Chroma 62000D programmable bidirectional DC power supplies provide both power source and load characteristics. These two quadrant power supplies allow power from the DUT to be converted back to the utility grid and so are ideal for testing renewable energy power systems such as PV, storage, and EV inverters as well as a wide range of bidirectional power conditioning system (PCS) and may also be used as a battery simulator. 62000D has applications in testing power components in electric vehicles as well as bidirectional on-board chargers (BOBC), bidirectional DC converters, and DC-AC motor drivers and can perform power conversion tests of Li-ion batteries in both charge and discharge directions.
To illustrate the 62000D unique capabilities, traditional DC power supplies need protection diodes to back EMF during motor testing does not damage the source. However, the 62000D bidirectional DC power supplies can drive the motor and also efficiently regenerate EMF to the grid, thereby avoiding the need for blocking diodes while saving space, energy, and configuration. In addition, the fast cross-quadrant bandwidth of the 62000D provides a transient response time of less than 1.5ms (-90% to +90%).
62000D bidirectional DC supplies include 9 different models with industry-leading power density at 18kW in 3U of vertical rack space. Model range from 6kW to 18kW, output current ratings up to ±540A, and voltage ratings up to 1800VDC. The master/slave feature allows for up to 10 models to be paralleled easily and safely up to 180kW.
62000D series is equipped with 100 programmable user settings through the unit's List Mode. The fast response time fills many testing needs, including the LV123 and LV148 standards required for new energy vehicle components. When combined with the Chroma Softpanel, the user can conduct the complex tests with simple clicks of the mouse.
62000D family of power supplies can easily be used in any region of the world due to its wide input range of 200-480 Vac and an active PFC low-current harmonic feed to grid, reducing power consumption, power system configuration, and ambient temperature changes under high-power testing. Control options include digital USB, LAN, CANbus, GPIB as well as analog APG interfaces.
Power Conversion Testing of Electric Vehicles and Microgrid Storage
Renewable energy sources such as PV, EV, fuel cell, and battery are the market trend as the replacement of traditional energy sources (coal, oil, etc.). Yet, the subsequent rising need for electricity will actuate the faster commercialization of distributed energy storage in microgrids. The bidirectional design of power conversion devices urges battery applications to achieve high efficiency, high voltage conversion, and high power density direction, which prompts the need for battery simulation (bidirectional power supply) testing designs.
Two-In-One: Bidirectional DC Power Supply and Load
Chroma's 62000D has a bidirectional switch-mode power supply design that offers two-quadrant operation with positive current/positive voltage as well as negative current/positive voltage, enabling both DC power supply output and regenerative DC load. The absorbed energy feeds back to the grid with a conversion efficiency up to 93% and can operate in constant voltage, constant current, and constant power modes. Compared to traditional power supply and load, the 62000D two-in-one bidirectional DC power supply saves space, reduces energy loss and heat dissipation, and is easier to wire and configure.
With the current evolution of electric cars, their on-board chargers are controlled through back and forth energy supply to V2G (Vehicle to Grid), V2L (Vehicle to Load), and V2H (Vehicle to Home). The regenerative load modes of the 62000D models include constant current (CC), constant voltage (CV), and constant power (CP) and simulate battery charging activity during developing and testing of the car. Where conventional methods needed one apparatus for DC power supply and another for regenerative DC load, one single Chroma 62000D can now fulfill both charging and discharging tests on its own.
▲Bidirectional on-board charger testing configuration
High Voltage 1800V PCS Testing
A power conditioning system (PCS) serves to realize bidirectional power conversion between the battery system and the grid with the terminal battery voltage of the newest devices reaching up to 1500V and having a charge/discharge function, active power control, reactive power regulation, and off-grid switch. A common issue for users is how to prepare an actual high voltage battery for testing the charge/discharge transition (with a standard <100ms) performance of this PCS and it is impossible to use R&D verification and manufacture with fast reproducibility, controllability, and safety. The high voltage 62180D-1800 (1800V/40A/18kW) model can be connected in parallel to reach 180kW/1800V/400A, so replacing the real battery simulation as power supply or regenerative power load to carry out this charge/discharge transition with a seamless switch.
High Transient Response < 1.5ms
Chroma 62000D allows seamless current conversion between the two quadrants of supply and electrical load without changing the output characteristics or causing damage. To use this in many bidirectional DC-DC and DC-AC battery charge/discharge tests requires very fast charge/discharge conversion. To increase this transient responsiveness, the 62000D bidirectional DC power supply has a high speed transient response time of less than 1.5ms (-90% to +90%) and gives stable voltage output.
▲ Simulation of actual driving conditions
To test the acceleration and braking of the motor driver under driving conditions, the conversion between the battery and power components will encounter supply and recharge of electrical energy. The very fast transient response of the 62000D two quadrants can simulate the battery and convert according to the actual needs of the motor, offering stable voltage and allowing current recharge during braking.
▲ Start-stop system motor driver test application
Battery Simulation Function
62000D are bidirectional DC power supplies that can be charged or discharged by an external power source. Therefore, with the operation of software, the 62000D become battery simulators that can simulate operation at different capacity (SOC) or import specific battery characteristics V-I curves. It can evaluate the product under different battery capacities or with different battery characteristics. 62000D is suitable for testing various products such as BOBC, PCS, ESS or motor drivers.
Testing Standards LV123 and LV148
Along with the global energy efficiency and carbon emission reduction trends, the car industry have established technical development standards for new energy vehicles, which define tests for a variety of electric vehicles. The LV123 guidelines specify the vehicle’s electrical characteristics and safety of high-voltage components, whereas the LV148 standard covers tests for electric and electronic components in 48V electrical system motor vehicles. Chroma 62000D has a high-speed CV dynamic response slope that can be controlled up to 180V/ms, which is applicable to the electrical characteristics tests of many vehicle guidelines. When combined with the Chroma Softpanel, the user can even conduct the tests at the push of a button.
Safety and AC Fault Protection
Chroma 62000D bidirectional DC power supplies have energy recycling function that returns energy to the grid. The internal protection design serves to identify input voltage and frequency anomalies. When detecting any anomalies, the 62000D will automatically turn off the output to ensure safe use of the grid. The 62000D is set up with OVP, OCP, OPP, OTP, Fan Fail, and AC Fault protection circuits. AC Fault protection includes OVP, UVP, Unbalance, Freq. Error, and OCP.
Four Auto-Operating Ranges
Chroma's 62000D bidirectional DC power supplies include four auto-operating ranges. The 62180D-600 has an 18kW/600V/120A output and operates flexibly in various combinations as the figure below shows. Compared with the three output ranges of competitors, the 62000D can give much greater current at low voltage. This offers an even wider coverage of low voltage/high current and high voltage/low current DUTs that other DC power supplies can test. When used into a standard ATE system or on a laboratory table, one 62000D can replace multiple DC power supplies to significantly save space and costs.
When testing high power 10kW~180kW conversion components (e.g. PCS, ESS, Charger, Inverter), users need to consider small volume, light weight, utilization rate, flexible assembly and disassembly for operation of various power systems, and influence of R&D during system failure and maintenance. The 62000D Series has a smart master/slave control mode that can connect 2 to 10 devices, enabling fast and simple series/parallel operation for use by R&D, QC, and at the production line. In this mode, the master scales values and downloads data to slave units so programming is as simple as using a single unit, and the digital current sharing is highly stable and without noise interference.
Master/slave parallel operation up to 180kW (*Call for availability) ▶
Universal AC Power Range 200~480VAC
Chroma 62000D bidirectional DC power supply is equipped with an active PFC >0.97 for low energy consumption and high conversion efficiency. Moreover, to fit the universal AC power input range, the 62000D series has a very wide input power range of three-phase 200Vac to 220Vac and 380Vac to 480Vac inputs. The user can buy one single device without having to configure it for use in other areas.
Chroma 62000D supports various remote interfaces, enabling the user to control the PC through the standard USB and LAN or optional GPIB interfaces. Moreover, the optional CAN interface as frequently used in the automobile industry is compliant with the CAN2.0 A 11-bit and CAN2.0 B 29-bit identifiers and has a V/I/P cycle time of up to 10ms.
User-Friendly Intuitive Control Interface
Chroma 62000D has a next generation human-machine control interface with an intuitive and user-friendly touch screen. Operation of the apparatus is as easy as using a smartphone, with its intelligent and convenient user interface; through icons on the touch screen, the user can complete any voltage/current settings and measurements, program sequence control settings, preview output waveforms, etc.