Up to 64 BC-TC modules can be arranged in series, parallel or matrix array configurations. Each module is able to operate independently, so that systems can be reconfigured, expanded or broken up as needs dictate. Inbuilt system comms allow users to switch between various set-ups.

The modular approach is useful for companies who regularly need to charge different sized energy storage devices. Individual modules can be used for the charging of multiple small devices, then grouped together for larger storage systems. 

Configurations up to 2kV are possible using a centre tapped earth. Please contact us for more details.

Sense Compensation

Sense plus terminals are built into the BC-TC for the connection of sense wire which compensates for voltage drops in the load lines. This has a number of advantages over traditional sense. It is permitted to interrupt the load line during operation (voltage on). 

The maximum voltage drop compensation is adjustable. The voltage difference between BC-TC output and sensing point is monitored. If a set limit is exceeded, the BC-TC unit shuts off. This is particularly useful for applications with long cables often prone to unwanted voltage drops. 

Versatile Limit Setting (VLS)

Versatile Limit Setting Example"]The VLS allows the BC-TC's output relays to be activated automatically when specific output values are met, protecting the battery from any damaging charge conditions. Output voltage, current and power values which exceed or fall below a given limit or operating window can be programmed to trigger the relays. Active and inactive areas of operation are defined by a limit value, hysteresis value or a directional designator for the hysteresis.

Constant voltage, current and power operating modes are provided.

Power Factor Correction

BC-TC modules have a Power Factor Correction (PFC) circuit integrated into the input stage as standard. This enhances the overall efficiency of the modules across the output power range when compared to a unit that does not have PFC. The current harmonics of the BC-TC meet the EN61000-12 regulations for a mains SCE >= 120 value. In practice, this means a significant lower peak current value, a decrease of RMS value of the phase current and less perturbations of other equipment running on the same grid.

The inbuilt PFC is also ideal for operating the charger from a generator. Generators tend to be sensitive against high current peaks, and their voltage controllers may have some stability problems with non-sinusoidal load currents. The PFC feature forms a lowpass filter and therefore, both the repetitive current peaks and also the harmonic content is enhanced. This will help the generator system maintain a stable and reliable output.

Wide Input Range (Option /WR)

A 360-528VAC wide input range is possible for selected models. This is ideal for systems which may regularly travel to different countries, such as when using the BC-TC for a global motorsports series.

A variety of control methods are available. As standard each module is built with isolated analogue and RS-232 interfaces. Front panel control and display along with IEEE 488.2 (GPIB), USB, RS-422 and Ethernet interfaces are optionally available.

RS-232 Interface

The RS-232 interface is configured as a Sub-D 9 pin connector (female) and is located on the front panel. This interface can be optionally moved to the rear panel. The graphical user interface, TopControl is operated via RS-232. The software runs on Windows and allows the user to control, measure and configure the power system.

Analogue Interface

The control port is configured as a Sub-D 25 female connector and is located on the rear panel. It allows output values to be set and read proportionally using a 0-10VDC analogue signal. Digital inputs and outputs enable various functions such as the interlock and output ON/OFF. A 10VDC reference is provided for analogue control. Digital functions are switched via a high/low signal. A 24VDC supply voltage is provided for these functions.

CANmp Interface (Option /CANMP)

CANmp is a high speed digital interface operating at 1kHz. The interface gives users the capability to customise the CAN protocol. Up to 50 messages are user configurable. Along with the CAN ID the data length code, byte order, start bit, data type and signal factor can be adjusted by the user. A DBC file is provided and messages can be easily configured within the standard windows software. Messages can be sent cyclically or upon receipt of a sync or syncID signal.

Standard TopControl GUI

All BC-TC units come with a simple and intuitive TopControl operating GUI as standard. Live values of the battery charger are displayed graphically along with any warning and error messages. The software provides a variety of second level parameters, ideal for users who like to optimise their charging processes. In standard user mode the operator can remotely program set values, enable voltage output as well as the ability to anlyse different variables including set and actual values via the integrated scope.

The scope function can simultaneously record up to 8 system variables. Recording can be started manually or by a defined trigger event from any variable of the system. All actual and set values (currents/voltages/power/internal resistance) can be recorded. Other recordable items include system temperatures, intermediate DC circuit, low voltage auxiliary power supplies, error related values and variables from the controller section. 

A password protected section is available to the advanced user and service technician. In addition to the standard functions the authorised user is able to:

• Program linear ramp functions at start up and set value steps during operation
• Configure multi-unit operation
• Program the PID controller parameters
• Program the unit's limit values
• Calibrate and adjust values as necessary
• Update the firmware

Function Generator (Option /TFE)

An embedded function generator allows exact DC waveforms to be implemented for pulsed charging. The tool allows users to deliver short burst of highly concentrated energy at user defined time intervals to the energy storage device. Pulse charging is thought to improve battery discharge capacity and help facilitate longer cycle life. Some studies have shown that pulse charging is also helpful in eliminating concentration polarisation. 

Voltage/current and voltage/power relationships can also be programmed where necessary. This allows specific charge profiles to be plotted out for sensitive energy storage devices. Parametric programming is possible, where instead of the time axis, an input variable V_IN, I_IN or P_IN can be selected.

Advanced Battery Charging (Option /BATCONTROL)

BatControl can implement specific charge profiles to your energy storage device. The GUI also allows a variety of performance issues to be investigated including lifetime tests, system degradation analysis, shot and burst overload tests among others.

Integrated Safety Relay (Option /ISR)

For additional safety, a mechanical interlock is available for the mains input of the BC-TC. The integrated safety relay provides shutdown safety according to EN 13849-1 category 2/3. The ISR is connected to the external safety switch loop. If the external loop is opened, the DC-output of the charger is powered down immediately.

Protection Against Output Bars (Option /PACOB)

A specially produced cover is available which provides protection against accidental contact of AC and DC current bars. 

Automatic Voltage Matching with RPP (Option /RPP)

An external arrangement providing Reverse Polarity Protection (RPP) is recommended for energy storage devices without an automatic voltage matching circuit. With the BC-TC energised but output off, the RPP senses the voltage of the connected energy storage device. A contactor is closed after matching the voltage, to prevent large inrush currents and arcing on start up.

Ruggedisation Specification (Option /4062)

Ruggedisation of units to military standards is possible. Many previous modifications have been carried out for shipborne and vehicle projects. Our design team can work with you to meet specific requirements and standards. This ensures suitability in harsh conditions by providing protection against shock, vibration and humidity.

One previous modification included modifying a BC-TC system to withstand up to 30g of mechanical shock across X, Y and Z axes. The PSU also could operate from temperatures as low as -10°C all the way up to 55°C. For more information about what ruggedisations have previously been achieved, please contact ETPS.

Remote Control Unit (Option /RCU)

The RCU is an external control unit for controlling multi-module systems, which reduces response times when implementing complex changes. The RCU is available as either a desktop unit or a 19" rackmounting module, with or without an emergency stop.

Liquid Cooling (Option /LCAL)

Liquid cooling of the BC-TC's power stage is available for units which may be subject to naturally hot or uncontrolled environments. This enables operation up to 45°C with no performance derating.

Standard 19" rackmounting modules can be treated to a laboratory rack or flight case integration. Common options include mains cables, passive indication of any residual DC voltage, isolation monitoring of DC cables and a panel mounted emergency stop. Switch panels with removable DC links can be fitted for modular systems. This simplifies the reconfiguration between series, parallel or independent use. Simple wheeled cabinets are also available. 

Having a high power battery charger mounted into a flight case on castors is often advantageous, especially when equipment is needed on multiple sites. Several power systems can be fitted into the same flight case. Door hangers are fitted for convenience. Existing ETPS systems can also be retrospectively integrated into new flight cases where requested.

If your test requirement is short term, we have a wide range of rental DC sources which can be used as battery chargers.