NI NHR 4808-16 User manual

Enabling Electrification
Your Partner in Test
Document Part Number 327570A-01
NHR 4808-16
DC Power Module
User Manual
September 2023

NHR 4808-16 DC Power Module User Manual
© National Instruments Corporation 1
Contents
Introduction ..............................................................................................................................3
NHR 4808-16 DC Power Module Overview...........................................................................3
Icons ......................................................................................................................................3
Warranty................................................................................................................................4
Intended Usage.....................................................................................................................4
Safety Notice – Module Does Not Have User Serviceable Parts Inside ..............................4
General Safety Notices .........................................................................................................5
Glossary................................................................................................................................. 5
What is the 4808-16 DC Power Module?...................................................................................6
Key Features of the 4808-16 DC Power Module...................................................................6
4808-16 Module Views ..........................................................................................................7
System Diagram and Theory of Operation ............................................................................10
Additional Features 4808-16 Module...................................................................................... 11
Emergency Stop Input........................................................................................................ 11
User Interlock Input............................................................................................................ 11
Programmable Trip Limits ................................................................................................. 11
Internal Monitoring.............................................................................................................11
4808-16 Module Specifications............................................................................................... 12
Electrical Output Specifications ........................................................................................12
Measurement Specifications..............................................................................................12
Trip, Mechanical, and Facility Specifications....................................................................13
Digital Interface .................................................................................................................. 14
Installing the 4808-16 Module ................................................................................................ 14
Unpacking the 4808-16 Module .........................................................................................14
Moving and Positioning the 4808 Module ......................................................................... 14
Location Mounting and Cooling.........................................................................................14
Recommended Service Feed, Breaker Size, and Facility Wiring ...................................... 15
Installing AC Facility Power................................................................................................15
Installing UUT Connections................................................................................................18
Installing LAN Connections ................................................................................................19
E-STOP and Interlock Wiring..............................................................................................19
Terminating the Parallel Interface..................................................................................... 20
Turn On and Turn Off Checklist .............................................................................................. 20
Powering Up the System....................................................................................................20
Powering Off the System.................................................................................................... 21
System Interfaces and Indicators...........................................................................................21

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Touch Panel Interface ........................................................................................................21
Output and System Status Indicators ...............................................................................21
Encoder Knob and Buttons ................................................................................................22
USB Port and Power Switch............................................................................................... 22
Analog IO Interface ............................................................................................................. 22
Digital IO Interface..............................................................................................................23
Paralleling IO Interface.......................................................................................................23
Air Intake.............................................................................................................................24
Touch Panel Control ...............................................................................................................25
Selecting An Operating Mode............................................................................................. 25
Wizard-Based Entry Screens ..............................................................................................26
Navigating the Wizard - On Screen Controls .....................................................................26
Example Usage – Standard Mode ...................................................................................... 26
Using the Encoder Knob and Buttons while Operating.................................................... 28
Settings Options .................................................................................................................29
External Software Control ......................................................................................................30
Maintenance............................................................................................................................ 30
Cleaning the 4808 ...............................................................................................................30
Cleaning the Module........................................................................................................... 30
Cleaning the Touch Panel Interface...................................................................................31
Calibration ..........................................................................................................................31
SCPI Programmers Reference ................................................................................................31
NI Services ...............................................................................................................................32

NHR 4808-16 DC Power Module User Manual
© National Instruments Corporation 3
Introduction
The 4808-16 DC power module is the industry leading solution for bi-directional power
testing and verification of battery modules and related systems. The 4808-16 has a built-in
contactor isolation (both facility and UUT), pre-charge, reverse polarity detection and
similar features not commonly found in commercial bi-directional power supply devices.
This manual applies to all hardware versions of the 4808-16 modules.
NHR 4808-16 DC Power Module Overview
The 4808-16 DC power module is a standalone device and consists of the following
features:
•A touch screen for manual operation
•A connection interface for an Emergency Off button
•A connection interface digital status and control
•A logic power supply for internal interlocks
•A communications port (LAN)
•Safety enclosure panels with strain reliefs for use outside of cabinets, providing:
oFacility and UUT connections (rear of unit)
oMain facility power breaker (lower rear of unit)
•Rack mountable option
•Cable accessories for wire connections, including:
oA paralleling control connection (for system expansion)
oAn input/ground connection
Icons
Refer to the following descriptions if one of these icons is marked on your product or used
in this guide.
NOTICE
Take precautions to avoid data loss, loss of signal integrity, degradation of
performance, or damage to the product.
CAUTION
Take precautions to avoid injury. Consult the product documentation for
cautionary statements when you see this icon printed on the product. Cautionary
statements are localized into French for compliance with Canadian requirements.
CAUTION: POSSIBILITY OF ELECTRIC SHOCK
Take precautions to avoid electrical shock.
PROTECTIVE CONDUCTOR TERMINAL (PE)

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Indicates a terminal that connects to accessible dead metal parts of the product.
Connect the PE terminal(s) to an earth ground system (protective conductor) for
safety.
Warranty
Warranty details, limitations, and other information are included within the general terms
and conditions provided with the product quote.
Intended Usage
The 4808-16 module is intended for use in temperature controlled, indoor laboratory
environments only. The product provides DC voltage control and measurement which are
primarily used in the evaluation, performance, functional, and endurance testing of
battery and supporting or similar DC products. Usage for other purposes outside of this
manual’s description which result in product failure may be considered as customer
abuse and therefore may not be covered under the warranty.
NOTICE
Operators of the equipment should be trained in safety procedures. Any damage
caused by non-intended usage is not covered under warranty.
Safety Notice – Module Does Not Have User
Serviceable Parts Inside
The 4808-16 module series contains no internally replaceable or serviceable parts.
CAUTION: POSSIBILITY OF ELECTRIC SHOCK
Internal adjustment or component replacement is only permitted by qualified NH
Research personnel. No internal adjustments or system access should be
attempted by non-NH Research personnel.
ATTENTION : POSSIBILITÉ DE CHOC ÉLECTRIQUE
Seul le personnel qualifié de NH Research peut effectuer un ajustement interne ou
le remplacement d'un composant. Aucun ajustement interne ou accès au système
ne doit être effectué par du personnel autre que NH Research.
CAUTION: POSSIBILITY OF ELECTRIC SHOCK
Remove all external voltage sources and allow a minimum of five (5) minutes for
internal capacitors to discharge before accessing terminals or servicing the
equipment.
ATTENTION : POSSIBILITÉ DE CHOC ÉLECTRIQUE
Retirer toutes les sources de tension externes et attendre au moins cinq (5)
minutes pour que les condensateurs internes se déchargent avant d'accéder aux
terminaux ou d'effectuer l'entretien de l'équipement.

NHR 4808-16 DC Power Module User Manual
© National Instruments Corporation 5
General Safety Notices
CAUTION: POSSIBILITY OF ELECTRIC SHOCK
Avoid accessing the internal components. Only a qualified electrician or trained
personnel should remove the facility service panel and output access cover. All
connections should be carried out under 0 V conditions. All connections should be
properly terminated leaving no exposed wires which could present an electrical
shock hazard. Always assume the output has potential even when OFF.
ATTENTION : POSSIBILITÉ DE CHOC ÉLECTRIQUE
Éviter d'accéder aux composants internes. Seul un électricien qualifié ou du
personnel formé peut retirer le panneau de service de l'installation et le capot
d'accès à la sortie. Toutes les connexions doivent être effectuées dans des
conditions de 0 V. Toutes les connexions doivent être correctement terminées en
ne laissant aucun fil exposé qui pourrait présenter un risque de choc électrique.
Toujours supposer que la sortie a un potentiel même si elle est sur OFF.
NOTICE
Observe all instructions and cautions in the user documentation. Using the
product in a manner not specified can damage the product and compromise the
built-in safety protection. Contact NI to report possible damage and to arrange for
repair.
NOTICE
Installation, maintenance, and servicing is only to be performed by qualified
skilled or authorized personnel. Use and operation of systems is only to be
performed by trained personnel. Systems must only be used in restricted access
locations and not accessible by ordinary persons.
Glossary
The following general terms are used throughout this document.
•Auxiliary (Module) or Auxiliary (Power Module)—An auxiliary module supplements
the power of a primary module when directed by the primary module. When
configured as an Auxiliary, it does not function independently of the primary as the
output channel is controlled by a master module.
•Battery Modules—Battery modules refer to a specific type of UUT and are a form of
battery assembly consisting of more than one cell and operating below a maximum
voltage of 80 V.
•Channel—A channel is comprised of a master output and the corresponding
auxiliary output. Each channel may be configured for DC operation as well as be
expanded by configuring and connecting an auxiliary module to produce a single
larger channel.
•Input—A generic term applied to the connection from the facility to the 4808. The
term Input does not imply the direction of power flow.

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•Module or Power Module—The generic name for one chassis as either standalone or
existing within the 4808 system. There are two primary module versions including a
“Primary” and an “Auxiliary”.
•Output—A generic term applied to the connection from the 4808 to the UUT. The
term Output does not imply the direction of power flow.
•Primary Module or Primary (Power Module)—A primary module contains the control
and communications hardware and the ability to instruct, command, and control
one or more auxiliary modules. Expand the current and power of a primary module
by connecting a compatible, properly configured auxiliary module.
•Unit-Under-Test (UUT)—The device being tested.
The following units apply to this document unless otherwise noted.
•Angles, degrees (°)
•Apparent power, Volt-Amperes (VA)
•Crest Factor—Calculated as the ratio of Current(AC-PEAK) to Current(AC–RMS).
•Current(AC), Amperes (ARMS)—Calculated as RMS across one cycle.
•Current(AC-PEAK), Amperes (APEAK)— Maximum instantaneous current value.
•Current(DC), Amperes (ADC)— Calculated as the average current.
•Energy, Ampere-Hours (Ah), Kilowatt-Hours (kWh)
•Frequency, Hertz (Hz)
•Power Factor—Ratio of True Power to Apparent Power.
•Resistance, Ohms (Ω)
•Time, seconds (s)
•True Power, Watts (W)
•Voltage(AC), Volts (VRMS) or VAC—Calculated as RMS across one cycle.
•Voltage(DC), Volts (VDC) or VDC—Calculated as the average voltage.
•Voltage(PEAK), Volts (VPEAK)—Maximum instantaneous voltage value observed.
•Voltage(PEAK-PEAK)—Maximum to minimum instantaneous voltage value observed.
What is the 4808-16 DC Power Module?
The 4808-16 DC power module is a regenerative, bi-directional, industry leading solution
for testing and verification of low voltage-high current battery modules, battery systems,
and related low-voltage high-current DC applications or support devices.
Key Features of the 4808-16 DC Power Module
•Built-in contactors to isolate the UUT when turned off
•Built-in automatic pre-charge and reverse polarity protection preventing high
current transitions from Off

NHR 4808-16 DC Power Module User Manual
© National Instruments Corporation 7
•Optimized for low-voltage (< 80 VDC) Power Hardware in the Loop (PHIL) applications
•Expandable voltage and current by paralleling a like module
oSame unit can be configured as the primary module or auxiliary unit
oField expandable to allow for future increased power demands
•Includes additional operating modes including uni-directional source, load, bi-
directional source/load and external control options for PHIL
NOTE
•PHIL, bi-directional, non-linear source/load (XY), and AC on DC operating
modes is limited to parallel groups of no more than 10 modules.
4808-16 Module Views
NOTICE
Avoid placing liquids near the front of the system. Accidental spills may draw into
the air intake resulting in damage to the 4808-16 power modules.
CAUTION: POSSIBILITY OF ELECTRIC SHOCK
Never insert metal objects or probes. Never allow metal fragments to be drawn
into the module openings. There are no user-serviceable parts behind the safety
cover.
ATTENTION : POSSIBILITÉ DE CHOC ÉLECTRIQUE
Ne jamais insérer d'objets métalliques ou de sondes. Ne jamais laisser de
fragment métallique entrer dans les ouvertures du module. Il n'y a pas de pièces
réparables par l'utilisateur derrière le cache de sécurité.
NOTE
NH Research recommends placing the 4808-16 module on a hard surface such as
concrete or a load bearing table with a minimum of 24 in. of unrestricted air space
to the front of each 4808-16 module in use and 30 in. air space to the rear.

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Figure 1: NHR 4808-16 Module – Front Exterior View
1. Touch Screen Display
2. Power Switch
3. USB Port for Touch Screen
4. Status Indicators
5. Encoder Wheel
6. Option Select Buttons
7. Air Intake
Figure 2: NHR 4808-16 Module – Rear Safety Enclosure Front Exterior View
1. Digital I/O Interface
2. UUT Connections
3. Main System Breaker
4. Air Exhaust
5. Cable Strain Reliefs
6. Paralleling Connections
7. Safety Enclosure Rear Panel Screws x10
DISCHARGECHARGEENABLED E-S TOP DSP S TA TU S LA N
O
21
ENCODER
1
7 7
2 3 4 5 6
A I N 1
G ND
A I N 2
VM O N
G ND
CM O N
DI N1
DI N2
DI N3
DI N4
G ND
5V
DO UT1
DO UT4
DO UT3
DO UT4
G ND
1 ESTO P
2 TI E 1- 2
3 DI SABL E
4 TI E 3- 4
PARALL EL I N
PARALL EL O UT
CAN/L AN 80VDC 3P+PE, 3PH, 30A, 50/60HZ
UUT UUT
80VDC 400A80VDC 400A
INPUT/GN D
380 - 480VAC
VO L TAG E SEN SE
I
O
1
6
7
5
4 4 4
444
3
55
55 2 2

NHR 4808-16 DC Power Module User Manual
© National Instruments Corporation 9
Figure 3: NHR 4808-16 Module – Rear Safety Enclosure Left-Side Front Exterior View
1. Top Panel of the Safety Enclosure
2. Top Panel Screws x11 (2 on right-side)
3. Rear Panel of the Safety Enclosure
Figure 4: NHR 4808-16 Module – Rear Safety Enclosure Interior View
1. Digital I/O Interface
2. CAN Interface
3. Sense Leads Connection
4. Facility Input Connection
5. Safety Ground Connection
6. UUT Power Connections
7. Ethernet (LAN) Connection
8. Paralleling Connections
2
2
3
1
3
A I N 1
G ND
A I N 2
VM O N
G ND
CM O N
DI N1
DI N2
DI N3
DI N4
G ND
5V
DO UT1
DO UT4
DO UT3
DO UT4
G ND
1 ESTO P
2 TI E 1- 2
3 DI SABL E
4 TI E 3- 4
PARALL EL I N
PARALL EL O UT
C AN
A B C
INPUT
3P+PE, 3PH
380 - 480VAC
30A, 50/60HZ
VO L TAG E SEN SE 80VD C
L AN
1
8
2 7 456
UUT
400A
80VDC 80V DC
400A
6
UUT
400A
80VDC 80V DC
400A