An electronic load complements a power supply when it comes to electronic testing. While a power supply tests electronic circuits under different sourcing conditions, an electronic load tests energy sources with static or dynamic loading.

Electronic loads are categorised into DC, AC, Regenerative DC, and Regenerative AC.

What is a DC Electronic Load?

A wide range of DC power sources, from DC power supplies and batteries to fuel cells and solar cells can be tested and characterised using DC electronic loads. Operating under various modes such as constant current (CC), constant voltage (CV), constant power (CW), and constant resistance (CR), DC electronic loads simulate power consumption under different load conditions, helping in the assessment of device energy efficiency under various operating scenarios.

DC power supplies such as battery chargers, converters, fuel cells, batteries, telecommunications rectifiers, etc must be tested for hundreds or thousands of cycles to determine factors like quality, longevity, durability, reliability, and expected lifetime.

Operating Modes

DC Electronic Loads work in many operating modes.

Constant Current (CC) mode

Here, the load’s power supply is a current source. At a constant current in the output terminals, the output voltage is varied with current load conditions.

Constant Resistance (CR) mode

Here, at a set resistance value, the load draws the current inversely to compensate for any change in the testing voltage.

Constant Voltage (CV) mode

At a fixed voltage. the electronic load sinks the current needed to keep the voltage constant.

Constant Power (CP) mode

For a constant wattage level during the test, the load draws the current proportionate to voltage change.

A well-designed DC programmable electronic load always controls the current, irrespective of the mode, allowing users to set a current level that the DC load will draw, regardless of any changes in voltage.

Regenerative DC Loads

Regenerative DC loads can simulate a wide range of load characteristics while also feeding energy back to the grid, providing an efficient and sustainable solution that reduces test environment temperatures, HVAC power consumption, and power conversion electricity costs.

Chroma 63700 Series Regenerative DC Electronic Loads

The Chroma 63700 Series Regenerative DC Electronic Loads are suitable for product reliability testing in a wide range of applications, such as Electric Vehicle Test Solutions, EV battery discharge, fuel cell discharge, high-power power supply aging, DC EV supply equipment (EVSE), unidirectional on-board chargers (OBC), fuel cell systems, energy storage systems (ESS), AC/DC and DC/DC power supply burn-in tests, and various power electronics applications.

The 63700 Series offers high power density within a compact 3U form factor, with a power rating of up to 18kW per unit and currents of up to 540A. A maximum of 10 units in parallel provides a maximum power and current of 180kW and 1200A respectively. Voltage can be set at 100V, 600V, 1200V, or 1800V.

What’s more, the master/slave control enables parallel operation of identical 63700 units for synchronised dynamic loading to store up to 256 programmable sequences, thereby reducing test duration and increasing throughput during automated testing.

The external signal control functionality allows the simulation of real current waveforms. The 63700 Series performs precise voltage and current measurements in real-time. Operation and setup are convenient with the TFT touch display and rotary knob on the front panel, with the capability to control via LAN, USB, GPIB, or CAN.

The 63700 Series is an ideal solution for design verification and integration into automated test systems with its over-current, over-power, and over-temperature protection functions, as well as an over-voltage alarm mechanism, ensuring product reliability during testing.

Battery testing is an important, but potentially dangerous, step in ensuring that equipment and solutions work properly. While battery testing differs depending on the type of battery test system used, there are numerous consequences if proper procedures and precautions are not followed. There are numerous hazards associated with batteries, with the most common concern being the prevention of fires and explosions. Batteries can be harmed during the manufacturing process, as well as during storage and charging. Lithium batteries, for example, have a negative reaction to extreme hot or cold temperatures and can be irreparably damaged in these conditions. Similarly, extreme heat or cold can cause a buildup that results in smoking or explosions. Continue reading the blog to learn about the feature that allows you to minimise battery risks and test them seamlessly with the battery test system.

Manufacturers typically provide specific instructions for charging and testing safely for consumers and clients. Because each manufacturer constructs battery systems differently, it is critical to heed each manufacturer's specific warnings and instructions.

Battery testing and safety regulations exist, and following these regulations is the best way to ensure functionality and safety during the testing process. These rules govern how individual parts and configurations should interact with each other.

While it may appear obvious, it is critical to ensure that the connection is correct during battery testing: batteries should be connected positive to positive and negative to negative. This ensures that the tester receives a reliable reading on whether the battery is working properly.

One of the most important aspects of battery testing is ensuring that safety modules are properly installed. It is not sufficient to ensure that the battery itself works. You must also ensure that the battery operates safely by using a fully functional and precise safety module.

Run individual tests to get a more in-depth picture of battery functionality. This includes not only testing the individual battery, but also the battery banks, battery connections, and the overall product that the battery powers, such as a vehicle. This ensures that all components work together and assists in identifying specific areas that are malfunctioning or pose a safety risk.

A certain kind of automobile testing tool used to determine the battery's charge rate is known as a battery tester. It is an electrical tool used mostly for evaluating the battery's viability, faults, or improper operation to assure the device's safety and security. It is crucial to assess, record, and keep track of the vital battery operating characteristics because batteries are the engine that drives many machines, power equipment, and other devices. These metrics, which are accepted by various governmental and safety regulatory organizations for a battery test system, include charge levels, voltage output measurement, level of charging capacity, impedance, etc. Therefore, having a battery testing device is crucial to avoiding catastrophic failures of the supported equipment and, consequently, the loss of crucial data. Its common uses include testing for microgrids, EVs, and battery cycling. Batteries come in a variety of varieties. Keep reading to find out more about battery tester types and the battery test system.

The AAA, AA, 9V, C, D, and 1.5V wired and wireless battery testers are primarily used to test the button cells in watches, calculators, clocks, and other electronic devices. They are also helpful for homes, vehicles, bikes, and other unique cases. The analog and digital testers are small and convenient. For home use, these batteries are effective. The battery status is shown on devices with LCD or LED panels. These are the three types of batteries that are available.

Battery impedance tester

In order to avoid battery failure, the impedance battery tester is used to test batteries. The tester evaluates the batteries' impedance resistance, voltage, and capacity. It pinpoints the early warning symptoms of frailty or overall decline in certain cells. It serves as a broad indicator of the health of batteries.

Battery discharge kit:

A discharge kit can evaluate it without replacing the battery in the system. The test time is shortened by its large discharge capacity. Safety measures, including a spark-free connection and an emergency safety fuse, are typically present.

Battery ground fault tracers

In ungrounded DC battery systems, ground faults can be quickly and easily found with a ground fault tracer. It is usable in environments with a lot of electronic noise. By determining the fault characteristic magnitudes, such as the resistive and capacitive characteristics, the fault tracing procedure is made simpler. Any industry that relies on a reliable power source to run measurement, communication, and control equipment uses it.