General Information- Document Usage: The manual should be kept near the equipment for reference and transferred with the equipment if relocated.
- Copyright: Unauthorized modification or use of this document is prohibited.
- Validity: Applicable to specific EA-ELR models listed in the document.
- Symbols and Warnings: Various symbols indicate potential hazards and important notices.
Warranty and Liability- Warranty: Covers functional competence and performance parameters from delivery.
- Limitation of Liability: Manufacturer is not liable for misuse, unauthorized modifications, or use of unauthorized parts.
Disposal- Equipment must be returned to the manufacturer for disposal according to European regulations.
Product Key- Explanation of product description and model identification.
Intended Usage- Designed for use as a variable voltage/current source or sink, installed in suitable equipment.
- Non-intended usage is the operator's responsibility.
Safety- Safety Notices: High voltage risks, proper handling, and configuration guidelines.
- Operator Responsibility: Ensures safety, compliance with regulations, and proper training for users.
- User Requirements: Only qualified individuals should operate the equipment.
Technical Data- Approved Operating Conditions: Operates in ambient temperatures from 0°C to 50°C, requires acclimatization if condensation occurs, and can operate at altitudes up to 2000 meters.
- Cooling: Uses air cooling with a fan; dust can obstruct airflow, so clear air paths are important.
- General Technical Data: Features a color TFT touch screen, rotary knobs, and pushbuttons for control.
- Specific Technical Data: Includes specifications for AC input voltage, frequency, power factor, and protective functions like overvoltage and overcurrent protection. Supports parallel operation of up to 64 units and complies with various safety and EMC standards.
Front and Rear Panel Description
The ELR 10000 3U features a front panel with a power switch, TFT control interface, rotary knobs for settings, USB host for data logging, and an On/Off push-button with LED status display. The rear panel includes an Ethernet interface, slots for additional interfaces, connectors for parallel system setup, remote sense connectors, DC output terminal, AC input connector, grounding screw, and a USB interface for communication and firmware updates.
Control Elements
The control panel includes a touchscreen display for setting and displaying values, rotary knobs for adjusting voltage, current, power, or resistance, and a USB port for connecting USB sticks. The touchscreen can be operated with fingers or a stylus, and the rotary knobs have push-button functions for precise adjustments.
General Description
The ELR 10000 3U series are energy-recovering electronic loads that can invert consumed DC energy with up to 95.5% efficiency. They feature an integrated function generator for creating set point curves and offer battery testing and MPP tracking for solar module tests. The devices support remote control via USB, Ethernet, and optional digital interfaces, and can be connected in parallel for increased power capacity.
Scope of Delivery and Accessories
The package includes the electronic load device, remote sensing plugs, USB cable, DC input covers, USB stick with documentation, AC connector plug, and strain relief set. Optional accessories include interface modules for various communication protocols and software licenses for advanced control features.
Control Panel (HMI)
The HMI consists of a touchscreen display, rotary knobs, a pushbutton, and a USB port. The display shows actual and set values for voltage, current, power, and resistance, and allows for menu access and status monitoring. The rotary knobs can be assigned to different functions, and the USB port supports data logging and sequence management.
USB Ports
The front USB port is used for connecting USB sticks for data logging and sequence management, while the rear USB port is for device communication and firmware updates. Supported file types for loading and saving include CSV files for function generators, user profiles, and log data.
Specifications and Interfaces
The device supports the Mod-Bus RTU protocol and SCPI language for remote control, automatically recognizing the message protocol used. The USB port is available for monitoring but does not have priority over other interfaces. The interface module slot can accommodate various modules, such as CANopen, RS232, Profibus, Ethernet, and ModBus TCP, allowing for user installation and retrofitting. The analog interface supports remote control via analog or digital signals, with switchable voltage ranges. The "Share BUS" connector facilitates parallel operation in a master-slave configuration, while the "Sense" connector compensates for voltage drops along DC cables. The master-slave bus uses RJ45 sockets for connecting multiple devices via RS485. The Ethernet port allows remote control and monitoring through a web interface or TCP/IP access, supporting SCPI or ModBus RTU protocols.
Installation and Commissioning
Transport and storage guidelines emphasize avoiding hand transport due to the device's weight and recommend using original packaging for relocation. Before installation, ensure the location can support the device's weight and verify the supply voltage. The device features energy recovery, feeding energy back into the grid, which requires adherence to local energy regulations. Installation requires selecting appropriate cables and ensuring proper AC supply connection by qualified personnel. The device must be installed in a closed appliance, such as a cabinet, with sufficient ventilation space. Connection to the AC supply should consider cable cross-section and length, with specific requirements for different power ratings.
Specifications
The document outlines the specifications for AC and DC cable connections, including maximum cross-sections and stripping lengths. It emphasizes the importance of using short mains cables or those with larger cross-sections to minimize resistance. The AC plug ratings are specified, and the document provides guidelines for grounding the enclosure and connecting to DC sources.
Procedures
Detailed installation steps are provided for mounting strain reliefs, grounding the enclosure, and connecting to DC sources. The document also includes instructions for installing interface modules and connecting various interfaces such as analog, USB, and Share bus.
Standards and Recommendations
The document recommends using flexible cables with ring lugs for DC connections and provides guidelines for remote sensing and grounding. It advises on the use of strain relievers for heavy DC cables and highlights the importance of proper cable cross-sections and electric strength.
Safety and Operation
Personal safety measures are emphasized, particularly for those working with dangerous electrical voltages. The document outlines the importance of using DC terminal covers and provides guidelines for operating modes, including voltage regulation and constant voltage operation.
Key Data from Tables and Figures
The document includes tables showing phase currents for different power models and recommended cable cross-sections based on current consumption. Figures illustrate the mounting positions for strain reliefs and examples of remote sensing wiring.
Critical Information
Key requirements include ensuring balanced current distribution for multiple units, using appropriate cable cross-sections to avoid voltage loss, and following safety protocols during installation and operation. The document also highlights the need for proper driver installation for USB connections and the importance of initial commissioning procedures.
Voltage Regulation Peaks
When operating in constant voltage regulation mode, the device may experience voltage overshoots when reacting to changes in DC input voltage. The transient time to stabilize the voltage can be adjusted by switching the voltage regulation speed between Slow, Normal, and Fast settings. Fast settings reduce peaks but may increase oscillation, especially with remote sensing.
Minimum Input Voltage for Maximum Current
Each model requires a minimum input voltage to sink its rated current due to internal resistance. If the input voltage is below this minimum, the device will draw less current proportionally.
Current Regulation
In constant current mode, the device maintains a steady current once the load reaches the set limit. If the power consumption exceeds the maximum power value, the device switches to power limiting mode.
Power Regulation
Power regulation maintains constant DC power by adjusting current and voltage according to the auto-range principle. Power derating occurs when operating on lower AC supply voltages, reducing available DC power.
Resistance Regulation
Constant resistance mode adjusts internal resistance to maintain a user-defined value, ensuring high input current at low voltages.
Dynamic Characteristics and Stability Criteria
The device's high bandwidth regulation circuit can cause instability when testing sources with their own regulation circuits. Adjusting the internal voltage regulator speed can improve stability.
Alarm Conditions
Various alarms signal issues such as power fail, overtemperature, overvoltage, overcurrent, overpower, and share bus fail. Each alarm condition is indicated optically and acoustically, with status messages available via digital interface.
Manual Operation
The device can be switched on using a rotary switch or external cutout. Configuration settings determine the DC input state after power-up. Remote control can be blocked during manual operation by activating 'Local' mode.
Configuration via the Menu
The settings menu allows configuration of operating parameters, accessed by touch when the DC input is off. The sub-menu 'Settings' includes options for presets, protection thresholds, adjustment limits, and remote control permissions.
Specifications and Features- Speed Settings: The voltage controller can operate at standard or fast speed, with fast speed increasing oscillation tendency.
- SEMI F47: A feature related to the SEMI F47 standard can be activated or deactivated.
- Analog Interface Range: Voltage range options are 0-5V or 0-10V for set/actual values, with corresponding reference voltages.
- REM-SB Level: Input pin REM-SB can operate in normal or inverted logic.
- Pin Assignments: Various pins (6, 14, 15) are assigned to signal different alarms and statuses, with multiple configuration options.
Procedures and Controls- DC Input State: Configurable states for DC input after power on, power fail alarms, remote control exit, and overtemperature alarms.
- Master-Slave Mode: Enables master-slave mode and defines unit position in the system.
- Termination Resistors: Activation of bus termination and bias resistors for digital master-slave bus stability.
- Display Settings: Option to turn off display backlight after 60 seconds of inactivity.
- System Initialization: Manual re-initialization of the master-slave system if detection issues occur.
Logging and Reset- USB Logging: Configurable logging settings including interval, start/stop conditions, and file format.
- Reset/Restart: Options to reset device settings to factory defaults or perform a warm restart.
Communication Settings- Ethernet and USB: Configurable settings for internal Ethernet port and optional interface modules, including IP address, subnet mask, and port settings.
- CAN Bus: Settings for baud rate, ID format, bus termination, and cyclic read/write operations.
- RS232: Selectable baud rates with fixed serial settings.
- Timeouts: Configurable timeouts for Ethernet and USB/RS232 communication to maintain socket connections.
Interface Monitoring
Interface monitoring can be activated or deactivated with a default timeout of 5 seconds, adjustable within a range of 5 to 65535 seconds. The default setting is off.
Communication Protocols
The device supports SCPI and ModBus protocols, with the ability to switch between Limited and Full compliance for ModBus. Full compliance ensures compatibility with market software.
HMI Setup
Settings include language selection (default: English), sound activation for key and alarm sounds, clock setup, and backlight settings. The backlight can be set to turn off after 60 seconds of inactivity.
Adjustment Limits
Adjustment limits apply to set values for voltage, current, power, and resistance. Default ranges are 0 to 102%, except for the 60V model which is adjustable to 100%. Limits can be set to protect against overvoltage.
Operating Modes
The device operates in U/I, U/P, and U/R modes, with set values adjusted via rotary knobs or numeric pad. The mode can be changed unless the device is in remote control or the panel is locked.
Manual Adjustment of Set Values
Set values for voltage, current, power, and resistance can be adjusted manually using rotary knobs or direct input. Limits are enforced, and adjustments are immediately submitted.
Switching the DC Input
The DC input can be switched on or off manually or remotely. Manual switching requires the HMI lock to be disabled if active.
USB Logging
Data can be logged to a USB stick in CSV format. Logging can be configured to start/stop with DC input or manually. The maximum log file size is 4 GB, and up to 1024 log files can be stored.
Quick Menu
A quick menu provides access to frequently used features, such as USB logging and master-slave settings. Features can be activated or deactivated with a tap.
Graph Feature
The graph feature visually displays voltage, current, and power values. It is not a recording feature but can be accessed anytime for monitoring.
Remote Control
Remote control is available via built-in interfaces or optional modules. Only one interface can control the device at a time, with status monitoring always possible.
Local and Remote Control
The document outlines the conditions under which local and remote control can be activated or inhibited. Local control locks remote access, requiring manual operation. Remote control can be reactivated once local control is deactivated. This is crucial for emergency adjustments or when the device is controlled by external software.
Remote Control via Digital Interface
Various digital interfaces are supported, including USB, Ethernet, CANopen, RS232, Profibus, ProfiNet, CAN, EtherCAT, and ModBus TCP. Each interface has specific ports and functionalities, detailed in the "Programming Guide Modbus & SCPI." Interface monitoring ensures the device does not operate uncontrolled if communication fails, with a user-definable timeout to manage this.
Remote Control via Analog Interface
The analog interface allows remote control of current, voltage, power, and resistance, along with status and alarm monitoring. It requires concurrent setting of voltage, current, and power values. The interface operates in 0-5V or 0-10V ranges, with set values limited by adjustment limits. Important notes include ensuring no excessive voltage is applied to pins and that set value inputs are not left unconnected.
Device Alarms and Acknowledgment
Alarms during remote control via the analog interface will switch off the DC input. Alarms are indicated on the front display and can be acoustically signaled. Acknowledgment is done by toggling pin REM-SB, which switches the DC input off and on.
Analog Interface Specifications
Detailed specifications for each pin on the analog interface are provided, including voltage and current set values, reference voltage, and alarm signals. The interface's resolution is limited by the digital micro-controller, with 26214 steps in the 10V range.
Application Examples
Examples include switching the DC input using pin REM-SB and remote control of current and power. The document emphasizes the need for low resistance contacts for switching and the use of potentiometers for generating set values.
Alarms and Monitoring- Definition of Terms: The document distinguishes between device alarms and user-defined events. Device alarms, such as overvoltage protection (OVP) and overheating protection (OT), automatically switch off the DC input. User-defined events can either switch off the DC input or provide an acoustic signal to alert the user. Actions for user-defined events include None, Signal, Warning, and Alarm, each with varying levels of notification and response.
- Device Alarm and Event Handling: Device alarms typically result in the DC input being switched off and require acknowledgment. Configurable alarms include OverVoltage Protection (OVP), OverCurrent Protection (OCP), and OverPower Protection (OPP), each with specific thresholds. Non-configurable alarms are based on hardware issues like Power Fail (PF) and OverTemperature (OT).
- User Defined Events: These events are configurable and only active when the DC input is on. They include UnderVoltage Detection (UVD), OverVoltage Detection (OVD), UnderCurrent Detection (UCD), OverCurrent Detection (OCD), and OverPower Detection (OPD). These events can be set to trigger an alarm and switch off the DC input.
Locking Mechanisms- Locking the Control Panel (HMI): The control panel can be locked to prevent accidental changes. The lock can be activated or deactivated using a PIN.
- Locking Adjustment Limits and User Profiles: Adjustment limits and user profiles can be locked with a PIN to prevent unauthorized changes. The same PIN is used for both HMI and limits lock.
- Loading and Saving User Profiles: The device supports up to 5 user profiles in addition to a default profile. Profiles store settings and can be quickly loaded to apply specific configurations.
Function Generator- Introduction: The built-in function generator can create various signal forms for voltage or current. It includes standard functions like Sine, Triangle, Rectangular, Trapezoid, and more complex functions like DIN 40839 and Arbitrary.
- General: The function generator is inaccessible in resistance mode. It has a resolution of approximately 52428 steps, and certain limitations on slope and ramp time have been removed in recent updates.
Device Operation Overview
The device operates with three set values: Voltage (U), Current (I), and Power (P), even in function generator mode. A selected function can be applied to either U or I, while the other two remain constant, potentially limiting the function's effect. For example, applying a sine wave to the current with a set voltage can result in a limited current if the power exceeds its set value.
Master-Slave Systems
In master-slave systems, adjustable set values known as U/I/P limits are transferred to all slave units. Proper configuration is crucial to ensure the system functions as expected without negative impacts from slave units.
Manual Operation
Functions can be selected and controlled via a touch screen when the DC input is off. Parameters and global set values must be adjusted carefully, especially in master-slave systems, to ensure correct operation.
Function Start and Stop
Functions can be started or stopped using the touch screen or the "On/Off" button. Stopping via the button turns off the DC input, while the touch screen maintains static values.
Function Types and Parameters- Sine Wave Function: Configurable parameters include frequency, amplitude, and offset. The maximum input power is calculated using these values.
- Triangular Function: Parameters include amplitude, offset, and time for rising and falling edges. The cycle time is the sum of these intervals.
- Rectangular Function: Configurable parameters include amplitude, offset, and time for pulse and pause widths. The duty cycle is defined by these intervals.
- Trapezoidal Function: Parameters include amplitude, offset, and time for slopes and base values. The function can be adjusted to form triangular or rectangular pulses.
- DIN 40839 Function: This function replicates automobile battery voltage during engine starting, divided into five parts with configurable parameters.
- Arbitrary Function: Offers 99 sequence points for complex function curves, with parameters for AC and DC start and end values, frequency, and time.
Schematic Diagrams and ApplicationsThe document provides examples of sequence points focusing on cycles with varying start and end frequencies. Examples illustrate configurations for generating DC settings, sine waves, and complex waveforms by linking sequence points. Key examples include:
- Example 5 & 6: Focus on DC settings with no sine wave generation.
- Example 7: Demonstrates discontinuity in progression due to settings.
- Example 8 & 9: Showcases sine wave generation with varying amplitudes and complex sequences.
Loading and Saving Arbitrary FunctionsThe manual describes the process for loading and saving sequence points using a USB stick. Key requirements include:
- 99 rows with 8 columns in CSV format.
- Specific file naming conventions and folder structure.
- Defined value ranges for parameters like frequency and time.
Ramp Function
Parameters for configuring a ramp function include start/end points and time delays. The function generates a ramp between start and end values, with options for rising, falling, or horizontal ramps.
IU Table Function
This function allows setting a DC input current based on voltage, using a table of 4096 values. The table must meet specific format requirements and is loaded via USB or remote control.
Battery Test FunctionDesigned for discharging batteries, this function offers static and dynamic discharge modes. Key settings include:
- Static mode: Configurable for constant current, power, or resistance.
- Dynamic mode: Includes pulsed current settings.
- Stop conditions: Define thresholds for voltage, capacity, and time.
The function does not include battery management capabilities, and external management may be required.
Data Recording and Logging
The device allows data recording to a USB stick during test runs, with data saved in CSV format. Active logging is indicated by a diskette symbol on the display. The log file includes parameters such as discharging current, max power, desired resistance, and actual values of voltage, current, and power.
Battery Test Stop Conditions
The battery test can be stopped manually, upon reaching maximum test time or battery capacity, or due to device alarms like over-temperature. It also stops when discharge end voltage or charging end current thresholds are reached.
MPP Tracking FunctionThe Maximum Power Point (MPP) tracking function is used to test solar panels. It offers four modes:
- Mode MPP1: Finds the MPP by setting parameters like open circuit voltage (UOC) and short-circuit current (ISC).
- Mode MPP2: Continuously tracks the MPP, adjusting voltage and power to maintain optimal performance.
- Mode MPP3: Directly jumps to user-defined MPP values, useful for repetitive tests.
- Mode MPP4: Allows user-defined curves with up to 100 points, loaded from a USB stick, and tracks these points to measure current and power.
Remote Control
The function generator can be remotely controlled using ModBus & SCPI protocols. It cannot be controlled via the analog interface directly.
Parallel Operation in Master-Slave Mode
Multiple devices can be connected in parallel to increase total current and power. The system uses a Share bus and a master-slave bus for dynamic balancing and control. Restrictions include different alarm reactions and the requirement for identical device models.
Master-Slave Configuration
The document outlines the setup and operation of a master-slave system for electronic units. It emphasizes the importance of configuring slave units before the master to ensure proper bus initialization. Termination settings vary based on the unit's position in the bus, with specific settings for BIAS and TERM resistors.
Mixed Systems
Combining units of different power classes can lead to unexpected total power outputs. The master should be selected from the highest power-rated units to achieve the desired total power.
Configuring Master-Slave Operation
Configuration involves setting each unit to master or slave mode via the Settings menu. The master unit automatically initializes the system, and the process can be repeated if necessary.
Operating the Master-Slave System
Once configured, the master controls the system, and slaves cannot be manually controlled. The master displays total system values and can be remotely controlled. Alarms and events are managed centrally by the master.
Alarms and Problem Situations
Loss of connection or alarms trigger safety measures, including shutting down DC inputs. The system must be re-initialized to clear alarms.
Series Connection
Series connection of electronic loads is prohibited due to potential damage from asymmetrical voltage distribution.
SEMI F47 Compliance
The document details compliance with SEMI F47 standards, which require devices to withstand voltage sags. Activation of this feature reduces maximum power output and is subject to certain conditions.
Service and Maintenance
Regular maintenance is not required, but fan cleaning may be necessary. Battery replacement should be performed by qualified personnel.
Fault Finding and Repairs
Users are advised to contact the supplier for repairs. Firmware updates should be approached cautiously to avoid rendering the device inoperable.
Firmware Updates
Firmware updates can solve device problems or add new features, transferring full responsibility to the user. Changes in firmware can significantly affect device applications, so it is recommended to thoroughly review the firmware history. New features may require updated documentation, which might be delivered later.
Troubleshooting Device Problems
A potential hazard is connecting a voltage source with reversed polarity to the DC input, which can damage the internal power stage. The probability is low, but safety measures include attaching warning signs and using fuses with DC cables to prevent damage.
Contact and Support
Repairs are generally carried out by the manufacturer, and the device should be returned with a fault description and invoice copy if under warranty. Technical support is available via telephone or email. Contact details for EA Elektro-Automatik in Germany and the USA are provided for further assistance.