Datasheet

NHR 9200 Battery Module/PackTest Systemni.com

Table of Contents
03

NHR 9200 Battery Module/Pack Test SystemApplications
Best forKey Features
Physical and Safety

04

Battery Test Applications

04

Highly Flexible Tester-per-Channel Design

04

Recycle Discharge Power Back onto the AC Line04

Wide Operating Envelopes

05

Digital Measurements, Scope Display and Charting Capability Built-In

05

Sub-millisecond Current, Voltage and Mode Transitions

06

Programmable Bi-Directional Power

06

Multiple Layers of Safety

07

The Power of Choice: Multiple Control Options

07

Enerchron® Test Executive (Option Available)

07

Battery Emulation and Burn-In Applications

08

NHR 9200 Battery Module/Pack Test System Specifications

ni.comNHR 9200 Battery Module/Pack
Test SystemApplications

AEROSPACEELECTRICVEHICLESMICROGRIDENERGY
STORAGE

FUEL
CELLS

SOLAR PV

BEST FOR:
Regenerative Battery Pack Test System for EV, Solar PV, Aerospace, Energy Storage, and more.

KEY FEATURES:





Bi-Directional Source/Load and Battery Cycler
Modular and scalable power – 12 to 252kW at 40 or 120VHigh configuration flexibility up to 21 channels
Regenerative power provides high energy efficiency
Current, voltage and mode transitions <1 mSecBuilt-in digital measurements for charting
Touch panel, LabVIEW® and IVI drivers
Flexible, easy control and integration with H/W and S/WBattery Emulation ModeMultiple layers of safety

PHYSICAL AND SAFETY:
MODEL

9200-4904

9200-4912

PhysicalTest Channel Connectors

Buss Bars

Anderson EBC A32

Cabinet² Dim. (HxWxD)

72” x 28” x 31”/1829mm x 711mm x 787mm

72” x 56” x 31”/1829mm x 1422mm x 787mm

Cabinet Weight (3 Ch.)1475lbs/669kg

Input Power³ per Module

3 Ø, 50 - 60Hz, 200VAC/30A, 208VAC/29A, 220VAC/27A, 380VAC/16.5A or 480VAC/13A

Operating Temperature

0-35°C full power

SafetyIsolation UUT Input

600V UUT to chassis

Isolation AC Input

1000V AC to DC Output / 1000V AC Input
to chassis

Interlocks

External user input, emergency stop,and rear service door

Programmable Safety Limits

Over-Voltage (OV) / Under-Voltage (UV),
Over-Current (OC), Over-Power (OP)

Watchdog Timer

Continuously monitors control
communications

Internal Protection

Over/Under-Voltage, Over-Current, OverPower, Internal Over-Temperatureni.com

1000V UUT to chassis

NHR 9200 BATTERY MODULE PACK TEST SYSTEM03

Battery Test ApplicationsNHR’s Regenerative Battery Pack Test System (9200) is ideal for lab and production testing of battery modules and energy storage devices.
The 9200 includes expandable power ranges from 12kW up to 252 kW with 40 or 120V bi-directional DC power modules. This battery cycler
provides optimal configuration that enables companies the flexibility to expand power levels as needed. It addresses the evolving battery
test requirements for electric vehicles, renewable energy storage and critical power applications. NHR’s battery test systems are used asbattery cyclers, regenerative, bi-directional DC sources, regenerative DC loads, high power DC sources, or Battery/DC emulators.

Highly Flexible Tester-per-Channel Design
9200 Testers are configured with independent, 12kW DC DC power modules that can be dynamically programmed both within a cabinet
and from cabinet-to-cabinet to run in parallel or independently. This capability provides for simultaneous testing a number of smaller
batteries each with a different test plan, power level and start/stop times. Alternately, a higher power battery can be tested by connecting
the power modules in parallel. The simplified diagram to the left illustrates (Fig. 1) how these can be configured to run both in parallel andindependently at the same time. For a laboratory or production facility that has a wide mix of batteries to test, this configuration flexibility
provides optimizing tester usage at all times.

TOUCH
PANEL

4912
4904

REGEN.
LOAD/
SOURCE< > BATTERY 1
12kW
DISCHARGE~

MAINS
3ø

<>

REGEN.
LOAD/
SOURCEREGEN.
LOAD/
SOURCEVOLTAGELAN SWITCH< > BATTERY 224kWDISCHARGE

CURRENTFIGURE 1

FIGURE 2

Independent testing of 2 different battery types

Discharge Operating Envelope

Recycle Discharge Power Back onto the AC Line
Over 87% of the energy that ends up as waste heat during battery discharge can be saved by converting it back to electrical power thatprecisely matches the facility AC line. The savings attained can increase the ROI of the entire test system within a few years. Furtheradvantages include a cooler work environment, smaller air conditioning capacity, and elimination of elaborate water cooling systems. Inaddition, using regenerative power helps reduce your carbon footprint and support your company’s environmental sustainability efforts.

Wide Operating Envelopes
Battery cycling testers are best evaluated on operating power envelopes rather than simply maximum kilowatts. The reasoning here is thatusers often do not know what combination of voltage and current they will be required to test in the future. NI provides an exceptionally wide
operating envelope to ensure that future test requirements will be met (Fig. 2).

ni.comNHR 9200 BATTERY MODULE PACK TEST SYSTEM

04

Digital Measurements, Scope Display and Charting Capability Built-In
A vast amount of precision measurement information is provided by the high-speed digitization of analog measurement signals withineach power module. One example is the simultaneous measurements of voltage, current, amp-hours and watt-hours that are continuously
available. The extent of this measurement information minimizes the need for supplemental instruments added to the test system. Anotherbenefit is that waveforms can now be displayed in real-time much like an oscilloscope and also charted (Fig. 3). Reports can incorporatesuch waveforms to document how the battery-under-test behaved during certain transient conditions.

FIGURE 3
Chart Recorder

Sub-millisecond Current, Voltage and Mode Transitions

400.0

26.0
25.8
25.6
25.4
25.2
25.0
24.8
24.6
24.4
24.2
24.0

350.0
300.0
250.0
200.0
150.0

CURRENTVOLTAGE

9200 power modules are able to simulate demanding real-world transient conditions through hyper- fast, slew-rate-controlled settingsand Macros. Macros are mini-programs up to 1000 steps that for speed purposes will execute within the power module rather than PC. In
combination with the 1.2Ms/sec digitized waveform captures (Fig. 4), a unique fast transient simulation and resulting UUT waveform display/record is provided. Macros can be saved to a library and then called by the PC test program when needed.

100.0
50.0
25.0
00.02

0.04

0.06

0.08

0.10

0.12

0.135

TIME (SECONDS)FIGURE 4High Speed Waveform Set (Red) and Capture (Green)ni.comNHR 9200 BATTERY MODULE PACK TEST SYSTEM

05

Programmable Bi-Directional Power
Each test channel is an 8kW source, a 12kW sink and operates as a fully programmable power supply, load, or battery. All of these operating
modes support constant-voltage (CV), constant-current (CC), and constant-power (CP) regulation (Fig. 5). More than one regulation mode
may be enabled at the same time, creating standard charge profiles like CCCV and CPCV.
Series Resistance provides a programmable emulation of voltage effects caused by the resistances found in wire harnesses, protection
circuits, or batteries.

FIGURE 5Power Supply, Electronic Load, and Programmable Battery Modes

Multiple Layers of Safety
NI offers multiple layers of safety already designed into the system. In addition to safetycontactors, reverse polarity checkers and pre-charge circuits, we also have additional
layers of hardware and software protection. Each test channel provides programmablesafety limits (Fig. 6) to prevent damage that could occur caused by operator error,
programming errors, external or internal faults. When a safety limit is triggered, the test
channel opens its output contactors isolating the test channel from the battery-under-test
and prevents further operation until the test channel fault is cleared. These programmablesafety limits can be set through the Touch-Panel manual interface, programmaticallythrough LabVIEW, Enerchron® and other programming languages.
Each test channel also provides a separate interlock input that can be connected to an
external test fixture. The test channel will open its output contactors isolating it if theinterlock input is triggered. The user can also abort testing and disconnect the battery/
module through an emergency power-off switch on the front of the cabinet.

FIGURE 6
Safety Settingsni.comNHR 9200 BATTERY MODULE PACK TEST SYSTEM

06

The Power of Choice: Multiple Control Options
Each 9200 cabinet, which contains up to three 12kW power
modules, has a Touch-Panel that controls and displays voltage,current, power along with other settings, limits and test status (Fig.
7). This Touch-Panel provides the ability to create, run, monitor,
chart and report battery charge/discharge profiles without writing
any code. The Touch-Panel can be used to manually control theoperating modes or program a simple, time- based, test profilethat can be saved for repeated use.
Another control option is the Enerchron® Test Executive which
is best suited for running long-term tests and includes a datacollection option. NI Battery Test Systems are designed to easily
integrate with your existing assets or future test requirement setups.
The third option is where user can utilize their own PCs and test
software to communicate with the 9200 through its IVI drivers.
This works well in instances where the customer has alreadywritten test programs and doesn’t want to replicate all this work.

FIGURE 7
Three Channel Monitor Panel

Enerchron® Test Executive (Option Available)
Enerchron is a powerful but easy to use test executive created for battery testing to simplify and accelerate your test automation. It’s acomprehensive battery test environment that includes integration with H/W and S/W tools. Enerchron is your shortest path to market.
Enerchron breaks the mold of traditional battery cycling software through its unique variable-based formulas.

Key Features





Dramatically reduce software development and post- processing time
Streamline your battery test process and workflow
Increase productivity and eliminate errors and repeated tests
Reduce stress and testing difficulties Stay on schedule and budget
Get to market faster

Battery Emulation and Burn-In Applications
A Battery Emulation Mode provides testing of power electronic systems that use a real battery. In this Emulation Mode, the test channel willsource and sink current as needed to maintain voltage regulation. Having a programmable battery emulator provides a more consistenttesting capability for products such as chargers, regenerative braking systems, and on board DC/DC converters. NHR’s battery emulation
mode precisely matches real-world characteristics of batteries due to its minimal use of output capacitance unlike off-the-shelf BiDirectional DC sources.
Another key 9200 application is DC power supply burn-in and long-term reliability testing. This type of testing takes advantage of theregenerative power capability resulting in an increased ROI; energy savings; and a safer and cooler work environment.

ni.comNHR 9200 BATTERY MODULE PACK TEST SYSTEM

07

NHR 9200 Battery Module/Pack Test System Specifications
MODEL NUMBER

9200-4904

9200-4912

Functional Capability
Operating States

Charge (Source), Discharge (Load), Standby, Battery

Charge/Discharge Modes

Constant-Voltage(CV), Current (CC), Power (CP), Resistance (CR)Charging Envelope

0 - 40V, 8kW, 600A

0 - 120V, 8kW, 200A

Discharging Envelope

1 - 40V, 12kW, 600A

4 - 120V, 12kW, 200A

Slew Rate

0.011V/S - 40kV/S, 0.0165A - 600kA/S

0.033V/S - 120kV/S, 0.055A - 200kA/S

Current Change TimeLess than 5mS

Parallelability

Synchronous control for up to 12 channels (144kW)

Current Reverse TimeLess than 10mS

MacrosDevelopment Source

Touch-Panel, Import from Excel or User’s
System Controller

Minimum Time Delay

50uS

Maximum Steps

1000

Maximum Step Delay

1mS - 7 Days

ProgrammingRange

Accuracy¹

Res¹

Range

Accuracy¹

Res¹

Voltage

0-40V

0.025% + 0.025%

0.005%

0-120V

0.025% + 0.025%

0.005%

Current±600A

0.1% + 0.1%

0.005%±200A

0.1% + 0.1%

0.005%

Power+8/-12kW

0.12% + 0.12%

0.005%+8/-12kW

0.12% + 0.12%

0.005%

Resistance

0-34Ω

2%

0.005%

0-100Ω

2%

0.005%

Slew Rate
Voltage

0.011V/s – 80V/ms

0.033V/s – 240V/ms

Current

0.17A/s – 3000A/ms

0.055A/s – 1000V/ms

Resistance

0.01Ω/s – 34Ω/ms

0.028Ω/s – 100Ω/m

2W/s – 8kW/s

2W/s – 8kW/s

Power
Test Measurement (4-Wire)

Range

Accuracy¹

Res¹Range

Accuracy¹Res¹Voltage, DC Avg.

0-40V

0.025% + 0.025%

0.005%

0-120V

0.025% + 0.025%

0.005%

Current, DC Avg., Amp-Hr

0-600A

0.1% + 0.1%

0.005%

0-200A

0.1% + 0.1%

0.005%

Power, Ah, kWh±12kW

0.12% + 0.12%

0.005%±12kW

0.12% + 0.12%

0.005%

Time

1ms - 1Yr

0.1%

0.005%

1ms - 1Yr

0.1%

0.005%

Control
Local User Interface

Touch-Panel with graphic meters and controls plus Macro development/execution screens

Ext. System CommunicationLAN (Ethernet)

Analog Current Monitor

0 - +10V chrg/0 - -10V discharge

Drivers (Win XP or Win 7)

LabVIEW, IVI-COM, IVI-C

Analog Voltage Monitor

0 to +10V full scale voltage

Calibration

Semi-Automatic, closed cover with standard lab equipment

Specs apply after 30 min. warm-up. Refer to User’s Manual for additional product specs. 2 Standard cabinet contains 1, 2 or 3 Modules, 3 Input Voltage set at placement of order

ORDERING INFORMATIONTYPICAL CONFIGURATIONS

9200-4904-36

9200-4912-36-2

Test Channels³, Maximum Test Power

3 @ 12kW, 36kW

6 @ 12kW, 72kWPower Modules, Voltage, Max. Current

4904, 40V, 1800A

4904, 120V, 1200A

Cabinets, Space (WxD), Height

1, 28 x 31” or 711 x 787mm, 72” or 1829mm

2, 56 x 31” or 1422 x 787mm, 72” or 1829mm

Part Number Construction

9200-4912-36-2
4912 – Power Module, 36 – kW per cabinet (1 module=12kW, 2 modules=24kW, 3 modules=36kW), 2 – Cabinets©2023 NATIONAL INSTRUMENTS. ALL RIGHTS RESERVED. NATIONAL INSTRUMENTS, NI, AND NI.COM
ARE TRADEMARKS OF NATIONAL INSTRUMENTS CORPORATION. OTHER PRODUCT AND COMPANYNAMES LISTED ARE TRADEMARKS OR TRADE NAMES OF THEIR RESPECTIVE COMPANIES. 111523

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