BT510 Battery Analyzer Users Manual May 2014 © 2014 Fluke Corporation. All rights reserved. Specifications are subject to change without notice. All product names are trademarks of their respective companies.
LIMITED WARRANTY AND LIMITATION OF LIABILITY Each Fluke product is warranted to be free from defects in material and workmanship under normal use and service. The warranty period is three years and begins on the date of shipment. Parts, product repairs, and services are warranted for 90 days.
Table of Contents Chapter 1 Title Product Overview and Specifications ............................................... 1-1 Introduction ............................................................................................ Contact Fluke ........................................................................................ Product Overview .................................................................................. Standard Equipment ...........................................................
BT510 Users Manual Edit a Profile ...................................................................................... Edit a Profile During Creation ........................................................ Modify a Profile During Measurement ........................................... Load a Profile .................................................................................... Load a Profile When Switched to Sequence Mode ....................... Load a Profile During Measurement in Sequence Mode .
List of Tables Table 1-1. 1-2. 1-3. 1-4. 6-1. Title Page Standard Equipment.................................................................................. Symbols..................................................................................................... Keys .......................................................................................................... Typical Elements on the LCD Display ....................................................... Parts and Accessories................
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List of Figures Figure 1-1. 1-2. 2-1. 2-2. 3-1. 3-2. 3-3. 3-4. 3-5. 5-1. 6-1. 6-2. 6-3. 6-4. 6-5. Title Page Standard Equipment.................................................................................. I/O Terminals ............................................................................................. Tilt Stand. .................................................................................................. The Belt Strap ................................................................
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Chapter 1 Product Overview and Specifications Introduction This chapter supplies information about the Product, safety information, contact information, and specifications.
BT510 Users Manual 1-2 • Battery Voltage – During the internal resistance test, the Product also measures the voltage of the battery under test. • Discharge Volts – The Discharge mode collects the voltage of each battery several times at a certain interval during a discharge or load test. Users can calculate the time a battery takes to drop to the cut-off voltage and use this time to determine the capacity loss of this battery.
Product Overview and Specifications Standard Equipment 1 Standard Equipment Items listed in Table 1-1 are included with the Product. Figure 1-1 shows the items. Table 1-1. Standard Equipment Item No. Description Quantity Mainframe 1 BTL10, Basic Test Lead 1 TL175, TwistGuard™ Test Leads 1 BTL_A, Voltage/Current Probe Adapter 1 BP500, 7.
BT510 Users Manual 2 1 3 4 5 7 6 8 10 9 13 14 11 12 Figure 1-1. Standard Equipment 1-4 hpo056.
Product Overview and Specifications Safety Information 1 Safety Information A Warning identifies conditions and procedures that are dangerous to the user. A Caution identifies conditions and procedures that can cause damage to the Product or the equipment under test. Warning To prevent possible electrical shock, fire, or personal injury: • Carefully read all instructions. • Read all safety information before you use the Product.
BT510 Users Manual 1-6 • Use only correct measurement category (CAT), voltage, and amperage rated probes, test leads, and adapters for the measurement. • Measure a known voltage first to make sure that the Product operates correctly. • Limit operation to the specified measurement category, voltage, or amperage ratings. • Keep fingers behind the finger guards on the probes. • Remove all probes, test leads, and accessories before the battery door is opened.
Product Overview and Specifications Safety Information 1 See Table 1-2 for a list of symbols used in this manual and on the Product. Table 1-2. Symbols Symbol Description Symbol Description Risk of danger. Important information. See manual. AC (Alternating Current) Hazardous voltage. DC (Direct Current) Earth ground.
BT510 Users Manual Keys and I/O Terminals Table 1-3 identifies and describes the keys. Table 1-3. Keys 1 8 2 7 3 6 5 4 hpo001.eps 1-8 Item Key Function 12 34 L M Switches between Meter and Sequence measurement modes. For details, see Chapter 3. Switches between Meter and Sequence memories. For details, see Chapter 5. Turns on or turns off the Product. Softkeys that work flexibly for various functions on the display.
Product Overview and Specifications Keys and I/O Terminals 1 Figure 1-2 shows the terminals of the Product. Figure 1-2. I/O Terminals hpo002.
BT510 Users Manual LCD Display The Product has an LCD display that shows different elements for each measurement function. Table 1-4 describes the typical elements for battery internal resistance measurement in Sequence mode. Table 1-4. Typical Elements on the LCD Display 1 2 3 4 5 6 20 19 7 18 8 9 17 10 16 11 15 14 13 12 hpo055.eps Item Item Description Profile name Average readings Probe connection status.
Product Overview and Specifications Specifications 1 Specifications General Specifications Fuse Protection for Resistance ...................... 0.44 A (44/100 A, 440 mA), 1000 V FAST Fuse, Fluke specified part only Power Supply Battery power ...................................................... BP500 smart battery pack: double cell lithium-ion, 7.4 V, 3000 mAh Battery life ........................................................... >8 hours in continuous full-load operation Battery charging time .....
BT510 Users Manual Accuracy Specifications Accuracy is specified for a period of one year after calibration, at 18 °C to 28 °C (64 °F to 82 °F), with relative humidity to 80 %. Accuracy specifications are given as: ±([% of reading] + [number of least significant digits]). Accuracy specification assumes ambient temperature stable ±1 °C. Function Resolution Accuracy 3 mΩ 0.001 mΩ 1%+8 30 mΩ 0.01 mΩ 0.8 % + 6 300 mΩ 0.1 mΩ 0.8 % + 6 3000 mΩ 1 mΩ 0.8 % + 6 6V 0.001 V 60 V 0.01 V 600 V 0.
Product Overview and Specifications Specifications 1 Records Capacity Function Meter Mode Sequence Battery Internal Resistance Saved by test sequence with time stamp, up to 999 records Up to 450 records in one profile Battery Voltage Display and save with battery internal resistance, up to 999 records Display and save with battery internal resistance, up to 450 records in one profile Discharge Voltage Not available Support up to 8 rounds for up to 450 batteries in one profile V dc Up to 999 r
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Chapter 2 Setup Introduction This chapter describes how to set up the Product. Tilt Stand The Product has a tilt stand that lets you see the screen at an angle when placed on a flat surface. See Figure 2-1. Figure 2-1. Tilt Stand hpo007.
BT510 Users Manual Belt Strap Figure 2-2 shows how to use the belt strap of the Product. Figure 2-2. The Belt Strap 2-2 hpo031.
Setup Adjust Display Contrast 2 Adjust Display Contrast To adjust display contrast: 1. Push to open the Setup menu. Contrast is already highlighted. 2. Push the – softkey to lighten contrast, or push the + softkey to darken contrast. Note If – is pushed too far, the display is blank. 3. Push the Back softkey to return to normal operation.
BT510 Users Manual 4. Use and to highlight the field to be edited. Use and L to increase or decrease value. 5. When the correct date and time is set, push the OK softkey. 6. Push the Back softkey to return to normal operation. To change the date format: 1. Push to open the Setup menu. 2. Use L and to highlight General and push the Select softkey. Date/time is selected by default. 3. Push the Format softkey to open the Date format menu. 4. Use L and to highlight the correct date format. 5.
Setup Set Auto Power Off Time hpo049.jpg 2 hpo048.jpg Warning To prevent possible electrical shock, fire, or personal injury, do not use the HOLD function to measure unknown potentials. When HOLD is turned on, the display does not change when a different potential is measured. To set AutoHold and AutoSave mode: 1. Push to open the Setup menu. 2. Use L and to highlight Auto mode. 3. Push the Select softkey to open the Auto mode menu. 4. Use L and to highlight Disable, HOLD, or HOLD+SAVE. 5.
BT510 Users Manual View Device Information The Product provides the following device information: model number, serial number, version, analog board version, and calibration date. To view the device information: 1. Push to open the Setup menu. 2. Use L and to highlight General, and push the Select softkey. 3. Use L and to highlight Device info., and push View softkey. The Device info… screen shows. 4. Push the Back softkey to return to the Setup screen.
Chapter 3 Use the Product Introduction This chapter provides information about how to use the Product. The Product provides two modes for different measurement purposes: Meter mode and Sequence mode. Meter mode lets you perform easy and fast measurements and save the measurement readings and timestamp to the Product memory. In this mode, the Product measures battery internal resistance and voltage, dc voltage, ac voltage, and ripple voltage.
BT510 Users Manual hpo001.jpg hpo002.jpg To switch back to Meter mode: 1. Push M. 2. When the Back to METER mode? screen shows, push the Continue softkey. The measurement screen of Meter mode shows. Note All measurements taken in Sequence mode will be saved to the memory. hpo003.jpg 3-2 hpo005.
Use the Product Use a Profile in Sequence Mode 3 Use a Profile in Sequence Mode In Sequence mode, the Product lets you manage, categorize, and analyze data by profiles. The figure below shows a typical profile. hpo006.jpg Manage Profiles Each Product stores up to 100 profiles. A profile describes the battery maintenance environment in a tree view.
BT510 Users Manual Create a Profile The Product provides these options to create a profile: • Create by default: Uses system default data to create each profile. • Copy from template: Copies data from an existing template. • String+1: Copies data from the previous profile and increases 1 to the value of Battery string. Note The “Copy from template” option is available only after templates are downloaded the from PC software. To create a profile in Sequence mode: 1.
Use the Product Use a Profile in Sequence Mode 3 Edit a Profile In Sequence mode, profiles can be edited during creation or during measurement. Edit a Profile During Creation To edit a profile during creation: 1. On the New Profile menu, use and L to highlight a data field to be edited. 2. Edit the data value. a. For Device ID and Battery string, use the – and +.softkeys to change the value. b. For other data fields, push the Edit softkey and use the arrow keys to change the data value.
BT510 Users Manual Load a Profile When Switched to Sequence Mode To load a profile when switched to Sequence mode: 1. On the Enter SEQUENCE mode? screen, push the Load softkey. The Load profile screen shows the list of history profiles in the Product memory. 2. Use and L to highlight the number of the profile to be loaded. 3. Push the Load softkey. Configurations of the selected profile show on the display. 4. Push the Continue softkey to confirm loading the selected profile.
Use the Product Make Measurements 3 Make Measurements Test Battery Internal Resistance and Voltage The Product can simultaneously test the internal resistance and voltage of a battery. This helps you to understand the overall state of the battery health. To test battery internal resistance and voltage, turn the rotary switch to mΩ. See Figure 3-1. A B C Figure 3-1. Test Battery Internal Resistance and Voltage D hpo018.eps Battery Test Probes To connect test probes to the battery pole: 1.
BT510 Users Manual Small Hole Circle Cylinder Screw Cylinder Clamp Cube Strip hsz008.eps Figure 3-2. Connect Test Probe to Battery Pole View Test Readings on the Screen This is a typical display of battery test in Meter mode. hpo028.
Use the Product Make Measurements 3 This is a typical display of battery test in Sequence mode: hpo031.jpg Battery number: Indicates the number of the battery that has been tested. Progress bar: The progress bar is generated according to the total number of batteries in the profile. Each cell corresponds to one battery. An empty cell indicates the corresponding battery is not tested yet. A full cell indicates the corresponding battery has been tested and the readings have been saved.
BT510 Users Manual The pointed cell becomes empty. Push the Save softkey to save new test readings for this battery. Activate Low-Pass Filter for Resistance Measurement Excessive high level of ac ripple voltage can have a negative impact on the battery resistance measurement. Use the built-in low pass filter to stabilize or reduce the impact of ac ripple on resistance measurements. To activate the low-pass filter for battery resistance measurement, push the LO softkey. The display shows the LO icon.
Use the Product Make Measurements 3 Set Measurement Thresholds The Product lets you define upper and lower measurement thresholds or tolerance ranges. These defined threshold values are then compared to the measured values to automatically identify and prompt the user with a PASS, FAIL or WARN indicator of battery out of tolerance conditions. The threshold function is disabled by default. You can set up to 10 set of thresholds and select one threshold as needed.
BT510 Users Manual The threshold set is applied and the T-X (X stands for value of No.) icon and the corresponding PASS/WARN/FAIL indication shows on the display. To disable measurement thresholds: 1. On the measurement screen, push the Threshold softkey to open the Select Threshold menu. The value of No. is already highlighted. 2. Use to set No. to ---. 3. Push the Confirm softkey. The T-X icon no longer shows on the display.
Use the Product Make Measurements 3 Measure Discharge Voltage In a typical battery load discharge test, you need to test the voltage of each battery in a battery string multiple rounds. In a typical load discharge test, the voltage of each battery is monitored from the start of the test when the batteries are at full capacity, until the voltage of any one battery while under constant load reaches a pre-defined minimum voltage level. Make Measurements To test discharge voltage: 1.
BT510 Users Manual Note You cannot go back to the previous round when you have started a new one. Measure DC Voltage The Product can measure dc voltage. It also shows the polarity on the display. To measure dc voltage, turn the rotary switch to . See Figure 3-3 for connections. Save UPS Vdc Figure 3-3. Measure DC Voltage hpo019.eps Set Measurement Range In this measurement mode, auto range is used by default.
Use the Product Make Measurements 3 Measure AC Voltage The Product supplies two independent readings to show the rms and frequency of ac voltage. To measure ac voltage, turn the rotary switch to . See Figure 3-4 for connections. Vac Figure 3-4. Measure AC Voltage UPS hpo021.eps Measurement Range The ac voltage measurement has only one range: 600 V. The frequency measurement uses auto ranging. This cannot be changed.
BT510 Users Manual Measure Ripple Voltage The Product can measure the ac component on a dc voltage, which is also known as ac ripple. A high ac ripple may result in a battery overheat and negatively impact the battery life. In addition, it may cause extra energy loss to the system. To measure ripple voltage, turn the rotary switch to RIPPLE VOLTS. Set Measurement Range In ripple voltage function, both ac voltage and dc voltage use auto range by default.
Use the Product Make Measurements 3 Measure Voltage with TL175 With the TL175 test lead, the Product can measure Discharge Volts, VDC, VAC, and Ripple Volts. To measure voltage: 1. Connect TL175 to the BTL_A adapter. 2. Connect the BTL_A adapter to the Product. 3. Turn the rotary switch to the necessary position. For details about the measurements, refer to the “Measure Discharge Volts”, “Measure DC Voltage”, “Measure AC Voltage” and “Measure Ripple Voltage” sections.
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Chapter 4 View Memory Introduction This chapter provides information about how to view measurement data that is manually or automatically saved to the Product memory. The Product has an internal memory that stores measurement data that can be viewed. Measurement data in Meter mode and Sequence mode shows separately. The total memory usage can be viewed in the Setup menu. View Data Saved in Meter Mode To view measurement data that is saved in Meter mode: 1. Turn the rotary switch to VIEW memory. 2.
BT510 Users Manual When the display shows Confirm to delete the reading?, push the Delete softkey. b. To delete all data in the measurement set, push the Delete all softkey. When the display shows Confirm to delete all readings?, push the Delete softkey. hpo064.jpg View Profiles Saved in Sequence Mode To view measurement data that is saved in Sequence mode: 1. Turn the rotary switch to VIEW memory. 2. Push M until MEMORY – SEQUENCE shows on the upper left corner of the display.
View Memory Delete Profiles Saved in Sequence Mode 4 Delete Profiles Saved in Sequence Mode To delete data saved in Sequence mode: 1. Turn the rotary switch to VIEW memory. 2. Push M until MEMORY – SEQUENCE shows on the upper left corner of the display. 3. When the View profile menu shows on the display, use and L to highlight a profile, and push the More softkey. a. To delete only the highlighted profile, push the Delete softkey.
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Chapter 5 Connection to PC Introduction This chapter contains information about how to connect the Product to a PC. Connect the Product to PC The Product has a USB port that lets you connect the Product to a PC via a USB cable. See Figure 5-1. Figure 5-1. Connection to PC hpo030.
BT510 Users Manual When connected to a PC, the PC Application can: • View data from Product memory • Export data from Product memory • Import data to Product memory • Delete data from the Product memory • Upgrade the Product firmware Note Please refer to PC Application help file for how to use the application.
Chapter 6 Maintenance Introduction This chapter covers basic maintenance procedures. Warning For safe operation and maintenance of the Product: • Use only specified replacement parts. • Use only specified replacement fuses. • Have an approved technician repair the Product. • The battery door must be closed and locked before you operate the Product. • Batteries contain hazardous chemicals that can cause burns or explode. If exposure to chemicals occurs, clean with water and get medical aid.
BT510 Users Manual 6-2 • Remove the batteries if the Product is not used for an extended period of time, or if stored in temperatures that exceed the specification of the battery manufacturer. If the batteries are not removed, battery leakage can damage the Product. • Connect the battery charger to the mains power outlet before the Product. • Use only Fluke approved power adapters to charge the battery. • Keep cells and battery packs clean and dry. Clean dirty connectors with a dry, clean cloth.
Maintenance Install or Replace the Battery Pack 6 Install or Replace the Battery Pack Warning Never operate the Product with the Battery Cover removed. Hazardous voltage exposure may occur. To install or replace a Battery Pack: 1. Make sure the Product is off. 2. Remove all probes and/or test leads. 3. Unlock the battery cover at the rear of the Product. Turn the screw a half turn. 4. Install the battery pack. 5. Put the battery cover back on the unit. 6. Tighten the screw.
BT510 Users Manual Replace the Fuse Warning To prevent possible electrical shock, fire, or personal injury: • Use only specified replacement fuses. • Replace a blown fuse with exact replacement only for continued protection against arc flash. To replace the fuse: 1. Make sure the Product is off and any test leads are disconnected. 2. Use a screwdriver to loosen the captive screw on the fuse cover at the upper end of the Product. 3. Install the new fuse. 4. Reinstall the fuse cover. 5.
Maintenance Replace the Probe Tips 6 Replace the Probe Tips Figure 6-3 shows how to replace the probe tips. Warning To prevent possible electrical shock, fire, or personal injury, use correct tip covers (CAT II or CAT III) in different CAT environments. Figure 6-3. Replace the Probe Tips hpo026.
BT510 Users Manual Zero Calibration This chapter describes how to do zero calibration. A zero calibration is required each time after a test probe is replaced. To do zero calibration: 1. Locate the zero calibration board on a flat surface horizontally. See Figure 6-4. 2. Set zero calibration in the Setup menu. a. Push . b. Push L until General is highlighted. c. Push the Select softkey. d. Push L until Zero calibration is highlighted. e. Push the Zero softkey. 3.
Maintenance Clean the Product 6 Clean the Product Warning For safe operation and maintenance of the Product, disconnect the Product and its accessories from all voltage sources during cleaning. Clean the Product with a damp cloth and a mild soap. Do not use abrasives, solvents, or alcohol. These may damage the Product markings and labels. Charge the Battery At delivery, the Lithium ion batteries may be empty and must be charged for 4 hours (with the test tool turned off) to reach full charge.
BT510 Users Manual Figure 6-5. Charge the Battery 6-8 hpo032.
Maintenance Parts and Accessories 6 Parts and Accessories Table 6-1 lists the user-replaceable parts and accessories. To order replacement parts or additional accessories, contact your nearest Fluke Service Center. See the “Contact Fluke” section. Table 6-1. Parts and Accessories Item No. Description Fluke Part Number Quantity BTL10, Basic Test Lead -- 1 TL175, TwistGuard™ Test Leads -- 1 BTL_A, Voltage/Current Probe Adapter -- 1 BP500, 7.
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