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NI NHR 4808-16 User Manual

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Document Part Number 327570A-01
NHR 4808-16
DC Power Module
User Manual
September 2023
Enabling Electrification
Your Partner in Test

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Summary of Contents for NI NHR 4808-16

  • Page 1 Document Part Number 327570A-01 NHR 4808-16 DC Power Module User Manual September 2023 Enabling Electrification Your Partner in Test...

  • Page 2: Table Of Contents

    NHR 4808-16 DC Power Module User Manual Contents Introduction ..........................3 NHR 4808-16 DC Power Module Overview ................3 Icons ............................3 Warranty ..........................4 Intended Usage ........................4 Safety Notice – Module Does Not Have User Serviceable Parts Inside ......4 General Safety Notices ......................
  • Page 3 NHR 4808-16 DC Power Module User Manual Touch Panel Interface ......................21 Output and System Status Indicators ................21 Encoder Knob and Buttons ....................22 USB Port and Power Switch ....................22 Analog IO Interface ......................22 Digital IO Interface ......................23 Paralleling IO Interface .......................

  • Page 4: Introduction

    NHR 4808-16 DC Power Module User Manual Introduction The 4808-16 DC power module is the industry leading solution for bi-directional power testing and verification of battery modules and related systems. The 4808-16 has a built-in contactor isolation (both facility and UUT), pre-charge, reverse polarity detection and similar features not commonly found in commercial bi-directional power supply devices.

  • Page 5: Warranty

    NHR 4808-16 DC Power Module User Manual Indicates a terminal that connects to accessible dead metal parts of the product. Connect the PE terminal(s) to an earth ground system (protective conductor) for safety. Warranty Warranty details, limitations, and other information are included within the general terms and conditions provided with the product quote.

  • Page 6: General Safety Notices

    NOTICE Observe all instructions and cautions in the user documentation. Using the product in a manner not specified can damage the product and compromise the built-in safety protection. Contact NI to report possible damage and to arrange for repair. NOTICE Installation, maintenance, and servicing is only to be performed by qualified skilled or authorized personnel.

  • Page 7: What Is The 4808-16 Dc Power Module

    NHR 4808-16 DC Power Module User Manual • Module or Power Module—The generic name for one chassis as either standalone or existing within the 4808 system. There are two primary module versions including a “Primary” and an “Auxiliary”. • Output—A generic term applied to the connection from the 4808 to the UUT. The term Output does not imply the direction of power flow.

  • Page 8: 4808-16 Module Views

    NHR 4808-16 DC Power Module User Manual • Optimized for low-voltage (< 80 V ) Power Hardware in the Loop (PHIL) applications • Expandable voltage and current by paralleling a like module o Same unit can be configured as the primary module or auxiliary unit o Field expandable to allow for future increased power demands •...
  • Page 9 3. USB Port for Touch Screen 4. Status Indicators 5. Encoder Wheel 6. Option Select Buttons 7. Air Intake Figure 2: NHR 4808-16 Module – Rear Safety Enclosure Front Exterior View A I N 1 G N D INPUT/GND A I N 2...
  • Page 10 NHR 4808-16 DC Power Module User Manual Figure 3: NHR 4808-16 Module – Rear Safety Enclosure Left-Side Front Exterior View 1. Top Panel of the Safety Enclosure 2. Top Panel Screws x11 (2 on right-side) 3. Rear Panel of the Safety Enclosure Figure 4: NHR 4808-16 Module –...

  • Page 11: System Diagram And Theory Of Operation

    NHR 4808-16 DC Power Module User Manual Figure 5: NHR 4808-16 Module – Side View (Right Shows Tilted Touch Screen Display) 1. Rack Mount Tabs System Diagram and Theory of Operation The 4808-16 module uses multiple power stages to manage the power flow between the facility and the DC testing output.

  • Page 12: Additional Features 4808-16 Module

    NHR 4808-16 DC Power Module User Manual • The first stage is a reversible and power factor corrected AC/DC inverter ensuring that power is drawn with near unity power factor. The output from the first stage is a non-isolated DC voltage.

  • Page 13: 4808-16 Module Specifications

    NHR 4808-16 DC Power Module User Manual 4808-16 Module Specifications Electrical Output Specifications Table 1: DC Output Ratings - Module Model 380 VAC Model 400 VAC Model 480 VAC Standard Operating 2-Quadrant with Programmable Voltage (CV), Current (CC), Modes Power (CP), Series-Resistance (CR)

  • Page 14: Trip, Mechanical, And Facility Specifications

    NHR 4808-16 DC Power Module User Manual Power Resolution 0.005% F.S. Additional Energy (Ah, kWh), Waveform Capture Measurements NOTE Measurement Specifications are valid for a default aperture window or greater, and the accuracy applies from 10% to 100% of the measurement range.

  • Page 15: Digital Interface

    NHR 4808-16 DC Power Module User Manual NOTE The 4808-16 module is equipped with a 40 A branch circuit breaker. Continuous use must not exceed 30 A/phase. Digital Interface Table 7: Control - Module Local User Interface Built-in Touch-Panel External System Comm...

  • Page 16: Recommended Service Feed, Breaker Size, And Facility Wiring

    NHR 4808-16 DC Power Module User Manual Place modules on a solid surface capable of supporting the device weight. Recommended Service Feed, Breaker Size, and Facility Wiring CAUTION: POSSIBILITY OF ELECTRIC SHOCK Avoid accessing the internal components. Only a qualified electrician or trained personnel should remove the facility service panel and output access cover.
  • Page 17 NHR 4808-16 DC Power Module User Manual NOTE For individual modules, use only copper wire cables, 8 AWG, 600 V 90 C. Class 1 circuits only. CAUTION: POSSIBILITY OF ELECTRIC SHOCK Connecting the system to a three-phase AC facility power should be done by a qualified electrician or trained personnel.
  • Page 18 NHR 4808-16 DC Power Module User Manual Figure 7: AC Input Wire Connection Diagram 3. (Optional) Remove the INPUT/GND strain reliefs. The installer may use approved 4. Torque wire connections to 39.8 in. ⋅ lb. conduit entries or glands. NOTE There is no phase rotation dependency for this system.

  • Page 19: Installing Uut Connections

    NHR 4808-16 DC Power Module User Manual CAUTION: POSSIBILITY OF ELECTRIC SHOCK Ensure the protective earth is properly installed before powering the system. ATTENTION : POSSIBILITÉ DE CHOC ÉLECTRIQUE S'assurer que la mise à la terre est correctement installée avant de mettre le système sous tension.

  • Page 20: Installing Lan Connections

    NHR 4808-16 DC Power Module User Manual To install the load connections, connect the UUT positive cable to the bus bar terminal marked positive (+) and the negative cable to the bus bar terminal marked (–). Torque connections (0.5 in. – 13 brass bolts) to 442 in. ⋅ lb.

  • Page 21: Terminating The Parallel Interface

    NHR 4808-16 DC Power Module User Manual • Pin 1 (ESTOP) is electrically connected to Pin 2 (TIE 1-2) • Pin 3 (Disable) is electrically connected to Pin 4 (TIE 3-4) The previous conditions allow an external E-STOP switch or dry contact to disable the system separately from the software programming interface.

  • Page 22: Powering Off The System

    NHR 4808-16 DC Power Module User Manual 2. Switch the main breaker to the ON position. 3. Switch the power switch on the front of the module to the ON position. NOTE For paralleled systems, the primary module is the last module to switch to the ON position.

  • Page 23: Encoder Knob And Buttons

    NHR 4808-16 DC Power Module User Manual • Discharge – Channel is enabled to sink power. Discharge does not imply that current is being drawn, only that the direction of power is enabled. • E-Stop – Emergency Stop Detected. One or more modules have their ESTOP to TIE1- 2 Connection open, or the paralleling cable is not present or terminated correctly.

  • Page 24: Digital Io Interface

    NHR 4808-16 DC Power Module User Manual Figure 9: Analog IO Interface A IN 1 A IN 2 VMON CMON • Analog In (AIN1/AIN2) are programmable for input range and function. Refer to the SCPI Programmers Reference for more information about the Analog IN options.

  • Page 25: Air Intake

    NHR 4808-16 DC Power Module User Manual Parallel IN Parallel Out Type ESTOP IN ESTOP OUT +15V Logic ! ESTOP SEN ! ESTOP SEN +15V Logic DISABLE IN DISABLE OUT +15V Logic ! DISABLE SEN ! DISABLE SEN +15V Logic...

  • Page 26: Touch Panel Control

    NHR 4808-16 DC Power Module User Manual Touch Panel Control The 4808-16 module (or a larger paralleled system) may be manually operated through the touch panel control on the front of the module. Figure 11: Touch Panel Control Selecting An Operating Mode The 4808-16 module (or larger paralleled system) can operate in one of the following operating modes.

  • Page 27: Wizard-Based Entry Screens

    NHR 4808-16 DC Power Module User Manual • Sine Dynamic – Imposing AC signal patterns on a DC output • MPPT – Maximum Power Point Tracking Loading for Solar • Macro – Complex profile generation NOTE Features such as Battery Emulation, Bi-Directional Source/Load, and HIL is limited to parallel groups of no more than 10 modules.
  • Page 28 NHR 4808-16 DC Power Module User Manual Figure 12: Standard Charge Mode – Set Current Flow • Charge—A unidirectional source to charge a battery • Discharge—A unidirectional load to discharge a battery • Battery—A bidirectional mode to emulate a battery In this example, the operator selects Charge and presses the right arrow to navigate to the next page of the wizard.

  • Page 29: Using The Encoder Knob And Buttons While Operating

    NHR 4808-16 DC Power Module User Manual Figure 14: Standard Charge Mode – Measurement Values Measurement values display in green. The Programmed settings display below the measurement values in white. After the system runs, the operator can select the following next step: •...

  • Page 30: Settings Options

    NHR 4808-16 DC Power Module User Manual In this mode, button 2 returns to the last setting used. Repeatedly pressing this button toggles between two settings allowing for a simplified way to do manual pulsing or to return to a setting which was previously acceptable.

  • Page 31: External Software Control

    NHR 4808-16 DC Power Module User Manual Data Logging—Data storage while operating • Event Log—History of errors when operating (used by NHR Field Service Teams) • External Software Control NH Research provides a programmer’s reference and LabVIEW drivers with the 4808 module.

  • Page 32: Cleaning The Touch Panel Interface

    NHR 4808-16 DC Power Module User Manual Complete the following steps to clean the front filter and remove dust buildup. Refer to Module Views section to locate components of the hardware. 1. Remove the four screws that secure the panel at the front of the module.

  • Page 33: Ni Services

    Visit ni.com/support to find support resources including documentation, downloads, and troubleshooting and application development self-help such as tutorials and examples. Visit ni.com/services to learn about NI service offerings such as calibration options, repair, and replacement. Visit ni.com/register to register your NI product. Product registration facilitates technical support and ensures that you receive important information updates from NI.
  • Page 34 National Instruments Patents Notice at ni.com/patents. You can find information about end-user license agreements (EULAs) and third-party legal notices in the readme file for your NI product. Refer to the Export Compliance Information at ni.com/legal/export-compliance...

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