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heinzinger ERS-BIC User Manual

Bidirectional power supply system
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Betriebsanleitung
User Manual
Bidirectional Power Supply System
Heinzinger
www.heinzinger.com
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ERS-BIC

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Summary of Contents for heinzinger ERS-BIC

  • Page 1 Betriebsanleitung User Manual Bidirectional Power Supply System ® Heinzinger ERS-BIC www.heinzinger.com...
  • Page 2 <Ausgangsspannung / Ausgangsstrom / Ausgangsleistung> <output voltage / output current / output power> Options M = Modifikation M = Modification Partnumber <Heinzinger Artikelnummer> <Heinzinger article number> Serialnumber <Geräteseriennummer> <S/N of device> Heinzinger electronic GmbH High Voltage - Smart Solutions Anton-Jakob-Straße 4 83026 Rosenheim –...

  • Page 3: Table Of Contents

    Manual ERS-BIC 160 kW V2.1 Contents Basic Information ............................ 5 Scope of Delivery ........................5 Disclaimer ............................ 5 Copyright ......................... 5 Liability, Warranty ....................5 Owner’s Responsibilities ................... 5 About this Manual ........................5 Manual as Part of the Device ................5 Symbols in the Manual ..................
  • Page 4 Power Hyperbola ERS-BIC 1200-1200/160 2C ........... 18 Safety Concept......................... 19 Signal Lights (optional) ..................19 Insulation Monitoring (optional) ..............20 Channelstop/Performance Level C(optional) ......... 20 Channelstop/Performance Level D(optional) ......... 20 Quick Discharge(optional) ................20 Set up and Start up ..........................21 General/Scope of Delivery ....................
  • Page 5 Manual ERS-BIC 160 kW V2.1 Switching the Unit On and Off ..................45 Operation and Display Elements ..................47 Device Operating Menus ..................... 48 Main Menu ......................48 Setup-Menu ......................50 System-Info ......................51 System-Info/Status ................... 52 System-Info/Measurements ................53 FPGA-Diagnosis ....................
  • Page 6 Special Safety Instructions for Troubleshooting ............. 70 Integrated Fuses, Phase Monitoring (optional) ............70 Temperature Monitoring ..................... 70 Flow Rate Monitoring of Cooling Water ..................70 Monitoring Coolant Temperature ..................71 Warnings ............................. 71 Error Messages ........................73 Troubleshooting Cluster Operation ................78 Care, Maintenance, Calibration ......................

  • Page 7: Basic Information

    Liability, Warranty Heinzinger electronic GmbH shall not be held liable for damages resulting from improper use of the products or from failure to observe the operating instructions as a whole or in part.

  • Page 8: Symbols In The Manual

    The operating guide must be passed on to the next owner or user of the product. This is a standard manual for the Heinzinger ERS-BIC series. Your device may not be equipped with all listed options. The technical specifications of your device may vary.

  • Page 9: Basic Safety Instructions

    Manual ERS-BIC 160 kW V2.1 2. BASIC SAFETY INSTRUCTIONS DANGER Risk of electrocution! During operation certain parts of the device and the connected load are inevitably at dangerous voltages. Cover all live parts! Always obey the five safety rules when connecting or disconnecting test equipment: Disconnect from mains ▬...

  • Page 10: Safety Symbols On The Device

    2.3 Safety Symbols on the Device Safety Symbols on the Device On the device there are safety symbols where applicable. They have to be observed. RISK OF ELECTRIC SHOCK There is a risk of shock from contacting electrically live parts in this labelled area. ATTENTION Please refer to the operating guide.

  • Page 11: Technical Specification

    Manual ERS-BIC 160 kW V2.1 3. TECHNICAL SPECIFICATION Table 1 Dimension / Weight Model series ERS BIC 1200-1200/160 2C 2400 Width /mm 1960 Height /mm Depth /mm 1500 Weight /kg Table 2 Mains Connection Mains Voltage 3x400 V Δ ±10% 47…63 Hz 3P/N/PE...
  • Page 12 3.5 Table 5 Interface Table 5 Interface Digital interface Control of voltage, current and power [CAN-Bus] Monitoring of voltage, current power and device state General control of device Digital I/O Potential free contacts / user specific Table 6 Voltage Precision Setting range 0…...
  • Page 13 Manual ERS-BIC 160 kW V2.1 Table 8 Cooling Coolant Water Material heat sinks Aluminum Supply temperature 18°C … 24°C Operating pressure 2.5 … 5 bar Pressure loss ca. 1.5 bar (higher at glycol content >10%) Required flow rate 28 l/min...

  • Page 14: Design And Function

    4.1 Device Views 4. DESIGN AND FUNCTION Device Views Exterior view: Fig. 1 Exterior view ERS BIC...
  • Page 15 Manual ERS-BIC 160 kW V2.1 Inside view: Fig. 2 Interior view ERS BIC...

  • Page 16: Block Diagram

    Fig. 3 Block diagram ERS-BIC (Output voltage and current may vary) Functional Description The test bench energy systems of the Heinzinger ERS-series are optimized for bidirectional Operation. They can either operate as power supplies or sinks that can feed energy back into the grid. This means that from a technical perspective the output and input of the unit can change.

  • Page 17: Single Channel Operation

    Manual ERS-BIC 160 kW V2.1 Single Channel Operation In single channel operation, two independent channels are available. The channels are electrically separated from each other. DC-Channel 1 DC-Channel 2 Connect sense for Channel 2 Connect sense for Channel 1 DUT 2 Fig.

  • Page 18: Parallel Operation

    4.3 Functional Description Parallel Operation By operating the device in parallel mode the output current of the ERS can be doubled. For this the isolation active front end multi parallel converter transformer 1 channel 600 V ±1200 A control communication measurement system Fig.

  • Page 19: Serial Operation

    Manual ERS-BIC 160 kW V2.1 Serial Operation By operating the device in serial mode the output voltage of the ERS can be doubled. For this the two output units of the ERS are connected in series using a copper bar and in the menu “Unit Param- eters”...

  • Page 20: Output Characteristics Of Ers-Systems

    900,00 600,00 300,00 0,00 -300,00 200 300 400 500 600 700 800 900 1000 1100 1200 -600,00 -900,00 -1200,00 -1500,00 -1800,00 -2100,00 -2400,00 VOLTAGE IN V parallel serial Fig. 10 Power hyperbola of two ERS-BIC 1200-1200/160 2C in cluster operation...

  • Page 21: Safety Concept

    Safety Concept ⚠ To ensure safe operation of the ERS and the adjacent test bench the following has to be observed: Devices of the Heinzinger ERS series may only be commissioned and used by trained technical per- sonnel. For safety reasons, the ERS system must be connected to the safety circuit of the test environment / test bench.

  • Page 22: Insulation Monitoring (Optional)

    4.5 Safety Concept Insulation Monitoring (optional) An insulation monitoring device continuously monitors the total insulation resistance of the DC-circuit of an output channel against ground (PE) and issues a warning message or an error message if one of the set response values is undershot. By default this values are set to: R〈an〉...

  • Page 23: Set Up And Start Up

    Manual ERS-BIC 160 kW V2.1 5. SET UP AND START UP CAUTION Risk of crushing from heavy loads! Wear safety shoes when transporting and installing the device! General/Scope of Delivery Due to its size, the device is transported in several segments. It consists of three / four individual modules that are connected to each other at the installation site.

  • Page 24: Ventilation

    In systems with I >1200 A, a minimum of 0.5 m of distance must be kept clear. An access from behind or the right hand side is an advantage but not absolutely necessary. Fig. 12 Clearances and positions of terminals for ERS-BIC 160kW...

  • Page 25: Cooling System

    Manual ERS-BIC 160 kW V2.1 Cooling System ERS devices are water-cooled and therefore remain significantly cooler in operation than air-cooled devices. This generally has positive effects on the service life of the capacitors and output stages. Also, the noise level is significantly lower than in an air-cooled system.

  • Page 26: Electromagnetic Compatibility

    5.4 Electromagnetic Compatibility Even in the long-term test at 80°C there is no significant loss of mass due to corrosion. Please note that the amount of antifreeze has a significant influence on the cooling effect and the flow behavior of the cooling medium. In the case of mixing ratios with an anti-freeze content greater than 1:10, a higher pump output is required in order to achieve the same flow through the ERS systems.

  • Page 27: Assembly Instruction

    Commissioning: Digital Multimeter (1000V DC) HV power supply unit minimum voltage 3000V e.g..: Heinzinger/LNC 3000/10 Power supply unit for external power supply 600V/4A e.g.: Heinzinger/GEN 600-4 Insulation tester, for example: Grossen Metrawatt Secutest 8 pieces crocodile clips (long) 5 pieces measuring cable 0.5 m Service plug (Heinzinger) 2 x Sense cable (connection cable 2 pol.
  • Page 28 HTS-Cabinet Mains/AFE-Cabinet Fig 13 Assembly order for ERS-BIC 160 kW To assemble the system, the front and side walls of the control cabinets must be removed; they can be lifted off after the locking screws have been unlocked by vertical positions. The grounding lines connected to the sheets must then be disconnected ⚠...

  • Page 29: Installation Of The Cooling System

    Manual ERS-BIC 160 kW V2.1 The gap between the joints, the cabinets must be sealed so that no water or dirt can penetrate into the system from above or from the side. When the back of the cabinets is no longer accessible after installation, a foam tape must be glued into the profile groove on both sides before assembly.
  • Page 30 5.5 Assembly Instruction ERS-BIC 250 T O O L I N G C H E M A T I C Mains/AFE Fig. 16 Schematic for cooling circuit ERS BIC 160 kW O O L I N G A T E R...

  • Page 31: Filling And Venting The Cooling Circuit

    Manual ERS-BIC 160 kW V2.1 sensor is installed in the cooling water Choke with cap flow, which monitors the cooling water temperature for compliance with the permissible range of 19-24°C. In the cooling water circuits 1-4 throttles are Solenoid installed for flow balancing and for Valve venting the system.

  • Page 32: Electrical Assembly Of The Ers

    5.6 Electrical Assembly of the ERS Electrical Assembly of the ERS After the ERS system has been set up and mechanically connected, the electrical connections be- tween the cabinet segments and the network or the automation system must be made. N T E R N A L L Y DC-Intermediate circuits 24V-supply and control lines...
  • Page 33 Manual ERS-BIC 160 kW V2.1 DC-L I N K The lines for connecting the DC intermediate circuit from the AFEs to the HTS cabinet must be laid on the left side of the AFE cabinet. Remove the acrylic cover Anschluss Sicherungshalter...

  • Page 34: Connecting 24V Supply, Control Lines

    5.6 Electrical Assembly of the ERS Connecting 24V Supply, Control Lines The connections for the 24V supply and the signal lines must be made between the Mains/AFE and HTS cabinets 24 V Supply, Control lines Fig. 23 Connections supply and control lines For this purpose, sockets are installed in the upper side of the AFE-cabinet, which must be connected to the plugs coming from the other cabinets.

  • Page 35: Internal Can-Bus

    Manual ERS-BIC 160 kW V2.1 Internal CAN-Bus The internal communication between the operator panel and the control boards takes place via a CAN-BUS connection. When setting up the ERS system, the connection HTS cabinet and Mains/AFE cabinet must be established. To do this, plug the plug and socket of each of the two CAN connections together and secure them against loosening.

  • Page 36: Start-Up

    Special Safety Instructions for Initial Commissioning N O T I C E Initial commissioning must be carried out by a Heinzinger technician or by an authorized company! Start-up After Storage If the device has been stored for more than a year prior to commissioning, a special switch-on proce- dure must be carried out in order to reform the intermediate circuit capacitors and to protect them from damage.

  • Page 37: Connection Of External Control

    Manual ERS-BIC 160 kW V2.1 N/PE 3P~ 400 V/50 Hz Fig. 29 Mains connection Before connecting, remove the covers on the terminals. T hen run the connecting cable through the cut-out in the base plate and mount it with the appropriate eyelets (M10) on the connecting lugs of the terminals.

  • Page 38: Load- And Sense-Connection

    5.7 Start-up BUS-C O N N E C T I O N Depending on the available interface option of the device, the CAN bus of the device is either con- nected directly, via a nine-pin Sub-D connector (-A28), or alternatively via a protocol converter (-A29) for the connection to the automation systems of the test bench.
  • Page 39 Manual ERS-BIC 160 kW V2.1 O N N E C T I O N E N S E In addition to the DC output, there is a sense terminal which is ideally connected to the load line as close as possible to the DUT. Alternatively, it can also be connected directly to the DC output in the system.

  • Page 40: Protective Grounding Test

    5.7 Start-up R O U N D I N G A B L E H I E L D S In order to avoid negative EMC influences, the following must be observed the shields of the connecting cables are connected over a large area of the cable catch rail.

  • Page 41: High Voltage Test

    Manual ERS-BIC 160 kW V2.1 Mounting plate DC-fuses Mounting plate AC-fuses Mounting plate HTS CH1 Mounting plate HTS CH2 Mounting plate control board Mounting HW-Interface Display casing at the backside of the door Grounding rail CH1 Grounding rail CH2 Mounting plate output unit CH1...

  • Page 42: Switching On Mains Supply

    5.7 Start-up 2) The neutral conductor must be disconnected in terminal -X2. 3) The mains contactor must be bridged with a cable (crocodile clamps). Abb. 36 Service plug and bridges mains contactor 4) The output of the ERS must be short-circuited and connected to device ground. The short-circuit must be created before the output contactors, i.e.
  • Page 43 Manual ERS-BIC 160 kW V2.1 DANGER When working under voltage, always make sure that you do not touch any live parts. Cover all live parts! Always obey the five safety rules when connecting or disconnecting test equipment: Disconnect from mains...

  • Page 44: External Supply Of The Hts

    5.7 Start-up External Supply of the HTS For safety reasons, the HTS stages are externally supplied with a suitable power supply unit =600 V/I =3 A) before operation at full power, in order to limit the energy that can be discharged in the output stage in the event of a fault.
  • Page 45 Manual ERS-BIC 160 kW V2.1 The menu is password protected. The password is hard coded and cannot be changed by the operator via the screen. Unless otherwise specified, the password is the same as the general commissioning password Pressing {B} first displays the password entry screen. The password must be entered digit by digit.
  • Page 46 5.7 Start-up Now switch both channels to pause and then parameterize the channels according to step two of the following reference value table Now start again with the same procedure as point (1) and work through all steps of the set point table.

  • Page 47: Operating

    Manual ERS-BIC 160 kW V2.1 6. OPERATING Special Safety Instructions for Operation WARNING Commissioning and operation only by trained specialist personnel! Switching the Unit On and Off When switching the device on and off, the following sequences should be observed to protect the...
  • Page 48 6.2 Switching the Unit On and Off W I T C H I N G O N Selecting the desired mode of operation(Batt-Sim/Batt-Test) Set the set-value and monitoring limits so that your test object check the max. set-values and is not endangered and monitored values Always set all set-values for V, I and P.

  • Page 49: Operation And Display Elements

    Manual ERS-BIC 160 kW V2.1 W I T C H I N G O F F Operation Activate pause Current is deactivated Open contactor(Relais button) The contactors are only opened once ≅ Deactivate channel(On-Off When deactivating a channel the AFEs are only switched Button of, when both are not needed any more.

  • Page 50: Device Operating Menus

    6.4 Device Operating Menus Device Operating Menus Main Menu The main menu after switching on the system (touch screen display): Fig. 42 Main Menu after switching on the device Depending on the operating mode battery test or battery simulation, the labeling/function of some control elements changes.
  • Page 51 Manual ERS-BIC 160 kW V2.1 Table 22 Description Main Menu Display Operation Current Output channel ON/OFF Switch channel ON/OFF green = off / red = on Status contactors (battery test) Open/Close contactors (battery test mode only) green = open / red = closed...

  • Page 52: Setup-Menu

    6.4 Device Operating Menus Setup-Menu Main Menu => Setup-Menu: Fig. 43 Menu - Setup By tapping one of the buttons, the respective submenu is called up. Access to the device and channel parameters is unrestricted, the submenus for commissioning, con- troller and service parameters are protected by a password, because improper modification of param- eters can lead to device malfunctions and in special cases to device damage.

  • Page 53: System-Info

    Manual ERS-BIC 160 kW V2.1 System-Info Main Menu => Setup-Menu => System-Info: Fig. 44 Menu - System/Device Info Information about the device and the software versions used. Table 24 System-Info Designation Function Device-Info Display of device data such as article number, output power, number of outputs and serial number.

  • Page 54: System-Info/Status

    6.4 Device Operating Menus System-Info/Status Main Menu => Setup-Menu => System-Info => Status: Fig. 45 Menu - System/Device Info - Status Information about the Output contactors switching cycles, channel wiring and network status. Table 25 Menu - System-Status Designation Function Counter for switching cycles of the output Relay Switching Cycles contactors.

  • Page 55: System-Info/Measurements

    Manual ERS-BIC 160 kW V2.1 System-Info/Measurements Main Menu=> Setup-Menu=> System-Info=> Measurements: Fig. 46 Menu - System/Device Info - Measurements In this menu you can view different voltages and currents as well as the temperature of the heat sink for diagnostic purposes. For 4-channel devices, there are two additional columns...

  • Page 56: Fpga-Diagnosis

    6.4 Device Operating Menus FPGA-Diagnosis Main menu => Setup-Menu=> System-Info=> FPGA-Diagnose: Fig. 47 Menu - System/Device Info - FPGA-Diagnose In this menu level you can read out the detailed status and error messages of the ERS system. Table 27 Menu System-Info-FPGA-Diagnose Designation Function RS485 STATUS RX...

  • Page 57: Dsp-Diagnosis

    In this menu level you can read the status and error messages of the DSPs. In case of a fault, the hexadecimal code can be passed on to the Heinzinger Service and is used for system diagnosis. Table 28 Menu - System-Info-DSP-Diagnosis...

  • Page 58: Error History

    In this menu you can read the last error messages of the ERS system. In case of a device fault, the content can be passed on to the Heinzinger service and is used for system diagnosis. A list of possible error and warning codes can be found in section 8.5, pp. 71.

  • Page 59: Unit Parameters

    Manual ERS-BIC 160 kW V2.1 Unit Parameters Main Menu => Setup-Menu => unit parameters Fig. 50 Menu – Unit Parameters In this menu level you can set global device parameters, the operating mode and check the cooling water circuit. Table 30 Menu Unit Parameters...

  • Page 60: Channel-Parameter

    6.4 Device Operating Menus Channel-Parameter Main Menu=> Setup-Menu => Channel-Parameter DC-Output[x]: Fig. 51 Menu – Channel-Parameter In this menu you can set the parameters of the output channels. Table 31 Menu Channel Parameter Designation function Function Select the function of the channel (Battery test or simulation), if the option is available Sense-Monitoring If the limit for the voltage difference between output...
  • Page 61 Manual ERS-BIC 160 kW V2.1 Table 31 Menu Channel Parameter Designation function The rapid discharge is activated when the channel is switched off and discharges possible capacities in the test sample. Deactivation of the fast discharge function is necessary if there is a risk of overloading the discharge resistor due to external voltage sources.

  • Page 62: Control-Parameters

    6.4 Device Operating Menus Control-Parameters Main Menu => Setup-Menu => Channel-Parameter DC-Output[x]: Fig. 52 Menu - Control Parameter In this menu you can configure the parameters of the control loops. Table 32 Menu Control Parameter Designation Function Voltage Loop Controller Set the parameters for voltage control Current Loop Controller Set the parameters for current control...

  • Page 63: Service-Parameters

    Service-Parameters Main Menu => Setup-Menu => Service-Parameter: This menu level is reserved for the Heinzinger service technician. The improper change of these pa- rameters can lead to device malfunctions and even device damage. Access is protected by a password Battery Models (optional) If an output channel is working in the function mode "battery simulation", the test bench energy...

  • Page 64: Parallel Cluster Operation

    6.6 Cluster Operation (optional) To set up cluster operation, the output channels of the individual devices are connected with load cables as shown in the following diagrams. The sense connections of the individual channels must be connected like the load. During cluster operation only one insulation monitor may be active at the connected devices, because otherwise they would interfere with each other in their function.

  • Page 65: Serial Cluster Operation

    Manual ERS-BIC 160 kW V2.1 Serial Cluster Operation For serial cluster operation, first the two individual channels of each ERS are connected in parallel and then both systems are connected in series. This doubles the output power compared to a single device.

  • Page 66: Establishing Cluster Operation

    6.6 Cluster Operation (optional) Establishing Cluster Operation: To set the ERS systems to cluster mode, the following steps must be performed. Step 1 : Selection of Master and Slave device at the terminal: Fig. 59 Changing to cluster operation mode Unit 1: =>...

  • Page 67: Exiting Cluster Operation

    Manual ERS-BIC 160 kW V2.1 Exiting Cluster Operation The following describes how two systems are switched back from cluster to single operation. Step 1: Ending common mode of operation ▬ Master-device: => Unit Parameter => Single Mode The terminal of the slave-device now shows the normal main menu again ▬...

  • Page 68: Interfaces

    7.1 Safety Loops 7. INTERFACES ERS systems can be equipped with one or more interfaces. CAN-Bus interface for remote control CAN-Gateway: Remote-control with different communication protocols Interlock loop for secure shutdown of the outputs Channel stop for shutdown of single channels Sense-connection Safety Loops Interlock...

  • Page 69: Channel Stop (Optional)

    Manual ERS-BIC 160 kW V2.1 Channel Stop (optional) For performance level C and above, there are additional pins for the channel stop. If the channel stop is triggered by the interruption of the connection between the related contacts, it specifically switches off the channel in question and the output contactors are opened.

  • Page 70: Gateway (Optional)

    7.3 Gateway (optional) Pin assignment: CAN Low CAN High CAN Gnd Fig. 62 Pin assignment for the CAN-Bus-Plug The CAN interface is electrically isolated from the ERS device. Notice: The housing must be connected to the cable shield! Gateway (optional) The device can optionally be equipped with an AnyBus™...

  • Page 71: Pin Assignment

    Manual ERS-BIC 160 kW V2.1 The node address cannot be changed during operation as the Gateway needs a reset for the changes to take effect. N O T I C E A protective cover is located above the rotary switches. Be careful not to damage or touch the circuit board underneath when the cover is removed.

  • Page 72: Operating Errors And Troubleshooting

    8.1 Special Safety Instructions for Troubleshooting 8. OPERATING ERRORS AND TROUBLESHOOTING Special Safety Instructions for Troubleshooting WARNING Before working on the device or the application connected to it, make sure that it is de-ener- gized; Even after switching off, there are still dangerous voltages due to residual charges that only slowly degrade.

  • Page 73: Monitoring Coolant Temperature

    Manual ERS-BIC 160 kW V2.1 Monitoring Coolant Temperature If the temperature of the cooling water is too low, condensation will occur on the heat sinks depend- ing on the humidity, which can lead to malfunctions and damage to the unit. To prevent this, the cooling water flow temperature must not fall below 18°C.
  • Page 74 8.5 Warnings Table 38 Warnings Code Name Description Charge or discharge mode is not set or is set 0x0D OPER_MODE_WARN simultaneously 0x0E CTRL_MODE_WARN Control mode Setting of new voltage is blocked (set point is 0x0F V_SET_BLOCK_WARN wrong) 0x10 P_DISTR_WARN Power distribution Setting of new battery model is blocked 0x11 BATTERY_MODEL_WARN...

  • Page 75: Error Messages

    Manual ERS-BIC 160 kW V2.1 Table 38 Warnings Code Name Description 0x28 PSET_OVERLOAD Set values > Overload Max 0x2E WRONG_DIRECTION Wrong charge/discharge polarity (Optional) Error Messages Error messages are displayed in the main menu. In addition, all error messages that have occurred can be read out via the interface.
  • Page 76 8.6 Error Messages Table 39 Error messages Code Name Description 0x11 COM_DSP1_ERR SPI timeout DSP1 0x12 COM_DSP2_ERR SPI timeout DSP2 0x13 COM_ADC1_ERR SPI Error ADC channel 1 0x14 COM_ADC2_ERR SPI Error ADC channel 2 0x15 COM_ADC3_ERR SPI Error ADC channel 3 0x16 C_MON_0_ERR Zero value of ADC output current...
  • Page 77 Manual ERS-BIC 160 kW V2.1 Table 39 Error messages Code Name Description 0x2F TEMP_L_OUT_SD Overtemperature output inductor 0x30 ADC_SYNC synchronization error ADC Board 0x31 V_MON_PRI_OV_ERR Overvoltage limit reached primary voltage 0x32 C_MON_HTS2_0_ERR Zero value of ADC inductor current 0x33 C_MON_HTS2_POS_ ERR Pos.
  • Page 78 8.6 Error Messages Table 39 Error messages Code Name Description Contactor switching cycles reached limit. Limits: 0x4D OUT_REL_LD_SWITCH (1: 10000), (2: 1000), (3: 100), (4: 10), (5: 2) OUT_REL_MINUS_ERR Error at negative output contactors 0x4E Internal SW Error EEP_CTRL_PARAM_ERR SW-Version 0802010003 (1000V; Ctrl-Board V2 F28335) 0x4F SHORTCUT _ERR Short-circuit...
  • Page 79 Manual ERS-BIC 160 kW V2.1 Table 39 Error messages Code Name Description 0x65 SPIC_LRC Error of Spi C Bus 0x66 DISCH_REL_OUT Error of discharge relay output 0x67 FAN_CTRL Fan control error (air cooled device) 0x68 MAINS_FAN_CTRL Fan supply error (air cooled device)

  • Page 80: Troubleshooting Cluster Operation

    In the frozen state you can switch to the mask for switching the device operation by clicking on the Heinzinger symbol in the upper right corner. It is important that Can-A is separated during this, since you otherwise can have two Master/Slave devices. If the ma- chines still do not start up independently, they must be restarted in a cluster, i.e.

  • Page 81: Care, Maintenance, Calibration

    For instruments used for regular assessment, occupational safety checks, quality as- surance of products and services, we recommend calibration after 1 year. On request, Heinzinger electronic will also carry out a DIN EN ISO 9001 compliant calibration of the instrument.

  • Page 82: Spare Parts

    If necessary, please contact our service department. Service Address Maintenance and repair work is carried out directly by the manufacturer. Please contact us if neces- sary: Heinzinger electronic GmbH Phone +49 8031 2458 0 Anton-Jakob-Str. 4 +49 8031 2458 58 83026 Rosenheim / Germany service@heinzinger.de...

  • Page 83: Index

    Manual ERS-BIC 160 kW V2.1 INDEX Connection 28 Cooling System Venting 29 AFE 14 Copyright 5 Assembly 25 Current Precision 10 Electrical 30 Grounding 33, 34 Internal Connections 30 Neutral 34 DC-Output 12 Assembly 24V-Supply 32 design 12 Assembly Control Lines 32...
  • Page 84 MPC 14 Safety rules 7 Safety Symbols 8 Scope of Delivery 5, 21 Sense-Connection 69 Operating 45 Sense-Monitoring 58 Operating ERrors 70 Serial Operation 17 Option Service 79 Battery simulation 61 Service Adress 80 Channel Stop 19, 67 Servicemode 42 Cluster Operation 61 Set-up 21 EtherCAT 68...

  • Page 85: Appendix

    Manual ERS-BIC 160 kW V2.1 APPENDIX CA N -B U S M ES S AG E S A. A. Ov e r v i e w C A N C om ma nd s Overview of all CAN commands ordered by their CAN-Bus ID.
  • Page 86 A . A . B . I D 0 x 2 0 0 – 0 x 2 F F ID-Name Sender Receiver Data Length Cycle Time Channel Valid for Mode 0x200 DEV_CTRL Remote Remote 0x201 CH_1_CTRL Remote Variable Time-Out Remote 0x202 CH_2_CTRL Remote...
  • Page 87 Manual ERS-BIC 160 kW V2.1 ID-Name Sender Receiver Data Length Cycle Time Channel Valid for Mode 0x362 CH_2_READ_ERROR_QUERY Remote 0x370 DEV_READ_WARN_QUERY Remote 0x371 CH_1_READ_WARN_QUERY Remote 0x372 CH_2_READ_WARN_QUERY Remote 0x381 CH_1_STATUS2_QUERY Remote 0x382 CH_2_STATUS2_QUERY Remote 0x391 CH_1_QUERY_SYSTEM_INFO Remote 0x392 CH_2_QUERY_SYSTEM_INFO Remote A .
  • Page 88 ID-Name Sender Receiver Data Length Cycle Time Channel Valid for Mode 0x5C2 CH_2_GET_PROT Remote Remote A . B . D e v i c e c o n t r o l The remote control interface sends data for device control to the DSP ID-Name Message ID Data length Sender...
  • Page 89 Manual ERS-BIC 160 kW V2.1 0..1 CH4_ERROR Error Ch4 0..1 SYNC_MODE Sync-mode on 0..1 DEV_ERR_CNT There are error-messages in the memory 0..1 UNIT_ENABLED Device is enabled 0..1 DEV_WARNING Device Warning 0..1 CH1_WARNING Warning Ch1 0..1 CH2_WARNING Warning Ch2 0..1 CH3_WARNING Warning Ch3 0..1...
  • Page 90 A . E . C h a n n e l C o n t r o l ID-Name Message ID Data Length Sender Receiver Cycle Time 0x201 => Channel 1 CH_CTRL 8 Byte Remote Timeout monitoring 0x202 => Channel 2 Byte Bits Values...
  • Page 91 Manual ERS-BIC 160 kW V2.1 A . G . C h a n n e l S t a t u s ID-Name Message ID Data Length Sender Receiver Cycle Time 0x301 => Channel 1 CH_STATUS_QUERY 0 Byte Remote 0x302 => Channel 2 0x101 =>...
  • Page 92 A . H . C h a n n e l S t a t u s I I ID-Name Message ID Data Length Sender Receiver Cycle Time 0x381 => Channel 1 CH_STATUS_II_QUERY 0 Byte Remote 0x382 => Channel 2 0x151 =>...
  • Page 93 Manual ERS-BIC 160 kW V2.1 0-15 0..65355 V_MON_SENS_A 0.1V Averaged voltage measured at the sense -32768… 16-31 C_MON_A 0.1A Averaged Amperage measured at the output 32767 <325kW -32768… 32-47 P_MON_A Averaged Wattage measured at the sense 32767 >325kW 100W A . K .
  • Page 94 A . N . B a t t e r y M o d e l S t a t u s ID-Name Message ID Data Length Sender Receiver Cycle Time 0x351 => Channel 1 CH_BAT_MODEL_QUERY 0 Byte Remote 0x352 => Channel 2 0x141 =>...
  • Page 95 Manual ERS-BIC 160 kW V2.1 A . P . C h a n n e l E r r o r M e s s a g e s ID-Name Message ID Data Length Sender Receiver 0x361 => Channel 1...
  • Page 96 DEV_READ_WARN_ACK 0x1F0 8 Byte Remote Byte Bits Values Max./Min. Name Description 0..65355 0..50 DEV_ERR_NO Error memory number 8-15 16-23 0..65355 0..9999 DEV_ERR_CODE Device warning code 24-31 32-63 0..FFFFFFFFh 0..4294967295 TIMESTAMP Timestamp in ms Answer 2: ID-Name Message ID Length Sender Receiver DEV_READ_WARN_NEW_ACK 0x1D0...
  • Page 97 Manual ERS-BIC 160 kW V2.1 0x1D1 => Channel 1 CH_READ_WARN_ACK 8 Byte Remote 0x1D2 => Channel 2 Byte Bits Values Max./Min. Name Description 0..63 0..50 CH_WARN_NO Error memory number 0..65355 0..9999 CH_WARN_CODE Channel warning code 22-31 0..1023 0..999 TIMESTAMP 0...

  • Page 98: Digital Control Loop

    D I G I T A L C O N T R O L L O O P B . A . C o n t r o l d i a g r a m...
  • Page 99 Manual ERS-BIC 160 kW V2.1 B . B . C o n t r o l S c h e m a t i c s Main controller: PI-controller Parameters P and I separately adjustable for each control mode (CV, CC, CP)
  • Page 100 B . D . C o n t r o l l e r S e t t i n g s B . D . A . E f f e c t o f t h e C o n t r o l P a r a m e t e r s Usually it is only necessary to adjust the parameters of the main controller Low values for P and I result in a “slower“...

  • Page 101: Electrochemical Potentials

    Manual ERS-BIC 160 kW V2.1 B . F . C o n t r o l l e r m o d e “ B a t t e r y T e s t ” Optimized for voltage-controlled bidirectional operation on inverters, DCDC converters, etc.

  • Page 102: Declaration Of Conformity

    D EC LA R AT IO N OF C O N FOR MIT Y...
  • Page 103 Sprache übersetzt werden. I S C L A I M E R The information contained in this document is subject to change without notice. Heinzinger electronic GmbH shall not be liabl e for errors contained in this document or for incidental or consequential damages in connection with the furnishing, performance or use of this mate- rial.
  • Page 104 Heinzinger electronic GmbH High Voltage - Smart Solutions Anton-Jakob-Strasse 4 83026 Rosenheim – GERMANY Phone: +49-8031-2458-0 Fax: +49-8031-2458-58 info@heinzinger.de www.heinzinger.com V2.1 07.06.2021...

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