The 63200E series are high power DC loads that include a choice of three operating voltages, 150V, 600V and 1,200V, with power levels from 2kW to 24kW and up to 2,000A in a single unit. Power levels can increase up to 240kW when multiple units are paralleled. These high power loads are designed for testing a wide range of EV products including DC charging stations, car battery discharge, on board charger power components, and other power electronics components. With its high power capabilities, parallel control and dynamic synchronization functions make this load ideal for automotive batteries, fuel cells and more.
The 63200E load's master/slave control application enables units with the same voltage specification to be used in parallel and synchronized dynamically to meet the power testing requirements. In addition, a 255-set data storage function has been built-in for recall of the stored settings at any time. When used in automated testing, the save and recall functions can save a great deal of time.
Each model of the 63200E ser ies has precision and real time voltage and current measurements. As short circuit testing is critical to power and automated testing, the 63200E includes short circuit simulation to effectively solve these application demands.
With the vacuum florescent display (VFD) and rotary knob, the 63200E series loads offer versatile front panel operation. For remote operation, users are able to control the 63200E via standard USB or optional Ethernet/LXI and GPIB interfaces.
The embedded PWM fan speed control reduces noise caused by fans. The 63200E series also has overcurrent, overpower, and over temperature protections as well as over voltage and polarity reverse alarms to improve product reliability. These DC loads are reliable, precision instruments ideal design validation testing and automated test system integration.
Application of Basic Loads
The 63200E series electronic loads operate in constant voltage, current, resistance, and power or impedance modes to satisfy a wide range of test requirements. For example, the CC and CR modes can ensure that the UUT voltage outputs remain stable when the load varies. For battery chargers or charging stations, CV mode can change the output voltage to ensure the charging current is precise. When the UUT is a battery, the electronic load changes to simulate device loading behavior. Many battery discharge applications and power consumption profiles can be simulated for analysis, making the CP mode the best choice for simulating electronic device loads.
New designs of electronic devices operate at very high speeds and demand rapid transient response characteristics. To address these applications, the 63200E Series offers high speed and programmable dynamic loading for testing. The figure shown below exhibits the programmable parameters such as current high/low level, T1/T2, rise/fall rate and execution times. As the load current continuously changes, the internal monitoring mechanism and line circuit can minimize the current waveform distortion with the dynamic change up to 5 kHz.
The dynamic mode provides a unique simulation capability allowing users to set the number of times each cycle repeats from 1~65535. This feature is suitable for peak current testing of fuses, on/off switches, coaxial cables, relays and batteries.
▲ Pulse Current
A motherboard can contain many capacitors. To avoid charging the motherboard capacitors when the server powers on with surge current triggering the power supply over current protection mechanism making the power supply fail to turn on successfully, the power supply requires conducting a turn on capacitive load test. The 63200E Series provides CZ mode for turn on capacitive load simulation to tackle this testing demand.
CZ mode is different from the CC and CP loading modes, as it simulates the actual inductance, impedance and capacitance for loading. Therefore, the load current is closer to the real situation. This is a voltage and current waveform simulation of the switching power supply in the turn on capacitive load test.
Programmable Load Timing
The 63200E series electronic load has 255 programmable timings built-in for various load condition simulations. Repeat loading can be done in a single sequence or all sequences. The minimum time of a sequence is 100ms and the resolution is 100ms. Following lists the applications for common programmed sequences.
- Battery discharge (electric car, and electric locomotive, etc.) simulating various dynamic load current waveforms, providing two levels above dynamic current simulation or one shot load simulation. (For single channel output UUT)
- Power supply mixed load modulation. (For multichannel output UUT)
- Load simulation for fuel cell life cycle testing.
User-Defined Hot Key Design
The 63200E provides 4 sets of user-defined hot keys that enable the user to enter the operation mode quickly. To change the hot key's definition, simply press it for 2 seconds.
Ultra High Power Density
The 63200E series have 36 models in total with 5 types of heights, 12 types of powers and 3 types of voltages. Its world leading ultrahigh power density design upends the concept of oversize and difficult moving high power electronic loads. It saves plenty of room and solves space issues when upgrading the electronic load in an automated test system.
3 Ranges and High Precision Measurement
60kW with slave units (41U Rack) ▶
The 63200E Series provides three operating current ranges and a built-in highly precision A/D converter, achieving 0.02%+0.02%F.S., 0.1%+0.1%F.S. and 0.1%+0.1%F.S. accuracy for voltage, current and power measurement respectively. Precise measurements like these are ideal for testing power efficiency and other critical parameters of the UUT.
Master/Slave Parallel Control
When increased power is required, two or more loads can be run in parallel to achieve the desired load current. The 63200E provides the user with smart Master/ Slave mode controls which enables the user to program the load currents of the Master and have them automatically calculated and downloaded to the slave loads. Using several loads in parallel to emulate a single load dramatically simplifies the operation. All models of the series can be integrated into a 19" width standard rack to save space. The 63200E can be controlled and reconfigured with automated testing applications via standard USB or optional Ethernet/LXI and GPIB interfaces.
Battery Discharge Testing
The 63200E has three discharge modes: CC, CR and CP. The electronic load can set cut off voltage and time (1~100,000 sec.) to stop loading correctly and make sure the battery is not damaged due to over discharge. In addition, it can measure the battery discharge power (WH, AH) and total discharge time. For example, when Load ON is pressed, the 63200E internal clock will start counting until the battery voltage is dropped to cut off voltage or Load OFF is pressed. The battery discharge test can also apply to super capacitor for discharge time testing.
DC Charging Stations and On Board Charger Testing
In the EV market, the DC charging station is an indispensable device. The 63200E series loads have models ranging from 2kW to 24kW and up to 2,000A operating voltage that are built to provide enough modes and functions for DC charging station functionality tests. Not only will these loads help R&D to perform functional tests and QA units to conduct verification tests, if integrated into an automated system, it will speed up production tests.
For on board charger testing, the 63200E can also be used to simulate the battery. When the on board charger starts charging the battery in current mode (CC), the 63200E can be set to voltage mode (CV) for loading. When the on board charger is performing floating charge on the batteries in voltage mode (CV), the 63200E has to change to current mode (CC) mode for loading.