heinzinger ERS-BIC User manual

Betriebsanleitung
User Manual
Bidirectional Power Supply System
Heinzinger
®
ERS
-
BI
www.heinzinger.com

Originalanleitung für Gerät mit Typenschild: / Original instruction for device with type plate :
Erklärung Typenschild /
Type Plate Explanation
Type ERS Nominalspannung in V> - Nominalstrom in A> \ Nominalleis-
tung in kW>
ERS nominal voltage in V> - nominal current in A> \ nominal power
in kW>
Input Versorgungsspannung> Frequenzbereich> Stromaufnahme>
supply voltage> frequency range> current consumption>
Output Ausgangsspannung / Ausgangsstrom / Ausgangsleistung>
output voltage / output current / output power>
Options M = Modifikation
M = Modification
Partnumber Heinzinger Artikelnummer>
Heinzinger article number>
Serialnumber Geräteseriennummer>
S/N of device>
Heinzinger electronic GmbH
High Voltage - Smart Solutions
Anton-Jakob-Straße 4
83026 Rosenheim – GERMANY
Phone: [phone]
Fax: [phone]
[e-mail]
www.heinzinger.com
V2.1 07.06.2021

Manual ERS-BIC 160 kW V2.1
1
ontents
1. Basic Information .................................................................................................................................... 5
Scope of Delivery ..................................................................................................................... 5
Disclaimer .................................................................................................................................... 5
Copyright ................................................................................................................. 5
Liability, Warranty ................................................................................................ 5
Owner’s Responsibilities ................................................................................... 5
About this Manual ................................................................................................................... 5
Manual as Part of the Device .......................................................................... 5
Symbols in the Manual ....................................................................................... 6
Significance of the Manual ................................................................................................... 6
2. Basic Safety Instructions ...................................................................................................................... 7
At the Device .............................................................................................................................. 7
Requirements to Personnel ................................................................................................. 7
Safety Symbols on the Device ........................................................................................... 8
Range of Use and Operating Guide .................................................................................. 8
Intended Use ............................................................................................................................. 8
Residual Risks and Precautions ......................................................................................... 8
3. Technical Specification ......................................................................................................................... 9
Table 1 Dimension / Weight ................................................................................................. 9
Table 2 Mains Connection .................................................................................................... 9
Table 3 Output .......................................................................................................................... 9
Table 4 Display/Control ......................................................................................................... 9
Table 5 Interface ..................................................................................................................... 10
Table 6 Voltage Precision ................................................................................................... 10
Table 7 Current Precision .................................................................................................... 10
Table 8 Cooling ......................................................................................................................... 11
Table 9 Battery Models ......................................................................................................... 11
Table 10 Environmental Conditions ................................................................................. 11
Table 11 Standards ................................................................................................................... 11
4. Design And Function ............................................................................................................................ 12
Device Views ............................................................................................................................ 12
Block Diagram ........................................................................................................................... 14
Functional Description .......................................................................................................... 14
Single Channel Operation................................................................................. 15
Parallel Operation ................................................................................................ 16
Serial Operation .................................................................................................... 17
Output Characteristics of ERS-Systems ....................................................................... 18

2
Power Hyperbola ERS-BIC 1200-1200/160 2C ........................................... 18
Safety Concept......................................................................................................................... 19
Signal Lights (optional) ..................................................................................... 19
Insulation Monitoring (optional) .................................................................. 20
Channelstop/Performance Level C(optional) ......................................... 20
Channelstop/Performance Level D(optional) ......................................... 20
Quick Discharge(optional) ............................................................................... 20
5. Set up and Start up ............................................................................................................................... 21
General/Scope of Delivery ................................................................................................... 21
Unpacking the Unit ................................................................................................................. 21
Environmental Conditions ................................................................................................... 21
Ventilation ............................................................................................................. 22
Clearances .............................................................................................................. 22
Cooling System .................................................................................................... 23
Recommendations for the Coolant ............................................................. 23
Electromagnetic Compatibility ......................................................................................... 24
Assembly Instruction ........................................................................................................... 25
Mechanical Assembly ........................................................................................ 25
Installation of the Cooling System ............................................................. 27
Filling and Venting the Cooling Circuit ..................................................... 29
Electrical Assembly of the ERS ....................................................................................... 30
Connecting Power Circuits ............................................................................. 30
Connecting 24V Supply, Control Lines ...................................................... 32
Internal CAN-Bus ................................................................................................ 33
Internal Grounding ............................................................................................. 33
Start-up ...................................................................................................................................... 34
Special Safety Instructions for Initial Commissioning ........................ 34
Start-up After Storage ..................................................................................... 34
PEN Connection ................................................................................................... 34
Mains Connection................................................................................................ 34
Connection of External Control .................................................................... 35
Load- and Sense-Connection ........................................................................ 36
Protective Grounding Test ............................................................................. 38
High Voltage Test .............................................................................................. 39
Switching on Mains supply ............................................................................40
External Supply of the HTS ........................................................................... 42
6. Operating .................................................................................................................................................. 45
Special Safety Instructions for Operation ................................................................... 45

Manual ERS-BIC 160 kW V2.1
3
Switching the Unit On and Off ......................................................................................... 45
Operation and Display Elements ..................................................................................... 47
Device Operating Menus ..................................................................................................... 48
Main Menu .............................................................................................................. 48
Setup-Menu .......................................................................................................... 50
System-Info ........................................................................................................... 51
System-Info/Status ........................................................................................... 52
System-Info/Measurements .......................................................................... 53
FPGA-Diagnosis ................................................................................................... 54
DSP-Diagnosis ...................................................................................................... 55
Error History ......................................................................................................... 56
Unit Parameters .................................................................................................. 57
Channel-Parameter ............................................................................................ 58
Control-Parameters ........................................................................................... 60
Service-Parameters ............................................................................................ 61
Battery Models (optional) ................................................................................................... 61
Model 1 ..................................................................................................................... 61
Model 2 .................................................................................................................... 61
Model 3 .................................................................................................................... 61
Model 4 .................................................................................................................... 61
Cluster Operation (optional) .............................................................................................. 61
Description ............................................................................................................. 61
Parallel Cluster Operation .............................................................................. 62
Serial Cluster Operation................................................................................... 63
Establishing Cluster Operation:.................................................................... 64
Exiting Cluster Operation ............................................................................... 65
7. Interfaces .................................................................................................................................................. 66
Safety Loops ............................................................................................................................ 66
Interlock ................................................................................................................. 66
Channel Stop (optional)................................................................................... 67
Feedback Output Contactor (optional)..................................................... 67
CAN-Bus ..................................................................................................................................... 67
Gateway (optional) ............................................................................................................... 68
Updating the Firmware.................................................................................... 68
Configuration ........................................................................................................ 68
Pin Assignment ................................................................................................... 69
Sense-Connection .................................................................................................................. 69
8. Operating Errors And Troubleshooting ....................................................................................... 70

4
Special Safety Instructions for Troubleshooting ..................................................... 70
Integrated Fuses, Phase Monitoring (optional) ........................................................ 70
Temperature Monitoring ..................................................................................................... 70
Flow Rate Monitoring of Cooling Water ..................................................................................... 70
Monitoring Coolant Temperature ..................................................................................... 71
Warnings ..................................................................................................................................... 71
Error Messages ........................................................................................................................ 73
Troubleshooting Cluster Operation ............................................................................... 78
9. Care, Maintenance, Calibration ......................................................................................................... 79
Care and Cleaning .................................................................................................................. 79
Venting the Cooling Circuit ................................................................................................ 79
Service and Maintenance .................................................................................................... 79
Not Using the Device ............................................................................................................ 79
Calibration ................................................................................................................................. 79
Spare Parts .............................................................................................................................. 80
Service Address ..................................................................................................................... 80
Index ....................................................................................................................................................................... 81
Appendix .............................................................................................................................................................. 83
A. CAN-BUS Messages ............................................................................................................... 83
B. Digital Control Loop .............................................................................................................. 96
C. Electrochemical Potentials ................................................................................................ 99
D. Reference List Accessories ................................................................................................ 99
E. Declaration of Conformity ................................................................................................ 100

Manual ERS-BIC 160 kW V2.1
5
1. BASI INFORMATION
Scope of Delivery
 ERS general-purpose test bench energy system
 User Manual
 Accessory package (sealing tapes, cable clamps etc.)
Disclaimer
opyright
Reprinting, duplication or use of extracts of this operating manual for purposes other than those
intended is not permitted and may result in legal action if not observed.
Liability, Warranty
Heinzinger electronic GmbH shall not be held liable for damages resulting from improper use of the
products or from failure to observe the operating instructions as a whole or in part.
Heinzinger electronic GmbH provides a 2-year warranty for manufacturing and material defects effec-
tive from the date of delivery. The warranty requires the exclusive use of genuine Heinzinger acces-
sories such as connectors and cables. For details on the manufacturer's warranty, please see the terms
of the agreement.
Unauthorized conversions and modifications to the system, as well as the use of non-approved spare
parts, will void all liability and warranty on the part of the manufacturer!
Owner’s Responsibilities
The owner is responsible for ensuring that:
 The system is only used in accordance with its intended use
 The system is set up and installed as specified (see chapter 5, pp. 21),
 The system is only operated by trained technicians,
 All safety and operating instructions are observed. These are relevant for the safety of personnel
and the machine. Failure to comply may reduce performance, increase the device's susceptibility to
malfunction, obstruct acceptance or certification, or void the warranty.
About this Manual
Manual as Part of the Device
 This manual applies onyl to ERS BIC 1200-1200/160 (see Type plate, p. 0) and must be observed.
 The operating guide should be retained for the entire service life of the product and updated where
applicable.
 The operating guide must be passed on to the next owner or user of the product.

1.4 Significance of the Manual
6
Symbols in the Manual
In some work steps during commissioning or operation dangerous situations can occur and/or in-
creased caution is required. Within the manual such steps are highlighted by the following symbols.
DANGER
Failure to observe the safety instructions will probably result in serious, irreparable personal
injury or even death!
WARNING
Warns of situations in which failure to follow the safety instructions may result in serious
injury.
AUTION
Warns of situations in which personal injury may occur.
N O T I E
Draws your attention to information that must be observed in particular to prevent impairment and
damage to and by the device.
Significance of the Manual
Please note that:
 The operating guide is part of the product
 The operating guide should be retained for the entire service life of the product and updated where
applicable.
 The operating guide must be passed on to the next owner or user of the product.
 This is a standard manual for the Heinzinger ERS-BIC series. Your device may not be equipped with
all listed options. The technical specifications of your device may vary.
Chapters and sections dealing with optional functions of the device are marked with "Optional”.

Manual ERS-BIC 160 kW V2.1
7
2. BASI SAFETY INSTRU TIONS
DANGER
Risk of electrocution! During operation certain parts of the device and the connected load are
inevitably at dangerous voltages.
over all live parts!
 Always obey the five safety rules when connecting or disconnecting test equipment:
▬ Disconnect from mains
▬ Secure against reconnection
▬ Verify that there is no more dangerous voltage
▬ Carry out grounding and short circuiting
▬ Provide protection from adjacent live parts
At the Device
WARNING
For safety reasons, never open the device – including the door – during operation under any
circumstances. Any modification to the device will void the warranty.
WARNING
Due to charged capacitors, there may also be dangerous potential in the D link or in front of
the output relays shortly after switching off. Therefore, you have to wait at least 5 minutes
after switching off the ERS, before opening the cabinet doors.
Requirements to Personnel
The device is designed for commercial use. The personnel are therefore subject to the statutory ob-
ligations regarding workplace safety. In addition to the warning and safety instructions in this manual,
the safety, accident prevention and environmental protection regulations applicable to the field of
application must be observed. The persons operating the device have to:
 Inform about the applicable health and safety regulations
 Duly carry out the assigned responsibilities for the operation, maintenance and cleaning of the
device.
 Read and understand the operating instructions completely before starting work.
 Use the prescribed and recommended protective equipment.
 Comply with the applicable regulations for handling HV systems
Any transporting, installation and commissioning and maintenance work must be performed by qual-
ified technicians (follow IEC 364 or DIN VDE 0100 and/or national accident prevention regulations).

2.3 Safety Symbols on the Device
8
Safety Symbols on the Device
On the device there are safety symbols where applicable. They have to be observed.
RISK OF ELE TRI SHO K
There is a risk of shock from contacting electrically live parts in this labelled area.
ATTENTION
Please refer to the operating guide.
Range of Use and Operating Guide
The device is designed for use in laboratories and production applications. Personnel must follow the
instructions in this user manual. For this reason, the manual should be kept near the device at all
times.
Intended Use
Safety, reliability and performance can only be guaranteed if:
 The device is used for the intended purpose, namely component testing in test bench applications
 Extensions, conversions or repairs may only be carried out by persons authorized by the
manufacturer
 The electrical installations comply with the applicable safety regulations
 The installation, connection and operating conditions prescribed in these operating instructions are
observed
Residual Risks and Precautions
The ERS-series test bench energy system is delivered in perfect condition. Despite this there are risks
to health and life if:
 Generally accepted engineering practice is not observed,
 The device is operated in spite of a known defect,
 The connected application violates applicable electrical safety regulations,
 The device has been switched off, and there is dangerous voltage at the output due to external
and/ or internal residual charges,
 Any instructions in this operating guide are not being followed.

Manual ERS-BIC 160 kW V2.1
9
3. TE HNI AL SPE IFI ATION
Table 1 Dimension / Weight
Model series ERS BIC 1200-1200/160 2C
Width /mm 2400
Height /mm 1960
Depth /mm 800
Weight /kg 1500
Table 2 Mains onnection
Mains Voltage 3x400 VAC Δ ±10% 47…63 Hz 3P/N/PE
Current consumption 3 x 280 A
Mains fuse internally 300 A/Phase (Circuit breaker)
Mains fuse externally >300 A
Mains connection/phase 1 x eyelet (bolt, Ø 10 mm)
Table 3 Output
Output Voltage Vnom 600 V (1200 V)
Output current Inom ±600 A (±1200 A)
Discharge time (no load) 1 minute
Efficiency > 93%
Output polarity floating1
Output terminal Conductor rail, 4 x screwed connection, Ø 10 mm
Table 4 Display/ ontrol
Output parameters via touch screen
Configurations via touch screen (password protected)
Service parameters via touch screen (password protected)
Device ON Rotary Switch
1Optionally either the positive or negative side can be grounded.
⚠ Voltage to ground >500V possible!

3.5 Table 5 Interface
10
Table 5 Interface
Digital interface
[CAN-Bus]
Control of voltage, current and power
Monitoring of voltage, current power and device state
General control of device
Digital I/O Potential free contacts / user specific
Table 6 Voltage Precision
Setting range 0… UNOM2
Reproducibility ≤ 0.1% UNOM
Voltage ramp-up time
(at step change in set
value)
1 ms [resistive load]
Control time at step in
load (10% to 90%)
≤ 1 ms [resistive load]
Stability over an 8-hour
period (constant
conditions)
≤ 0.1% UNOM
Residual ripple ≤ 0.2% UNOM for f = 0 … 1 MHz
Table 7 urrent Precision
Setting range 0 A … INOM
Reproducibility ≤ 0.1% INOM
Current ramp-up time
(at step change in set
value)
1 ms [resistive load]
Stability over an 8-hour
period (constant
conditions)
≤ 0.1 % INOM
Temperature coefficient ≤ 0.01% INOM /K
Residual ripple ≤ 0.4 % INOM for f = 0 … 1 MHz
2 Reduced dynamics and current in regenerative operation 50V

Manual ERS-BIC 160 kW V2.1
11
Table 8 ooling
Coolant Water
Material heat sinks Aluminum
Supply temperature 18°C … 24°C
Operating pressure 2.5 … 5 bar
Pressure loss ca. 1.5 bar (higher at glycol content >10%)
Required flow rate 28 l/min
Cooling power 12 kW
Connection Ø 1“
Requirements on Coolant See Table 16, p. 23
Positioning of coolant
connection
See section 5.3.3, p. 23
Table 9 Battery Models
Range internal resistance 0.1 – 1 Ω [resolution 0.1 mΩ]
Battery model (optional) 3 standard battery models as RC network integrated.
Table 10 Environmental onditions
Operating temperature +5 … + 40°C
Humidity 15 … 70% (non condensing at 18°C)
Table 11 Standards
Protection class
according EN 60529
IP 22 (with installed base covering)
EMC EN 61000-6-2 (grade 3)
EN 61000-6-4 (grade 4)
Harmonic Distortion THDV = 1.7% (typical)
Noise emission Noise level (A) ≤ 64 dB

4.1 Device Views
12
4. DESIGN AND FUN TION
Device Views
Exterior view:
Output
Channel 1
Output
Channel 2 Mains switch
Touch display
Fig.
1
Exterior view ERS BIC

Manual ERS-BIC 160 kW V2.1
13
Inside view:
Mains connection
3p
PE/N
Coolant connec-
tion
Output Unit
Channel 2
Output Unit
Channel 1
Isolating transfor-
mer
Controlboard HTS
Fig.
2
Interior view ERS BIC

4.2 Block Diagram
14
Block Diagram
Functional Description
The test bench energy systems of the Heinzinger ERS-series are optimized for bidirectional Operation.
They can either operate as power supplies or sinks that can feed energy back into the grid. This means
that from a technical perspective the output and input of the unit can change. For the sake of clarity,
the manual will always refer to the grid side as input and the DC side as output.
The ERS is constituted from the following functional units.
 Potential separation:
The potential separation to the grid and between the two input channels is provided by an isolating
transformer with two isolated secondary coils.
 Active Front End:
Each of the two Active Front Ends (AFE) consists of a frequency converter operating at 4 kHz
switching frequency. These each generate an intermediate DC voltage circuit of approx. 715 V. While
the AFE supplies the DC intermediate circuit with energy during source operation of the ERS, it
feeds the energy absorbed at the output of the ERS back into the grid via the transformer during
sink operation.
 HTS:
A Multi-Parallel Converter (MPC) serves as a step-up/down converter (German: Hoch-/Tief-
setzsteller, HTS) in the output stage of the ERS. It consists of four IGBT modules, each forming a
synchronous converter. A following choke serves as energy storage. Each of these elements has
the ability to work either as a step-up converter or a step-down converter depending on the direc-
tion of current, enabling the bidirectional operation of the ERS. A synchronous control distributes
the current over the modules, which allows an increased overall performance. To control the set
values of voltage, current and power, the IGBTs are controlled by a control unit with a pulse-white-
modulated (PWM) signal. A choke and capacitors smooth the output current and voltage.
Mains 3P / 400 V~50 Hz
control
system communication GUI measurement
isolation
transformer
AFE
active front end
MPC
multi parallel converter
600 V
±600 A
600 V
±600 A
2 single
channels
=
=
=
=
~
=
~
=
Fig.
3
Block diagram ERS
-
BIC (Output voltage and current may vary)

Manual ERS-BIC 160 kW V2.1
15
Single hannel Operation
In single channel operation, two independent channels are available. The channels are electrically
separated from each other.
Below you will find an overview of the possible current combinations, depending on the device type.
Table 12 Specifications single channel mode
Device type 1200-1200/160
Voltage 2 channels, 600 V
Current 2 channels, 600 A each
Power 2 channels, 80 kW each
Fig.
4
Connecting an ERS BIC for Single Channel Operation
+
+
-
-
-
X11
-
X12
Connect sense for
Channel 2
Connect sense for
Channel 1
DC
-
Channel 2
DC
-
Channel 1
DUT 2
DUT 1
+
-
-
+

4.3 Functional Description
16
Parallel Operation
By operating the device in parallel mode the output current of the ERS can be doubled. For this the
two output units of the ERS are wired parallel and, in the menu “Unit Parameters” (see section 6.4.9,
p. 57), the channel wiring has to be set to “Parallel”.
For serial operation only one isolation monitor may be active.
Below you will find an overview of the possible current combinations, depending on the device type.
Table 13 Specifications parallel mode
Device type 1200-1200/160
Voltage 1 Channel 600 V
Current 1 Channel 1200 A
Power 1 Channel 160 kW
~
=
Mains 3P / 400 V~50 Hz
control
system communication GUI measurement
isolation
transformer
AFE
active front end
MPC
multi parallel converter
600 V
±1200 A
1 channel
~
=
=
=
=
=
Fig.
5
Block diagram of parallel wiring o
f the ERS output channels
Fig.
6
Connecting a ERS BIC for parallel operation
+
+
-
-
DUT 1
+
-
-
X11
-
X12
Connect sense for
Channel 2
Connect sense for
Channel 1
Connection of CH 1 (+) with CH 2 (+) and CH 1 (-) with
CH 2 (-) (connecting cables included in delivery)
DC
-
Channel 2
DC
-
Channel 1

Manual ERS-BIC 160 kW V2.1
17
Serial Operation
By operating the device in serial mode the output voltage of the ERS can be doubled. For this the
two output units of the ERS are connected in series using a copper bar and in the menu “Unit Param-
eters” (see section 6.4.9, p. 57) the channel wiring has to be set to “Serial”.
For serial operation only one isolation monitor may be active.
Below you will find an overview of the possible current combinations, depending on the device type.
Table 14 Specifications serial mode
Device Type 1200-1200/160
Voltage 1 Channel 1200 V
Current 1 Channel 600 A
Power 1 Channel 160 kW
Mains 3P / 400 V~50 Hz
control
system communication GUI measurement
isolation
transformer
AFE
active front end
MPC
multi parallel converter
1200 V
±600 A
1 channel
=
=
=
=
~
=
~
=
Fig.
8
Block diagram of
serial
wiring o
f the ERS output channels
Fig.
7
Connecting the ERS BIC for serial operation
+
+
-
-
DUT 1
+
-
-
X11
-
X12
Connect sense for
channel 2
Connect sense for
channel 1
Connect CH 1 (-
) and CH 2 (+) in series (bridge included in
delivery)
DC
-
Channel 2
DC-Channel 1

4.4 Output Characteristics of ERS-Systems
18
Output haracteristics of ERS-Systems
Power Hyperbola ERS-BI 1200-1200/160 2
Fig. 9 Power hyperbola ERS-BIC 1200-1200/160 2C
-1200,00
-1050,00
-900,00
-750,00
-600,00
-450,00
-300,00
-150,00
0,00
150,00
300,00
450,00
600,00
750,00
900,00
1050,00
1200,00
0 100 200 300 400 500 600 700 800 900 1000 1100 1200
CURRENT
IN A
VOLTAGE
IN V
single channel mode parallel serial
Fig.
10
Power hyperbola of two
ERS
-
BIC 1200
-
1200/16
0 2C
in cluster operation
-2400,00
-2100,00
-1800,00
-1500,00
-1200,00
-900,00
-600,00
-300,00
0,00
300,00
600,00
900,00
1200,00
1500,00
1800,00
2100,00
2400,00
0 100 200 300 400 500 600 700 800 900 1000 1100 1200
CURRENT
IN A
VOLTAGE
IN V
parallel serial