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ZAHNER EL1002 Operation Manual

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30/06/2022

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Summary of Contents for ZAHNER EL1002

  • Page 1 30/06/2022...
  • Page 2 Electronic Load...

  • Page 3: Table Of Contents

    6.3 Two-Electrode Cell Connection Scheme ......... 21 6.4 Parasitic Inductances ............... 22 7 Connection Configurations ..............25 7.1 Applications for the EL1002 without external devices ....26 7.1.1 Full cell configuration (Standard Kelvin Scheme) ..... 26 7.1.2 Half-cell configuration – Cathode ..........27 7.1.3 Half-cell configuration –...
  • Page 4 7.3.1 DUT connected to the EL1002 with an additional DC load using the EXT+ terminal ................ 31 7.3.2 DUT connected to the EL1002 with a parallel DC load ..32 7.4 Applications with an additional power supply in series ....34 7.4.1 Charging batteries ...............

  • Page 5: Electronic Load El1002

    Zahner products are carefully manufactured, calibrated and tested to ensure our high-quality standard. Packing of the electronic load EL1002 and accessories is done with great care to avoid damage during transport. Upon receipt of the Zahner shipment, please check the device and accessories to make sure they are intact. If a product is damaged during shipment, please immediately contact your Zahner’s...

  • Page 6: Caution

    Pay attention to the wire connections and strictly follow the guidelines of this manual. Accidentally reversed polarity may damage your device. During operation the potential on the positive (+) terminal of the EL1002 should be at least 1 V higher than the negative (–) terminal.
  • Page 7 Don’t touch the electrical connections during operation. Never apply potentials exceeding 100 V using the EL1002. The maximum current through the positive (+) terminal of EL1002 must never exceed 200 A. The maximum current through the shunt/current measurement unit of the EL1002 must never exceed 680 A.

  • Page 8: Introduction

    (PEM) and solid oxide (SO) fuel cells. The EL1002 allows for power dissipation of up to 1 kW in terms of voltages up to 100 V and currents up to 200 A. In combination with a third-party instrument (electronic loads or sources), measurements at higher currents (up to 680 A) can be carried out.

  • Page 9: Epc42 Controller Card

    (PP2X2 and/or XPOT2) or electronic loads (EL1002) can be connected. Up to four EPC42 cards can be installed in a ZENNIUM series potentiostats. Therefore, a total of up to 16 external devices (PP2X2, XPOT2, EL1002) can be connected to a ZENNIUM series potentiostat with four EPC42 cards.

  • Page 10: Stand-Alone Mode

    Electronic Load 3.2 Stand-Alone Mode Zahner’s power potentiostats or electronic loads (PP2X2, XPOT2, EL1002) can also be operated in stand-alone mode, for which a Windows 10/11 or Linux computer is necessary. For software updates, Windows 10/11 is required and the use of a virtual machine is not permitted.

  • Page 11: Operation Basics

    The EL1002 external electronic load is a one quadrant potentiostat. This means that it can sink (but cannot source) current in a fixed, given polarity. Hence, when the EL1002 is connected to a battery, it can only discharge the battery, while charging is not possible without a third-party source.

  • Page 12: Conductor Rails

    Always connect the anode (-) pole of a battery, fuel cell etc. with the negative (-) terminal of the EL1002 and the cathode (+) to the positive (+) terminal! If that DUT is connected to the EL1002 using wrong polarity, the polarity error LED will light up.

  • Page 13: Safety Interlock

    The EL1002 is equipped with various signal and warning LEDs on the front panel as well as a buzzer. The status LED lights up green when the CPU of the EL1002 is running and the device is ready for use. When the CPU is busy with a task or command, the status LED lights up orange.

  • Page 14: Operation Steps

    -13- 4.2 Operation Steps Turn ON external power supply/load (if it is planned to be used). 2. Turn ON the ZENNIUM device as well as the EL1002 and allow for 15 minutes of warm-up time. 3. Start the Thales software.
  • Page 15 Electronic Load -14- ⚠ Do not sink external DC current during EL1002 start up and calibration. No current is allowed to flow through the current measuring device, otherwise it will be calibrated as an offset.

  • Page 16: Thales Software

    Electronic Load -15- 5 Thales Software The EL1002 requires Thales version 5.8.3 or later. All external potentiostats are directly controlled by the Thales software. In Thales, each device has a unique device number which is identical to the EPC42 port number to which the external potentiostat is connected, if no RMUX card is installed.
  • Page 17 Electronic Load -16- If no device is connected to the selected EPC42 port, an error message is displayed and the Thales software automatically switches to the internal potentiostat. If the selected device is connected, the Thales software automatically starts the start-up calibration routine of the external potentiostats upon selection.
  • Page 18 For convenience, the EL1002 connection scheme with the third-party DC load is shown here. Now connect the sense cables from the EL1002 to the DUT. Here, a battery is used as DUT. Thereafter, connect the power cables used for the desired EL1002 arrangement.
  • Page 19 -18- When the DUT is connected correctly, the voltage is negative and the current flowing into the EL1002 is positive. When changing the device number, the now unselected external potentiostat will hold its DC conditions such as DC potential or current and its on/off status until the...

  • Page 20: Cell Connection Fundamentals

    -19- 6 Cell Connection Fundamentals All Zahner’s measuring instruments follow the same 4-electrode cell connection scheme, which is also referred to as 4-terminal sensing or Kelvin connection. This includes connections to the working electrode (copper rail denoted with -), working electrode sense (WES), reference electrode (RE), and counter electrode (copper rail denoted with +).

  • Page 21: 4-Electrode Cell Connection Scheme

    Electronic Load -20- 6.2 4-Electrode Cell Connection Scheme The advantage of a 4-electrode connection scheme is illustrated in Fig. 9. A pouch cell is connected to the ZENNIUM potentiostat using a 4-electrode connection scheme. With the WES and RE being directly connected to the pouch-cell, the contact resistance for the WE and CE can be ignored as they don’t affect the voltage drop between WES and RE, which cannot be realized in a 2-electrode connection.

  • Page 22: Two-Electrode Cell Connection Scheme

    Electronic Load -21- �� = �� ∗ �� ������ �������� �������� �� ������ �� �������� �� �������� Using the 4-electrode connection scheme, the contact resistances do not influence the measured cell impedance, as long as the cell impedance is much smaller than the object impedance.

  • Page 23: Parasitic Inductances

    EL1002 to the object. Two of these wires are attached to each other by cable ties to minimize the mutual inductance. Theoretically, twisting the cables around each other is the most preferable configuration as the magnetic fields are mutually compensated (canceled out) most effectively.
  • Page 24 1 V is still available at the EL1002. If the voltage falls below 1 V, the control loop of the EL1002 is not working properly, causing collapsed amplitude and/or distorted...
  • Page 25 This makes the object voltage less relevant as the voltage drop across the wire can be compensated. Electronic loads or one-quadrant potentiostats such as the EL1002 do not have a voltage output that could compensate for voltage drops. In summary it should be noted that the cabling is essential for high current applications.

  • Page 26: Connection Configurations

    It is important to know that EL potentiostats SINK current from the DUT and therefore the cell connections must be as short and as thick as possible. Otherwise the measurements may be faulty and it may even look like as if the EL1002 was defective.

  • Page 27: Applications For The El1002 Without External Devices

    DUT, here -3 V . However, the output potential between the terminals of the EL1002 will be less than 3 V. This decrease (Fig. 14, b) is caused by the voltage drop (V = I*R) within the system, which depends on the current flowing through the system.

  • Page 28: Half-Cell Configuration - Cathode

    Electronic Load -27- 7.1.2 Half-cell configuration – Cathode This configuration is used with DUTs such as (rechargeable) batteries and fuel cells if only the cathodic part of the cell is to be investigated. Fig. 15: Half-cell configuration - Cathode 7.1.3 Half-cell configuration – Anode This configuration is used with DUTs such as (rechargeable) batteries and fuel cells if only the anodic part of the cell is to be investigated.

  • Page 29: Partial Cell Configuration

    17 cells in a battery or a fuel cell, which is shown in Fig. 18: Fig. 18: EL1002 with PAD4 The sensor cables (green and blue) of the PAD4 card must be twisted around each other in analogy to the main channel to minimize artifacts.

  • Page 30: General Notes For Applications With External Supply Or Load

    -29- 7.2 General notes for applications with external supply or load ⚠ During the startup and calibration of the EL1002, do not sink external DC current. No current is allowed to flow through the current measuring device, otherwise it will be calibrated as an offset.
  • Page 31 This brings the real behavior closer to the ideal behavior. To avoid errors with this more advanced setup with an external source or sink, it is a useful idea to automate the measurement process. To control the EL1002 and a power supply with Python, we provide an example on GitHub.

  • Page 32: Applications With An Additional Dc Load

    I ≥ 0. The external load must operate in constant current mode. The current flow cannot be switched off by the EL1002 in this configuration, as it is also dependent on the external device, which is controlled separately.

  • Page 33: Dut Connected To The El1002 With A Parallel Dc Load

    7.3.2 DUT connected to the EL1002 with a parallel DC load To sink more current from the DUT than possible by only the EL1002 (680 A), an external load can additionally be connected in parallel to the DUT and EL1002 as shown below.
  • Page 34 Electronic Load -33- Fig. 21: One-quadrant representation of a battery or fuel cell connected to the EL1002 and a parallel external load. Fig. 21 illustrates the two independent current loops for the parallel connection of the EL1002 and an external load with the DUT in the one-quadrant representation.

  • Page 35: Applications With An Additional Power Supply In Series

    The potential will be indicated as positive in the EL1002, because the battery connection is now reversed with regard to the sense cables. The measured current must be positive (I ≥ 0). Fig. 22: One-quadrant representation of an EL1002 in series with a battery and an external power supply.
  • Page 36 (R). Fig. 23: EL1002 in series connection with a battery and an external power supply in reversed connections.

  • Page 37: Electrolysis Of Fuel Cells

    Electrolysis of the fuel cell utilizes the same cell connection scheme as for charging of batteries (7.4.1). The potential will be indicated as positive in the EL1002 (because the connection is reversed with regard to the sense cables) The measured current must be positive (I ≥...

  • Page 38: Compensation For Voltage Drop (Zero Volt Option)

    If a current value is set in the galvanostatic mode of the EL1002 at which the voltage drop exceeds the fuel cell potential, this current value will not build up.
  • Page 39 EL1002. To compensate for the voltage, drop at high currents, a small additional potential of usually 1 V is provided by the external power supply to the fuel cell (Fig.

  • Page 40: Applications With An Additional Power Supply In Parallel Using The Ext+ Terminal

    Discharging: current through DUT is POSITIVE The current flow cannot be switched off by the EL1002 in this configuration, as it is also dependent on the external device which is controlled separately. Fig. 27: EL1002 with additional DC supply using EXT terminal.

  • Page 41: Charging

    EL1002 and then eventually back to the power supply. The AC current between the + and – terminals of the EL1002 is only allowed in one direction (from + to -) and is therefore flowing in reversed direction with respect to the charging current.

  • Page 42: Discharging

    Electronic Load -41- The DC current flowing to the + terminal of the EL1002 must be higher than the EIS amplitude (A ), as the EL1002 only allows current flow into one direction. If the DC current is less than the EIS amplitude, then a complete sine excitation by the EL1002 is not possible.

  • Page 43: State Of Charge (Soc)

    (preferably, at least 1 A higher) than the AC amplitude used for EIS excitation. Here, if the EL1002 is turned off, the power supply will start charging the DUT at a charging current of 2 A...

  • Page 44: Summary Parallel Power Supply With Pad4

    Here, the maximum power dissipation is calculated by DC current + AC current, corresponding to the maximum current, multiplied by the voltage. The maximum power dissipation within the EL1002 must not exceed 1000 W. This must be considered particularly at low AC frequencies. Fig. 32: EL1002 with supply to EXT summary.

  • Page 45: Specifications

    Electronic Load -44- 8 Specifications The following section lists the specifications of the EL1002. 8.1 Ranges and tolerances Voltage Ranges Voltage Range Range Standalone [V] Range Thales [V] Tolerance Index Factor -5.0 -4.0 ±500 µV ±0.1% of reading -100 -100 ±12.5 mV ±0.1% of reading...

  • Page 46: General Specifications

    Impedance Range 1 µΩ - 100 Ω Impedances below 10 mΩ must be measured galvanostatically. EL1002 is optimized for galvanostatic operation on objects below 1 Ω. The device is not intended for Ohmic inductive objects. ²Hardware feature will be unlocked in the future by a free software update.

  • Page 47: Safe Operation Conditions

    -46- 8.3 Safe operation conditions The maximum power dissipation (sink) of the EL1002 is 1000 W. Fig. 3 is important for determining the power dissipation, which can be simply calculated by the formula P = U * I. It is important to always use the correct voltage and current that applies for the specific setup.

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