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K-3980 Battery Load Bank 

 

4 

 

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) 

Summary of Contents for K-3980

Page 1: ...K 3980 Battery Load Bank User Manual K 191211 V2 7...

Page 2: ...T 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 MEA...

Page 3: ...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...

Page 4: ...strument 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 you...

Page 5: ...oad 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...

Page 6: ...de 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 us...

Page 7: ...y Symbols Description of symbols used in this manual WARNING Indicates correct operation to prevent a significant hazard that could result in serious injury or other bad consequences to users or the p...

Page 8: ...y 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 g...

Page 9: ...ies 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 m...

Page 10: ...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 en...

Page 11: ...table 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 volt...

Page 12: ...de 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...

Page 13: ...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 bat...

Page 14: ...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...

Page 15: ...igh 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 wh...

Page 16: ...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...

Page 17: ...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...

Page 18: ...nk 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...

Page 19: ...rrent 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 ta...

Page 20: ...w 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 met...

Page 21: ...s of DAC cable They are for connecting with different series of batteries in a string For detailed way of connection please refer to the text below About DAC leads K 3980 also has two kinds of data ac...

Page 22: ...owever all DACs have been programmed with different serial numbers to match specific K 3980 unit Therefore for DAC connection with batteries use them in the order of DAC 1 DAC 2 and so forth b If you...

Page 23: ...beginning from negative pole no matter the whole string begins from the negative pole or possible pole Hereafter 0 below indicates the black lead which is connected with negative pole of batteries Eve...

Page 24: ...2 If you need 2 serial cables for cell connection but have spare DAC leads then connect and cell numbers are less than what one DAC can measure we have two situations 1 If you only need one DAC seria...

Page 25: ...t DAC will be the last testing lead M labeled with highest serial number will be connected with positive pole of the last N cell and testing lead M 1 will be connected with positive pole of N 1 cell s...

Page 26: ...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 prevent it from over wearing This is pretty important to use the...

Page 27: ...Fig 3 3 NOTE Above figure is only for reference Specification and version information will differ based on different configuration The following main menu will show after initialization of about 10 s...

Page 28: ...ent K 3980 models you have different options Cell type 1 2V 2V 6V or 12V Cell No Indicates tested cells quantity If there is no connection with DAC set is as 0 DIS I indicates working current Tot end...

Page 29: ...displayed in K 3980 LCD screen and PC software will be reversed In another word voltage value of first cell will become value of the last cell second will become second last and so forth They are Tot...

Page 30: ...Press any key to exit go back to data management menu download the previous records to a USB drive and delete the data to continue discharging process After entering discharge screen it needs 1 minut...

Page 31: ...s arrow key to check voltage value of each cell as below These values will keep changing as discharge goes and will stop until one of the setting conditions meets its threshold Fig 4 1 1 5 Press arrow...

Page 32: ...tive DAC from its testing leads and plug the new DAC Select the backup DAC e g 03 already programmed in Kongter factory on screen and error case Then confirm the replacement All DACs have been program...

Page 33: ...DACs with each battery string in the sequence of String 1 DAC 1 2 String 2 DAC 1 2 and so forth Operation After the above wire connection please do the setting as per 4 4 3 Function Setting Then go to...

Page 34: ...1 2 2 Fig 4 1 2 3 NOTE During battery discharge current value of each string may vary more or less depending on actual capacity of each battery To test real battery capacity by battery discharge you a...

Page 35: ...conditions e g total end voltage reach their setting value Therefore please mind the time to avoid over discharging of the ignored cells 2 If there is no DAC it is no need to input ignore cell After...

Page 36: ...h a serial cable as below Fig 4 1 4 1 In parallel load test please confirm these things first A The two units have the same nominal voltage e g 220V 50A and 220V 100A max current in parallel connectio...

Page 37: ...This part will introduce other supplemental ways of discharge including assistant discharge test External discharge test and Charge Monitor under Other Tes Fig 4 2 4 2 1 Assistant Discharge Assistant...

Page 38: ...eeded In the above example it should be set as 25Amps Other parameter settings are the same as that of DIS test previously introduced in 4 1 1 Discharge Test Set all the parameters in the above three...

Page 39: ...witched to each other during discharging by press arrow keys 4 2 2 External test External discharge test means that the load bank does not discharge batteries Its main function is to display the value...

Page 40: ...hat of K 3980 discharging Cell cut off voltage normally it is 0 9 time of standard voltage Discharge capacity ending value of string discharge capacity Discharge time and First cell polarity After set...

Page 41: ...creens could be switched to each other during discharging by press arrow keys 4 2 3 Charge Monitor This is a supplemental function for monitoring data when using external charger for battery string Al...

Page 42: ...on time ends it will enter monitoring screen like Fig 4 2 3 3 Press arrow key to view voltages of each cell as below Fig 4 2 3 4 Then continue to page down to view the cells with highest voltages Fig...

Page 43: ...to the main menu and select Data Fig 4 3 4 3 1 Read Data Results After entering Data select View Data relevant data DIS data External data or Assist data and testing date one by one as below Fig 4 3...

Page 44: ...main unit 4 3 3 Delete Data Results In above Fig 4 3 2 press arrow key to select Delete as below Fig 4 3 3 1 Select the relevant date of testing data as below to delete Fig 4 3 2 4 3 4 Data Format Sel...

Page 45: ...ystem time parameter management and functions please select System in main menu like Fig 4 4 Fig 4 4 4 4 1 Time Setting Select Syst time under the menu System and press ENT like below Fig 4 4 1 Use fo...

Page 46: ...ib under the menu Param manage to go to the next step Fig 4 4 2 1 Press ENT to start calibration as below When calibration is done screen will automatically exit Fig 4 4 2 1 1 After zero calibration e...

Page 47: ...20V and 380V String type should be identical to the nominal voltage of the Load bank For example if your models is 48V 110V 300A Strg type here should be firstly selected as 48V Meanwhile voltage test...

Page 48: ...e charge monitor For current calibration you will need an adjustable current clamp as current standard 1 For built in current sensor Before calibration connect the load cable between battery and load...

Page 49: ...rnal current sensor Select Outside I calib for external current calibration This is for calibrating Optional Kongter current clamp To do this Kongter s current clamp should be connected with outside D...

Page 50: ...l be needed to distinguish one string from other Select String S N under Param manage and input your self defined number as below Fig 4 4 2 3 4 4 3 Function Setting These are customized settings for A...

Page 51: ...en one load bank hooks up with more than one battery strings e g two that are in parallel connection And all these strings come with DACs These DACs are grouped to fit different strings in the way of...

Page 52: ...e shooting If the load bank appears abnormal operation try the following solutions No signals on the screen after the load bank is on The power supply may not be connected properly If so correct t it...

Page 53: ...LYZING SOFTWARE 6 1 Operation Environment Browser Google Chrome IE10 browser Minimum configuration 2G memory processor dual core system win7 Recommended configuration 4G memory processor I3 and system...

Page 54: ...does not open automatically please open the browser manually and enter the address localhost 8082 or click the software icon named like Wireless Monitor System V1 0 1 on computer desktop Fig 6 3 You...

Page 55: ...could options for setting battery info and discharge monitor For battery info setting there is setting for battery make and battery specification Click them respectively you will the screen as below...

Page 56: ...delete as per your need Fig 6 4 2A Main screen Fig 6 4 2B Add edit and delete function Click the icon in site layer you could add battery string info That will make the data structure as 4 layers You...

Page 57: ...3A below to upload the measurement data which is downloaded from load bank Click File Upload in the next screen to upload the measurement from your computer and click on OK to save Fig 6 4 3A Fig 6 4...

Page 58: ...nerate a report you could select the time interval of data at the option of Time For example if you select 15 minutes the report will extract the data every 15 minutes Fig 6 4 4B View detailed measure...

Page 59: ...ould select the relevant string or create a new string that the monitored data will belong to For example you could click on existing String 1 on left column and then click Monitor on the right top to...

Page 60: ...ve on the monitoring screen You could click on the button Stop to stop the monitor if necessary 7 CONTACT KONGTER Kongter Test Measurement Co Limited ADD 405 Bldg 62 Songpingshan Langshan Rd Shenzhen...

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