Electric test system

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Product
DC Power and Energy Absorber Test System (Regenerative Sponge) for testing regenerative loads and DC power applications.

Description
Integrated test rack combining DC power supplies and a regenerative energy absorber rated 400 VDC at ±150 A to support up to 60 kW peak power. Designed for lab and production test of actuators, motors and regenerative systems with local and remote control options.

Overview
The system comprises DC power supplies, AC distribution and interlock, an energy absorber control chassis and an absorber load resistor chassis. The absorber chassis contains a blocking diode to prevent regenerative current returning through the power supplies and provides discrete system-level current readback and control.

DC Power Supplies

• Two supply types, each 0–400 VDC at 75 A.
• SGI: Master supply with GPIB (IEEE-488) programming interface and local front-panel control.
• SGA: Slave supply operating as a voltage-controlled current source.
• Master/Slave configuration delivers up to 400 V at 150 A (60 kW) with control via the Master (local or GPIB/SCPI).
• Voltage and current readback available; SGI current readback reports combined output.
• Regenerative current routed to the absorber chassis via blocking diode; supply internal regen path disabled.

Energy Absorber Load Chassis
Resistive regenerative load assembled from high-power resistors in series/parallel banks yielding approximately 1.5 Ω total resistance, rated for 30 kW continuous and 60 kW peak.

Energy Absorber Control Chassis
Contains IGBT and SCR clamps, GPIB programmer, measurement and drive circuits, and high-current bus capacitors for energy storage and slew-rate control. A differential amplifier and blocking diode detect and regulate regen current; when bus voltage exceeds thresholds the absorber IGBT connects the load to discharge the bus and maintain voltage with ~5 V peak-to-peak ripple. Front-panel status LEDs, OVP detection for secondary SCR, AC contactor control and 0–10 V analog outputs for voltage and current monitoring are provided. Internal GPIB provides voltage/current monitoring and programming.

Communication
Power supplies and absorber chassis are programmed and monitored via GPIB using SCPI commands; rear-rack GPIB connection provided for integration.

AC Control and Distribution
Includes AC distribution, circuit breakers, pin-and-sleeve input connectors and mains disconnect interlock contactors. Example AC input for 60 kW DC output: 400 VAC, 3-phase, 4-wire with ~120 A per phase. Door interlock and single-point grounding provided.

DC Output
DC output delivered via MS-type connector with mating connector provided; ampacity matched to system rating.

Technical specifications

• Regenerative absorber rating: 400 VDC at ±150 A (system-level).
• Max configured output: up to 400 V at 150 A (60 kW) in Master/Slave.
• Alternative mention: 60 kW at 480 VDC and 150 A referenced in AC section.
• DC supply modules: two types, each 0–400 VDC, 75 A (SGI = Master with GPIB; SGA = Slave).
• Absorber load resistance: ≈1.5 Ω from series/parallel high-power resistors.
• Continuous/peak absorber ratings: 30 kW continuous, 60 kW peak.
• Blocking diode prevents regen current through supplies; system current readback separate.
• Absorber control: IGBT and SCR clamps, bus capacitors, comparator thresholds for IGBT drive.
• Monitoring: voltage/current readbacks on supplies and absorber; 0–10 V analog outputs for external monitoring.
• Communications: GPIB (SCPI) for supplies and absorber; rear rack GPIB connection.
• AC input example: 400 VAC, 3-phase, 4-wire; ~120 A/phase for 60 kW DC output.
• DC output connector: MS type (mating connector provided).
• Protection/features: OVP for secondary SCR, front-panel LEDs, interlocks and mains disconnect contactors.