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Battery Cyclers and DC Testing

A comprehensive testing solution that performs

For more than four decades, Unico has been providing innovative DC power solutions for industry. We pioneered the first high-power electronic DC servo drives back in 1967. From the earliest stages of automotive HEV development, Unico has supplied DC power solutions for battery simulation. With the 2460, we introduce a system engineered specifically for battery cycling and DC testing.

The Unico 2460 battery cycling and DC testing system combines the 2460 family of dual-output DC power supplies with software specifically tailored for testing HEV battery packs, ultra- and supercapacitor packs, fuel cells, power electronic converters, and other devices.

Control Precision and Flexibility

The 2460 system is highly configurable and provides the flexibility and performance to accommodate even the most demanding testing applications.

Control Modes

The 2460 can precisely regulate key electrical parameters such as current, power, voltage, and simulated load resistance.

Seamless Mode Switching

On-the-fly toggling between control modes facilitates handling changing parameter constraints.

High-Frequency Update Rates

Typical update rates from 1 kHz (1.0 ms) to 10 kHz (0.1 ms) allow digital control loops to accurately track constant, ramping, or otherwise varying commanded target levels.

User Programmable

Users are provided several options for programming test cycles and load profiles that suit their unique application requirements.

UEdit® Tools

The optional UEdit® tool suite provides embedded programming, data logging, and chart recording capabilities. Ladder and function-block editors define such test features as: • Control mode selection (current, power, voltage, or resistance) • Parameter levels • Protection limits • Ramp rates • Delay and dwell times • Cycle repeat counts

PC Controller

A fully featured PC controller option is available with the user programming capabilities of widely recognized software packages such as Simulink and LabView.

Preprogrammed

Rather than program their own test profiles, users can instead select from and execute existing test programs previously developed by Unico. Data logging and test report generation can also be provided. Available test programs, which are part of the LabView test suite, include: 
• Constant current discharge cycling 
• Constant and peak power testing 
• Variable-power testing 
• Federal Urban Driving Schedule (FUDS) and similar test regimes 
• Dynamic stress test (DST) 
• Partial discharge testing 
• Hill climb testing 
• Thermal performance testing 
• Fast charge testing
• Life cycle testing

High-Speed Link

A high-speed communications interface is optionally available to accept commands from existing customer controllers that are used to generate test profiles. Wired and fiber-optic options are available. Supported protocols include: 
• CANbus
• LonWorks 
• ControlNet
• Modbus Plus 
• DeviceNet
• Modbus TCP 
• EtherCat
• Profibus 
• Ethernet I/P 
• ProfiNet 
• Interbus S 
• USB

Protection

The 2460 system incorporates features that protect test articles from overstressing, including:
• Reverse voltage clamp
• Programmable current, voltage, and power overstress protection
• Voltage equalization circuit to limit inrush currents on power-up
• Output filters protect from potentially harmful ripple voltage and current
• Optional user-defined alarm thresholds including temperature and cell voltage monitoring

Additional Options

• Battery simulation
• Series/parallel operation
• Line regeneration
• Common bus energy sharing
• Arc flash compliant data port

Features

Specifications

Input

 

Voltage

200 to 690 V AC, three-phase

Frequency

50 / 60 Hz

Power Factor

> 99%

Total Harmonic Distortion (THD)

< 5%

Isolation Transformer

Yes

Output

 

Maximum Voltage

350, 700, 900, or 1000 V DC1

Minimum Voltage

1% of maximum, typical

Current and Power

Refer to table below

Voltage Ripple

< 0.1 V DC, typical

Current Ripple

< 0.1 A DC, typical

Voltage Step Response

< 10 ms

Current Step Response

< 1 ms

Protection

Extensive electronic protective and diagnostic features are included

Packaging

 

Standard Enclosure

NEMA 1 (IP20) or NEMA 12 (IP55)

Standard Cooling

Air

Optional Cooling

Water/glycol

Standards

 

Available Approvals

UL, cUL, CE, IEEE-519

Selected Ratings

Output1         Rating at Each Output2  Combined Output Rating3

V DCmaximum

A DCcontinuous

kWcontinuous

A DCcontinuous

kWcontinuous

350

250

75

500

150

350

385

116

770

231

350

405

122

810

243

350

565

170

1,130

339

350

630

189

1,260

378

700

210

126

420

252

700

315

189

630

378

700

490

294

980

588

900

279

212

558

424

900

355

270

710

540

900

434

330

868

660

1,000

234

198

468

395

1,000

340

287

680

575

1,000

364

308

728

615

Continuous Ratings

Continuous ratings assume 120% overload capability for one minute.

Rating Extensions

The table above illustrates a subset of available ratings. Unico’s system construction allows considerable flexibility to achieve either higher or lower ratings than shown. Contact Unico for more options.
1  Some models can be connected in series to achieve approximately double the standard voltage rating.
2  Other current and power ratings are available.
3  Multiple units can be connected in parallel to achieve a proportional increase in continuous currents and powers.