Bidirectional DC-DC Converter
Bidirectional DC-DC Converter
These modular DC-DC converters feature a user adjustable input/output on the low side, making them ideal for many applications.
|Power:||0 to 20kW||0 to 2MW This maximum is achieved by using units in master-slave.|
|Input:||735 to 765VDC||800 to 830VDC|
|Output:||0 to 58.5VDC||0 to 1500VDC This maximum is achieved by using units in master-slave.|
|Control:||Standard: Analogue, RS-232 | Options Available incl. CAN|
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The CON-DSS is modular bidirectional DC-DC Converter. This new integrated approach features high dynamics enabling the user to switch quickly between quadrants.
The low side of the converter features a user adjustable input/output, making it extremely versatile for a broad range of applications. A comprehensive software program is provided for operation over the serial or LAN interface.
- Stack Units up to 2MW in Master/Slave
- Series Operation up to 1500VDC
- GUI with Built-in Scope Function
- Adjustable Internal Resistance
- Optional Function Generator
- User Controllable Output
Up to 64 CON-DSS 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 test houses and research labs who regularly test different sized power devices. Individual modules can be used for the day to day testing of multiple small devices, then grouped together for larger projects.
Operating Ranges and Features
Internal Resistance Range
Each module is built with a user programmable internal resistance range as standard. This makes the power systems ideal for simulating the ouput of energy storage devices such as battery packs, fuel cell stacks and super capacitors. The exact range varies by module and can be viewed in the selection table. An extended programming range is available (option /IRXTS).
Sense plus terminals are built into the CON-DSS 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 CON-DSS output and sensing point is monitored. If a set limit is exceeded, the CON-DSS unit shuts off. This is particularly useful for applications with long cables often prone to unwanted voltage drops.
Versatile Limit Setting (VLS)
The VLS allows the CON-DSS's output relays to be activated automatically when specific output values are met, protecting the DUT 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.
Every module features constant current, constant voltage, constant power as standard. Adjustable internal resistance is also provided.
Interfaces and Control
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.
An optional CANmp high speed digital interface operating at 1kHz is particularly popular with automotive users. The interface gives users the capability to customise the CAN protocol. Up to 50 messages are user configurable. Messages can be sent cyclically or upon receipt of a sync or syncID signal.
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.
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.
Standard TopControl GUI
All CON-DSS units come with a simple and intuitive TopControl operating GUI as standard. Live values of the power system 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 test 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)
Complex DC waveforms can be implemented through an optional embedded function generator. The highly programmable nature of the function generator allows users to plot out exact waveforms. This is often advantageous when emulating a power device with a very specific behaviour profile. For example, when quality testing fuel cell powered equipment, the specific behaviour of a discharging fuel cell can be programmed and replicated.
As well as custom shapes, standard square, sawtooth and sine waveforms can be plotted against time. Voltage/current and voltage/power relationships can also be programmed where necessary. Parametric programming is possible, where instead of the time axis, an input variable VIN, IIN or PIN can be selected.
APPLICATION SPECIFIC GUIs
Battery Emulation (Option /BATSIM)
BatSim provides a convenient method for the CON-DSS to emulate different sized battery stacks. Nearly all relevant electrical characteristics are programmable, including the number of cells, energy capacity, cut off limits, chemistry type and nominal voltage.
Electric/Battery Drive Cycling (Option /BATCONTROL)
Drive cycle tests can be implemented using BatControl. Previous data obtained from a test track can be imported and recreated, allowing the CON-DSS to simulate a real world driving test inside a lab environment. Battery and capacitor charge/discharge profiles can also be implemented through the GUI.
Capacitor Simulation (Option /CAPSIM)
The bidirectional characteristics of a real capacitor stack can be emulated when CapSim is installed with CON-DSS modules. Number of cells in series/parallel, state of charge, cell cut off limits, dynamic capacitance and resistance are programmable.
Solar Array Simulation (Option /SAS)
SASControl software has all EN 50530 tests pre-installed. The GUI allows users to edit irradiance, temperature and amplitude values. Previous tests have been conducted using over 400,000 invividual data points, with more possible.
Safety and Protection
Integrated Safety Relay (Option /ISR)
For additional safety, a mechanical interlock is available for the input of the CON-DSS. 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 power system 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.
Reverse Polarity Protection (Option /RPP)
When researching energy storage devices, Reverse Polarity Protection (RPP) is recommended for devices without a pre-charge circuit. With the CON-DSS 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 /4111
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 CON-DSS 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 CON-DSS'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.
Form Factor and Enclosures
The standard 19" CON-DSS rackmounting modules can be treated to a laboratory rack or flight case integration. Common options include 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 programmable power system mounted into a flight case on castors is often advantageous, especially when several departments or test cells share the same equipment. Multiple 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.
The versatile programming capability of the CON-DSS ensures that it is popular across many research and development sectors. Common applications include battery/capacitor emulation, implementing drive cycles, fuel cell loading, testing flywheels, battery cycling, component lifetime testing, as well as the testing of inverters and DC-DC converters.
Cranking Curve Testing
Electrical components within a vehicle's subsystem must be able to withstand a wide range of input voltage surges and drops during a start-up. The CON-DSS can accurately recreate these conditions within a lab environment. This increases reproducibility and accuracy of results when compared to using real batteries.
Hard to replicate conditions such as voltage cranking during a cold start can be achieved. Voltage/current and voltage/power relationships can be programmed against time where necessary.
Powering Downhole Tools
Applications with long load lines often suffer from unintended voltage drops, such as downhole tools used in hydrocarbon exploration. The CON-DSS's sense plus allows voltage drops to be compensated for throughout the entire length of a load line. This feature is also ideal for powering subsea devices.
Voltage Drops and Interrupts
In electronic systems sudden voltage interruptions may cause unexpected behaviour. Supply line disturbances may have several causes, including an additional switch on of large capacitive loads parallel to the supply line or a short circuit caused by loads sharing the supply. The CON-DSS can generate many complex DC waveforms to test devices under realistic conditions to identify any potential issues.
|Max Power||Line Voltage||Source Voltage||Sink Voltage|
|CON-DSS 20-58||20kW||735 - 765VDC||0 - 58.5VDC||6 - 58.5VDC||Add|
|CON-DSS 20-65||20kW||800 - 830VDC||0 - 65VDC||6 - 65VDC||Add|
|CON-DSS 20-117||20kW||735 - 765VDC||0 - 117VDC||12 - 117VDC||Add|
|CON-DSS 20-130||20kW||800 - 830VDC||0 - 130VDC||12 - 130VDC||Add|
|CON-DSS 20-350||20kW||735 - 765VDC||0 - 350VDC||50 - 360VDC||Add|
|CON-DSS 20-400||20kW||800 - 830VDC||0 - 400VDC||50 - 400VDC||Add|
|CON-DSS 20-450||20kW||735 - 765VDC||0 - 450VDC||40 - 450VDC||Add|
|CON-DSS 20-500||20kW||800 - 830VDC||0 - 500VDC||40 - 500VDC||Add|
|CON-DSS 20-540||20kW||735 - 765VDC||0 - 540VDC||50 - 540VDC||Add|
|CON-DSS 20-600||20kW||800 - 830VDC||0 - 600VDC||50 - 600VDC||Add|
|CON-DSS 32-58||32kW||735 - 765VDC||0 - 58.5VDC||6 - 58.5VDC||Add|
|CON-DSS 32-65||32kW||800 - 830VDC||0 - 65VDC||6 - 65VDC||Add|
|CON-DSS 32-117||32kW||735 - 765VDC||0 - 117VDC||12 - 117VDC||Add|
|CON-DSS 32-130||32kW||800 - 830VDC||0 - 130VDC||12 - 130VDC||Add|
|CON-DSS 32-350||32kW||735 - 765VDC||0 - 350VDC||50 - 350VDC||Add|
|CON-DSS 32-400||32kW||800 - 830VDC||0 - 400VDC||50 - 400VDC||Add|
|CON-DSS 32-450||32kW||735 - 765VDC||0 - 450VDC||40 - 450VDC||Add|
|CON-DSS 32-500||32kW||800 - 830VDC||0 - 500VDC||40 - 500VDC||Add|
|CON-DSS 32-540||32kW||735 - 765VDC||0 - 540VDC||50 - 540VDC||Add|
|CON-DSS 32-600||32kW||800 - 830VDC||0 - 600VDC||50 - 600VDC||Add|
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