is the mobile part to facilitate the handling of the device on-site.
This carriage includes the energy supply, connectors for the DC Current Generators, a Control Unit platform and a
work surface.
The energy supply consists of:
Battery Chargers (1)
Ultracapacitors (2)
Batteries (3)
1
2
3
Fig 3: Support Carriage: Compartment overview.
Item Description
1 Compartment for the Battery Chargers.
This compartment contains one or two Benning ADC III rectifiers.
The rectifier is based on switch mode technology.
The number of installed battery chargers depends on the system’s maximum configuration:
Maximum Configuration Chargers
8,000 A 1
12,000 A 2
20,000 A 2
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BALTO Modular hardware

2 Compartment for the Ultracapacitors
The energy storage modules - used as a buffer for the Batteries - are of type 16 V and consist of 6
cells of 3,000 F placed in series.
The compartment can hold up to 5 modules of 16 V connected in parallel.
The number of installed modules depends on the system’s maximum configuration:
Maximum Configuration Modules
8,000 A 3
12,000 A 4
20,000 A 5
3 Compartment for the Batteries.
This compartment contains the Batteries, placed in rows of 7 cells connected in series, cells being 2
V 25.0 Ah each.
Type: Enersys Cyclon 0820-0004.
The compartment can hold up to 4 rows connected in parallel.
The number of installed rows depends on the system’s maximum configuration:
Maximum Configuration Battery Rows
8,000 A 2
12,000 A 3
20,000 A 4
The standard Support Carriage configurations are typically sufficient for normal testing conditions.
For increased testing capabilities, it is possible to use a Support Carriage with an increased energy compartment. For
example, an 8,000 A system can benefit from using a Support Carriage designed to support up to 20,000 A as it
contains a larger energy supply.
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BALTO Modular hardware

4.2 Emergency Stop Device
The Emergency Stop Device physically breaks the circuit and disconnects the DC Current Generators from the energy
supply.
The Emergency Stop Device is located inside the Support Carriage and the operating lever is mounted on top.
Operate only using the lever.
Switch off and on is performed manually.
When the lever is switched to the ON position ‘CONNECT’, the energy supply is connected and the system can
be used normally.
To disconnect the energy supply, switch the lever to ‘DISCONNECT’.
Fig 4: Support Carriage: Emergency Stop Device.
CAUTION : Use the Emergency Stop Device only in case of an emergency. Excessive operation may cause
wear and damage to the contacts.
CAUTION : Before switching the lever back on, please consult the chapter ‘Troubleshooting’ - section
‘Emergency Stop Device’.
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