Electronic dc load with energy recovery (98 pages)
Summary of Contents for Elektro-Automatik ELR 9000 HP
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Operating Manual ELR 9000 HP Electronic DC Load with Energy Recovery Attention! This document is only valid for devices with firmware “KE: 2.24” (standard version) resp. “KE: 2.08” (GPIB, 3W) and “HMI: 2.14” and “DR: 1.6.5” or higher. For availability of up-...
ELR 9000 HP Series TABLE OF CONTENTS GENERAL About this document ........5 2.3.6 Grounding of the DC input ......35 1.1.1 Retention and use ..........5 2.3.7 Connection of remote sensing ....35 1.1.2 Copyright ............5 2.3.8 Connecting the “Share” bus ......36 1.1.3 Validity ............5...
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ELR 9000 HP Series 3.10.2 General ............65 3.10.3 Method of operation ........66 3.10.4 Manual operation .........66 3.10.5 Sine wave function ........67 3.10.6 Triangular function ........68 3.10.7 Rectangular function ........68 3.10.8 Trapezoidal function ........69 3.10.9 DIN 40839 function ........69 3.10.10 Arbitrary function ..........70 3.10.11 Ramp function ..........74...
Limit of liability All statements and instructions in this manual are based on current norms and regulations, up-to-date technology and our long term knowledge and experience. EA Elektro-Automatik accepts no liability for losses due to: • Usage for purposes other than defined • Use by untrained personnel...
A piece of equipment which is intended for disposal must, according to European laws and regulations (ElektroG, WEEE) be returned to EA Elektro-Automatik for scrapping, unless the person operating the piece of equipment or another, delegated person is conducting the disposal. Our equipment falls under these regulations and is accord-...
ELR 9000 HP Series Safety 1.7.1 Safety notices Mortal danger - Hazardous voltage • Electrical equipment operation means that some parts will be under dangerous voltage. Therefore all parts under voltage must be covered! • All work on connections must be carried out under zero voltage (input not connected to voltage sources) and may only be performed by qualified and informed persons.
ELR 9000 HP Series 1.7.2 Responsibility of the user The equipment is in industrial operation. Therefore the operators are governed by the legal safety regulations. Alongside the warning and safety notices in this manual the relevant safety, accident prevention and environmental regulations must also be applied.
ELR 9000 HP Series 1.7.5 Alarm signals The device offers various possibilities for signalling alarm conditions, however, not for danger situations. The sig- nals may be optical (on the display as text) acoustic (piezo buzzer) or electronic (pin/status output of an analog interface).
ELR 9000 HP Series 1.8.3 Specific technical data Model HP 5 kW ELR 9080-170 ELR 9200-70 ELR 9360-40 ELR 9500-30 ELR 9750-20 AC supply Voltage 342...528 V Phases 2ph, PE Frequency 50/60 Hz ±10% Efficiency ≤ 92.5% ≤ 93.5% ≤ 93.5% ≤...
ELR 9000 HP Series Model HP 5 kW ELR 9080-170 ELR 9200-70 ELR 9360-40 ELR 9500-30 ELR 9750-20 Analog interface Set value inputs U, I, P, R Actual value output U, I Control signals DC input on/off, remote control on/off, R mode on/off...
ELR 9000 HP Series Model HP 10 kW ELR 9080-340 ELR 9200-140 ELR 9360-80 ELR 9500-60 ELR 9750-40 AC supply Voltage 342...528 V Phases 3ph, PE Frequency 50/60 Hz ±10% Efficiency ≤ 92.5% ≤ 93.5% ≤ 93.5% ≤ 94.5% ≤ 94.5% DC Input Max.
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ELR 9000 HP Series Model HP 10 kW ELR 9080-340 ELR 9200-140 ELR 9360-80 ELR 9500-60 ELR 9750-40 Analog interface Set value inputs U, I, P, R Actual value output U, I Control signals DC input on/off, remote control on/off, R mode on/off...
ELR 9000 HP Series Model HP 15 kW ELR 9080-510 ELR 9200-210 ELR 9360-120 ELR 9500-90 AC supply Voltage 342...528 V Phases 3ph, PE Frequency 50/60 Hz ±10% Efficiency ≤ 94.5% ≤ 93.5% ≤ 93.5% ≤ 94.5% DC Input Max. input voltage U...
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ELR 9000 HP Series Model HP 15 kW ELR 9080-510 ELR 9200-210 ELR 9360-120 ELR 9500-90 Analog interface Set value inputs U, I, P, R Actual value output U, I Control signals DC input on/off, remote control on/off, R mode on/off...
ELR 9000 HP Series Model HP 15 kW ELR 9750-60 ELR 91000-40 ELR 91500-30 AC supply Voltage 342...528 V Phases 3ph, PE Frequency 50/60 Hz ±10% Efficiency ≤ 94.5% ≤ 93.5% ≤ 94.5% DC Input Max. input voltage U 750 V...
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ELR 9000 HP Series Model HP 15 kW ELR 9750-60 ELR 91000-40 ELR 91500-30 Analog interface Set value inputs U, I, P, R Actual value output U, I Control signals DC input on/off, remote control on/off, R mode on/off Status signals...
ELR 9000 HP Series 1.8.5 Control elements Figure 6 - Control Panel Overview of the elements on the control panel For a detailed description see section „1.9.6. The control panel (HMI)“ and „1.9.6.2. Rotary knobs“. Touchscreen display Used for selection of set values, menus and settings, as well as display of actual values and status.
General description The electronic high performance loads of the ELR 9000 HP series are a progressive development of the ELR 9000 series with higher DC power ratings, new models and a wider AC input range which is now suitable for 380 V, 400 V and 480 V grid voltages.
IF-AB interface modules and the programming of the device using those interfaces can be found in separate documentation. It is available on the USB stick which comes with the device or as PDF download from the Elektro-Automatik website. 1.9.5 Options These options are usually ordered along with the device, as they are permanently built in or preconfigured during the manufacturing process.
ELR 9000 HP Series 1.9.6 The control panel (HMI) The HMI (Human Machine Interface) consists of a display with touchscreen, two rotary knobs, a button and an USB port. 1.9.6.1 Touchscreen display The graphic touchscreen display is divided into a number of areas. The complete display is touch sensitive and can be operated by finger or stylus to control the device.
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ELR 9000 HP Series • Status display (upper right) This area displays various status texts and symbols: Display Description Locked The HMI is locked Unlocked The HMI is unlocked Remote: The device is under remote control from..Analog ..the built-in analog interface USB &...
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ELR 9000 HP Series 1.9.6.4 Resolution of the displayed values In the display, set values can be adjusted in fixed increments. The number of decimal places depends on the device model. The values have 4 or 5 digits. Actual and set values always have the same number of digits.
The device can be addressed via this port either using the international standard ModBus RTU protocol or by SCPI language. The device recognises the message protocol used automatically. Details for remote control can be found on the web site of Elektro-Automatik or on the included medium.
2.1.2 Packaging It is recommended to keep the complete transport packaging for the lifetime of the device for relocation or return to Elektro-Automatik for repair. Otherwise the packaging should be disposed of in an environmentally friendly way. 2.1.3 Storage In case of long term storage of the device it is recommended to use the original packaging or similar. Storage must be in dry rooms, if possible in sealed packaging, to avoid corrosion, especially internal, through humidity.
Preparation Mains connection of an energy back-feeding electronic load of ELR 9000 HP series is done via the included 5 pole plug on the back of the device. Wiring of the plug is at least 3 strand or, for some models, 4 strand of suitable cross section and length.
ELR 9000 HP Series 2.3.4 Mains connection (AC) • Connection to an AC mains supply may only be carried out by qualified personnel! • Cable cross section must be suitable for the maximum input/output current of the device (see table below)! • Before plugging in the input plug ensure that the device is switched off by its mains switch!
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The scheme below depicts an often unconsidered problem: the current load of the local electric installation. The devices of series ELR 9000 HP recover energy and feed it back to the local or public grid. The recovered current then adds to the grid current and this can lead to an overload of the existing installation. Considering any two connection points, no matter of what kind, there is usually no extra fusing installed.
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ELR 9000 HP Series Schematic depiction with 1 recovering load: 16 A Grid up to 29 A 13 A Consumer 1 ELR 9000 HP Consumer 2 When running a higher number of recovering, i. e. energy backfeeding units on the same leg of the installation, the total currents per phase increases accordingly.
ELR 9000 HP Series 2.3.5 Connection to DC sources • In the case of a device with a high nominal current and hence a thick and heavy DC connec- tion cable it is necessary to take account of the weight of the cable and the strain imposed on the DC connection.
ELR 9000 HP Series Examples of the type 1 terminal: • 90 ° up or down • space saving in depth • no bending radius • horizontal lead • space saving in height • large bending radius 2.3.6 Grounding of the DC input Grounding one of the DC input poles is allowed.
Installation of an interface module The various interface modules, which are available for ELR 9000 HP standard version models with Interface slot, can be retrofitted by the user and are exchangeable with each other. The settings for the currently installed module vary and need to be checked and, if necessary, corrected on initial installation and after module exchange.
ELR 9000 HP Series 2.3.10 Connecting the analog interface The 15 pole connector (Type: Sub-D, D-Sub) on the rear side is an analog interface. To connect this to a control- ling hardware (PC, electronic circuit), a standard plug is necessary (not included in the scope of delivery). It is generally advisable to switch the device completely off before connecting or disconnecting this connector, but at least the DC input.
ELR 9000 HP Series Operation and application Personal safety • In order to guarantee safety when using the device, it is essential that only persons operate the device who are fully acquainted and trained in the required safety measures to be taken when working with dangerous electrical voltages • For models which accept dangerous voltages, the included DC terminal cover, or an equivalent,...
ELR 9000 HP Series 3.2.2 Current regulation / constant current / current limitation Current regulation is also known as current limitation or constant current mode (CC) and is fundamental to the normal operation of an electronic load. The DC input current is held at a predetermined level by varying the internal resistance according to Ohm’s law R = U / I such that, based on the input voltage, a constant current flows.
ELR 9000 HP Series Alarm conditions This section only gives an overview about device alarms. What to do in case your device indi- cates an alarm condition is described in section „3.6. Alarms and monitoring“. As a basic principle, all alarm conditions are signalled optically (text + message in the display), acoustically (if activated) and as a readable status and alarm counter via the digital interface.
ELR 9000 HP Series Manual operation 3.4.1 Powering the device The device should, as far as possible, always be switched on using the rotary switch on the front of the device. Alternatively this can take place using an external cutout (contactor, circuit breaker) of suitable current capacity.
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ELR 9000 HP Series EA Elektro-Automatik GmbH Fon: +49 2162 / 3785-0 www.elektroautomatik.de Page 42 Helmholtzstr. 31-37 • 41747 Viersen Fax: +49 2162 / 16230 ea1974@elektroautomatik.de Germany...
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ELR 9000 HP Series EA Elektro-Automatik GmbH Fon: +49 2162 / 3785-0 www.elektroautomatik.de Page 43 Helmholtzstr. 31-37 • 41747 Viersen Fax: +49 2162 / 16230 ea1974@elektroautomatik.de Germany...
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ELR 9000 HP Series EA Elektro-Automatik GmbH Fon: +49 2162 / 3785-0 www.elektroautomatik.de Page 44 Helmholtzstr. 31-37 • 41747 Viersen Fax: +49 2162 / 16230 ea1974@elektroautomatik.de Germany...
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ELR 9000 HP Series EA Elektro-Automatik GmbH Fon: +49 2162 / 3785-0 www.elektroautomatik.de Page 45 Helmholtzstr. 31-37 • 41747 Viersen Fax: +49 2162 / 16230 ea1974@elektroautomatik.de Germany...
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ELR 9000 HP Series 3.4.3.1 Menu “General Settings” Setting P. Description Allow remote control 1 Selection “NO” means that the device cannot be remotely controlled over either the digital or analog interfaces. If remote control is not allowed, the status will be shown as “Local”...
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ELR 9000 HP Series Setting P. Description Enable R mode 7 Activates (“Yes”) or deactivates (“No”) the internal resistance control. If activated, the resistance set value can be adjusted on the main screen as additional value. For details refer to „3.2.3. Resistance regulation / constant resistance“...
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ELR 9000 HP Series IF Level 1 Description Node Address Selection of the Profibus or node address of the device within range 1...125 via direct input Function Tag String input box for a user-definable text which describes the Profibus slave function tag.
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ELR 9000 HP Series IF Level 1 Level 2 Level 3 Description Function Tag String input box for a user-definable text which describes the Profinet slave function tag. Max. length: 32 characters Location Tag String input box for a user-definable text which describes the Profinet slave location tag.
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ELR 9000 HP Series Element Description Com Timeout Timeout USB/RS232 (in milliseconds) Default value: 5, Range: 5...65535 Defines the max. time between two subsequent bytes or blocks of a transferred message. For more information about the timeout refer to the external programming documentation “Programming ModBus &...
Changing the operating mode In general, the manual operation of an ELR 9000 HP distinguishes between three operating modes (U/I, P/I, R/I) which are tied to set value input using the rotary knobs or ten-key pad: This assignment must be changed if one of the four set values is to be adjusted which is currently not available.
ELR 9000 HP Series 3.4.6 Manual adjustment of set values The set values for voltage, current, power and resistance are the fundamental operating possibilities of an elec- tronic load and hence the two rotary knobs on the front of the device are always assigned to two of the four values in manual operation.
► How to remotely switch the DC input on or off via the digital interface See the external documentation “Programming Guide ModBus & SCPI” if you are using custom software, or refer to the external documentation of LabView VIs or other documentation provided by EA Elektro-Automatik. EA Elektro-Automatik GmbH Fon: +49 2162 / 3785-0 www.elektroautomatik.de...
ELR 9000 HP Series 3.4.10 Recording to USB stick (logging) Device data can be recorded to USB stick (2.0 / 3.0 may work, but not all vendors are supported) anytime. For specifications of the USB stick and the generated log files refer to section „1.9.6.5. USB port (front side)“.
Models with option 3W installed offer a GPIB port instead of the interface module slot, which makes it impossible to install and use any of these interface modules. The standard models of series ELR 9000 HP support, in addition to the built-in USB port, the following optionally available interface modules:...
General information about the interface modules With the standard models of series ELR 9000 HP, one of the plug-in and retrofittable modules listed in 3.5.3.1 can be installed. It can take over remote control of the device alternatively to the built-in USB type B on the back side or the analog interface.
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ELR 9000 HP Series 3.5.4.2 Resolution and sample rate The analog interface is internally sampled and processed by a digital microcontroller. This causes a limited resolu- tion of analog steps. The resolution is the same for set values (VSEL etc.) and actual values (VMON/CMON) and is 26214 when working with the 10 V range.
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ELR 9000 HP Series 3.5.4.5 Overview of the Sub-D Socket 3.5.4.6 Simplified diagram of the pins Digital Input (DI) Analog Input (AI) It requires to use a switch with low resist- High resistance input (impedance V~0.5 ance (relay, switch, circuit breaker etc.) in >40 k..100 kΩ) for an OA circuit.
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ELR 9000 HP Series • Remote control is not active In this mode of operation pin “REM-SB” can serve as lock, preventing the DC input from being switched on by any means. This results in following possible situations: Parameter Behaviour input „REM-SB“...
ELR 9000 HP Series Alarms and monitoring 3.6.1 Definition of terms There is a clear distinction between device alarms (see „3.3. Alarm conditions“), such as overvoltage protection, and user defined events such as OCD (overcurrent detection). Whilst device alarms primarily serve to protect the connected DC source by switching the DC input off, user defined events can do the same (action = ALARM), but can also simply give an acoustic signal to make the user aware.
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ELR 9000 HP Series Some device alarms are configurable: Alarm Meaning Description Range Indication OverVoltage Triggers an alarm if the DC input voltage reaches the Display, analog 0 V...1.1*U Protection defined threshold. The DC input will be switched off. IF, digital IF...
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ELR 9000 HP Series 3.6.2.1 User defined events The monitoring functions of the device can be configured for user defined events. By default, events are deactivated (action = NONE). Contrary to device alarms, the events only work while the DC input is switched on. It means, for instance, that you cannot detect undervoltage (UVD) anymore after switching the DC input off and the voltage is still sinking.
ELR 9000 HP Series Control panel (HMI) lock In order to avoid the accidental alteration of a value during manual operation, the rotary knobs or the touchscreen can be locked so that no alteration of values will be accepted without prior unlocking.
ELR 9000 HP Series Loading and saving a user profile The menu “Profiles” serves to select between a default profile and up to 5 user profiles. A profile is a collection of all settings and set values. Upon delivery, or after a reset, all 6 profiles have the same settings and all set values are 0.
ELR 9000 HP Series 3.10 The function generator 3.10.1 Introduction The built-in function generator is able to create various signal forms and apply these to the set value of voltage or current. The standard functions are based on an arbitrary generator and directly accessible and configurable using manual control.
ELR 9000 HP Series 3.10.3 Method of operation In order to understand how the function generator works and how the value settings interact, the following should be noted: The device operates always with the three set values U,I and P, also in function generator mode.
ELR 9000 HP Series ► How to load a function After setting the values for the required signal generation, tap on the touch area The device will then load the data into the internal controller and changes the display. Shortly afterwards the static values are set (power and voltage or current), the DC input is switched on and the touch area enabled.
ELR 9000 HP Series 3.10.6 Triangular function The following parameters can be configured for a triangular wave function: Value Range Description I(A), U(A) 0...(Nominal value - (Offs)) of U, I A = Amplitude of the signal to be generated I(Offs), U(Offs) 0...(Nominal value - (A)) of U, I Offs = Offset, based on the foot of the triangular wave 0.1 ms...36000 s...
ELR 9000 HP Series 3.10.8 Trapezoidal function The following parameters can be configured for a trapezoidal curve function: Value Range Description I(A), U(A) 0...(Nominal value - (Offs)) of U, I A = Amplitude of the signal to be generated I(Offs), U(Offs) 0...(Nominal value - (A)) of U, I Offs = Offset, based on the foot of the trapezium 0.1 ms...36000 s...
ELR 9000 HP Series 3.10.10 Arbitrary function The arbitrary (freely definable) function offers the user further scope. There are 99 sequence points available for use on current I or voltage U, all of which have the same parameters but which can be differently configured so that a complex function process can be built up.
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ELR 9000 HP Series Schematic diagram: Applications and results: Example 2 Focussing 1 cycle of 1 sequence point from 99: The DC values at start and end are the same but the AC (amplitude) not. The end value is higher than the start so that the amplitude increases with each new half sine wave continuously through the sequence.
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ELR 9000 HP Series By linking together a number of differently configured sequence points, complex progressions can be created. Smart configuration of the arbitrary generator can be used to match triangular, sine, rectangular or trapezoidal wave functions and thus, e.g. a curve of rectangular waves with differing amplitudes or duty cycles could be produced.
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ELR 9000 HP Series 3.10.10.1 Loading and saving the arbitrary function The 99 sequences of the arbitrary function, which can be manually configured with the control panel of the device and which are applicable either to voltage (U) or current (I), can be saved to or loaded from a common USB flash drive via the front side USB port.
ELR 9000 HP Series ► How to save a sequence point table to an USB flash drive: Do not plug the USB flash drive yet or remove it. Access the function selection menu of the function generator via MENU -> Function Generator -> Arbitrary...
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ELR 9000 HP Series Uploading of a table from an USB flash drive must use text files in CSV format (.csv). Plausibil- ity is checked on loading (values not too high, number of values correct),and possible errors reported in which case the table will not be loaded.
ELR 9000 HP Series 3.10.13 Battery test function The purpose of the battery test function is to discharge various battery types in industrial product tests or laboratory applications. It is only available via ac- cess on the HMI, at least as setup and use are described below, but can also be achieved in remote control using the arbitrary function generator.
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ELR 9000 HP Series 3.10.13.3 Other parameters These parameters are available in both battery test modes, but the values are separately adjustable in each. Parameter Range Description Discharge voltage 0...Nominal value of U Variable voltage threshold to make the test stop when reached (is...
ELR 9000 HP Series 3.10.13.6 Possible reasons for battery test stop The battery test function run can be stopped by different reasons: • Manual stop on the HMI with button STOP • After the max. test time has been reached and action “End of test” was set for it • After the max.
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ELR 9000 HP Series 3.10.14.2 Mode MPP2 This mode tracks the MPP, so it is closest to the operation of a solar inverter. Once the MPP is found, the function won’t stop, but try to track the MPP permanently. Due to the nature of solar panels this can only be done below the level of the MPP.
ELR 9000 HP Series 3.10.14.5 Load or save MPP4 data The 100 voltage values on the user-defined curve used to run in mode MPP4 can either be loaded from USB stick or via digital interface. Using the way to load via HMI requires following file format (for correct naming see 1.9.6.4): • Type CSV (text file)
This can be done using the standard models with display and control panel or the new slave models (ELR 9000 HP Slave, available from mid 2018). These models are intended to run as slave only and thus have no display and cheaper. Only disadvantage: the slave models are only available as 15 kW versions, so they only match the 15 kW standard models.
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Accept the settings with the touch area and return to the main page. ► Step 1: Configuring all slave units (ELR 9000 HP Slave series models without display) Connect the Slave series model via the rear USB port or via Ethernet interface to a PC.
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ELR 9000 HP Series ► Step 2: Configuring the master unit Enter then GENERAL SETTINGS and press until reaching Page 11. Specify the unit as master with tough area . A warning requester will appear which has to be acknowledged with OK, otherwise the change will be reverted.
ELR 9000 HP Series • Loss of connection to any slave will result in shutdown of all DC inputs, as a safety measure, and the master will report this situation in the display with a pop-up “Master-slave safety mode”. Then the MS system has to be re-initialised, either with or without re-establishing connection to the disconnected unit(s) before.
(see section „1.9.10. Share connector“) and a sink, in this case a series ELR 9000 HP electronic load. The source and the sink function alternately in order to test a device, such as a battery, by deliberate charging and discharging as part of a functional test, or a motor by clipping excess energy with the sink.
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ELR 9000 HP Series 3.11.3.3 Settings on the devices The master-slave settings in the MENU also affect the Share bus. For correct 2QO operation, all involved load units must be slaves on the Share bus. This is achieved by setting the master-slave mode to OFF or SLAVE, de- pending on if there is digital master-slave in use or not.
Contact the supplier in case of suspicion and elicit the steps to be taken. It will then usually be necessary to return the device to Elektro-Automatik (with or without warranty). If a return for checking or repair is to be carried out, ensure that: • the supplier has been contacted and it is clarified how and where the device should be sent.
4.3.1 Preface The devices of series ELR 9000 HP feature a function to re-adjust the most important DC input related values, which can help in case these have moved out of tolerance. The readjustment is intended to compensate small deviations of up to 1% or 2% rated value. There are several reasons which could make it necessary to re-adjust a unit: component aging, component deterioration, extreme ambient conditions, high frequent use.
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ELR 9000 HP Series 4.3.3.1 Calibrating the set values ► How to calibrate the input voltage Adjust the connected voltage source to approx. 102% of the maximum voltage specified for the ELR device. For the example with an 80 V ELR this would be 81.6 V for the source.
Contact and support Repairs Repairs, if not otherwise arranged between supplier and customer, will be carried out by EA Elektro-Automatik. For this the device must generally be returned to the manufacturer. No RMA number is needed. It is sufficient to pack- age the device adequately and send it, together with a detailed description of the fault and, if still under guarantee, a copy of the invoice, to the following address.
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ELR 9000 HP Series EA Elektro-Automatik GmbH Fon: +49 2162 / 3785-0 www.elektroautomatik.de Page 91 Helmholtzstr. 31-37 • 41747 Viersen Fax: +49 2162 / 16230 ea1974@elektroautomatik.de Germany...
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ELR 9000 HP Series EA Elektro-Automatik GmbH Fon: +49 2162 / 3785-0 www.elektroautomatik.de Page 92 Helmholtzstr. 31-37 • 41747 Viersen Fax: +49 2162 / 16230 ea1974@elektroautomatik.de Germany...
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EA Elektro-Automatik GmbH & Co. KG Development - Production - Sales Helmholtzstraße 31-37 41747 Viersen Germany Fon: +49 2162 / 37 85-0 Mail: ea1974@elektroautomatik.de Web: www.elektroautomatik.de...
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