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1 NEW EMC TEST REQUIREMENTS For Electric Vehicles CONDUCTED RF EQUIPMENT POWER AMPLIFIERS Markus Fuhrer 27.03.2015

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1

NEW EMC TEST REQUIREMENTS

For Electric Vehicles

CONDUCTED RF EQUIPMENT POWER AMPLIFIERS

Markus Fuhrer 27.03.2015

E/ECE/324/Add.9/Rev.5

Addendum 9: Regulation No. 10 Revision 5

Uniform provisions concerning the

approval of vehicles with regard to

electromagnetic compatibility

16 October 2014

ECE=Economic Commission for Europe

Inland Transport Committee

World Forum for Harmonization of Vehicle Regulations

Working Party on Lighting and Light-signaling

www.unece.org

2

IEC Product standards for vehicle

IEC/EN 61851-1 Part 1: General requirements

IEC 61851-21: 2001 Electric vehicle conductive charging system

-Part 21-1: Electric vehicle on board charger emc

requirements for conductive connection to

an a.c/d.c. supply

IEC 61851-22: 2001 Electric vehicle conductive charging system

- Part 22: AC electric vehicle charging station

(IEC 69/184/CD:2010)

IEC/EN 61851-23 Part 23: DC electric vehicle charging station (2014)

IEC/EN 61851-24

-Part 24: Digital communication between a d.c.

EV charging station and an electric vehicle for control of

d.c. charging (2014)

There are other not mentioned product standards for

EMC testing of electric vehicles.

3

Special definitions in Chapter 2

ESA electronic sub-assemblies an electrical and/or electronic device or set(s) of devices intended to be part

of a vehicle, together with any associated electrical connections and wiring,

which performs one or more specialized functions.

RESS rechargeable energy storage system

that provides electric energy for electric propulsion of the vehicle.

Definitions and terms Chapter 2

Overview ECE R-10 Annexes for Chapter 7

1 Examples of approval marks

2A Vehicles 2B Sub-assembliy

3 ECE Marks for Vehicle / Sub-assembly

RE (Emission) RI (Immunity)

4 BBRE 5 NBRE

Sub-Assembly ESA

9 RI (Immunity) RE ( Emission)

8 NBRE 7 BBRE Chamber

TEM, BCI

Stripline

10 Transients

11 Harmonic

12 Flicker

6 RI

Vehicles

ISO 7627-2

Immunity

Emission

CE (Emission) CI (Immunity)

13 CERF(ac/dc)

14 CERF(telecom)

15 EFT

16 Surge

ECE R-10 EMC

17 Harmonic

18 Flicker

CI (Immunity)

19 CERF(ac/dc)

20 CERF(telecom)

21 EFT

22 Surge

CE (Emission)

4

General information (administrative)

Annex 1 Examples of approval marks

Annex 2A Information document for type approval of a vehicle with respect to

electromagnetic compatibility

Annex 2B Information document for type approval of an electric/electronic

sub-assembly with respect to electromagnetic compatibility .

Annex 3A Communication concerning the approval or extension or refusal or withdrawal of

approval or production definitively discontinued of a type of

vehicle/component/separate technical unit with regard to Regulation No. 10

Annex 3B Communication concerning the approval or extension or refusal or withdrawal of

approval or production definitively discontinued of a type of electrical/electronic sub-

assembly with regard to Regulation No. 10

5

ECE R-10

Annex 4 Method of measurement of radiated broadband electromagnetic emissions from vehicles

Annex 5 Method of measurement of radiated narrowband electromagnetic emissions from vehicles

Annex 6 Method of testing for immunity of vehicles to electromagnetic radiation

Annex 7 Method of measurement of radiated broadband electromagnetic emissions from

electrical / electronic sub-assemblies (ESAs)

Annex 8 Method of measurement of radiated narrowband electromagnetic emissions from

electrical/electronic sub-assemblies

Annex 9 Method(s) of testing for immunity of electrical/electronic sub-assemblies to electromagnetic

radiation

Annex 13 Method(s) of testing for emission of radiofrequency conducted disturbances on AC or DC power

lines from vehicles .

Annex 14 Method(s) of testing for emission of radiofrequency conducted disturbances on network and

telecommunication access from vehicles

Radiated measurements and tests for vehicles and ESA

6

ECE R-10

Immunity measurements and tests for vehicles and ESA

Annex 10 Method(s) of testing for immunity to and emission of transients of electrical/electronic sub-

assemblies .

ISO 7637-2 Testimpulses 1, 2a, 2b, 3a, 3b and 4, interferences from transient emission

Annex 11 Method(s) of testing for emission of harmonics generated on AC power lines from vehicle

IEC 61000-3-2 // IEC 61000-3-12

Annex 12 Method(s) of testing for emission of voltage changes, voltage fluctuations and flicker on AC power

lines from vehicle

IEC 61000-3-3 // IEC 61000-3-11

Annex 15 Method of testing for immunity of vehicles to Electrical Fast Transient/Burst disturbances conducted

along AC and DC power lines

IEC 61000-4-4

Annex 16 Method of testing for immunity of vehicles to surges conducted along AC and DC power lines

IEC 61000-4-5

New Test requirements on car manufacturers

7

ECE R-10

Immunity measurements and tests for vehicles and ESA

Annex 19 Method(s) of testing for emission of radiofrequency conducted disturbances on AC or DC power

lines from an ESA

Annex 20 Method(s) of testing for emission of radiofrequency conducted disturbances on network and

telecommunication access from an ESA

Annex 17 Method(s) of testing for emission of harmonics generated on AC power lines from an ESA

IEC 61000-3-2 // IEC 61000-3-12

Annex 18 Method(s) of testing for emission of voltage changes, voltage fluctuations and flicker on AC power

lines from an ESA

IEC 61000-3-3 // IEC 61000-3-11

Annex 21 Method of testing for immunity of an ESA to Electrical Fast Transient/Burst disturbances

conducted along AC and DC power lines

IEC 61000-4-4

Annex 22 Method of testing for immunity of ESAs to surges conducted along AC and DC power lines

IEC 61000-4-5

New Test requirements on car manufacturers

8

ECE R-10

IEC/EN 61851-21 - 22: Standards for vehicle charging

Charging at home 120 V 15 A – 20 A 1.8 – 2.4 kW 8 – 20 hours

Charging in Public Slow charging 240 V 30 – 40 A 7.2 – 9.6 kW 3 – 8 hours Fast charging 480V 3 phases 60 – 150 kW DC fast charging < 30 min.

IEC Product standards IEC 61581-21 / -22

IEC 61851-21 Ed. 1.0 part 21

EMC requirements on board chargers for electric vehicles for conductive connection to an ac / dc supply

Tabelle 1 – Störfestigkeitsprüfungen

Ambient

Phenomenas Test spez. Unit

Basic

Standards Remarks

Test

criteria

1.1 Electrost.

Discharge

CD ± 8 kV (charge voltage) ISO 10605.2:

2008

See test procedure in ISO

10605.2:2008.

„Vehicle test method“

B

Air discharge ± 15 kV (charge voltage) B

1.2

Radio-frequency

electromagnetic field.

Amplitude modulated

20 to 800

30

80

MHz

V/m (r.m.s.)

% AM (1 kHz)

ISO 11451-2:

2005

Vehicle test

Vert. polarisation of the E field a

NOTE 1& 4

A

1.3

Radio-frequency

electromagnetic field.

Pulse modulated

800 to 2000

25

ton: 577

T: 4600

MHz

V/m (r.m.s.)

µs

µs

ISO 11451-2:

2005

Vehicle test

Vert. polarisation of the E field a

NOTE 1

A

1.4 Fast transients

(a.c. or d.c. power lines)

± 2

5/50

5

kV (open circuit test voltage)

Tr/Th ns

Repetition frequency kHz

IEC 61000-4-4:

2004 NOTE 2 B

1.5 Fast transients (pilot line)

± 1

5/50

5

kV (open circuit test voltage)

Tr/Th ns

Repetition frequency kHz

IEC 61000-4-4:

2004 Capacative clamp is used. B

1.6

Surge (a.c. power lines)

line-to-earth

line-to line

1.2/50 (8/20)

± 2

± 1

Tr/Th µs

kV (open circuit test voltage)

kV (open circuit test voltage)

IEC 61000-4-5:

2005

Each surge shall be applied 5 times at

1mn (or less, minimum 10 s) interval for

each of the following angles: 0, 90, 180

and 270°

B

1.7

Surge (d.c. power lines)

line-to-earth

line-to line

1.2/50 (8/20)

± 0.5

± 0.5

Tr/Th µs

kV (open circuit test voltage)

kV (open circuit test voltage)

IEC 61000-4-5:

2005 Each surge shall be applied 5 times at

1min (or less, minimum 10 s) interval. B

IEC Product standards IEC 61581-21

10

The Standard requires Power Fail tests acc. IEC 61000-4-11 and Harmonic Immunity acc. IEC 61000-4-13

1.8 Supply voltage

harmonics

Class 2 in Tab 1to3 of

IEC 61000-4-13

IEC 61000-4-13:

2009 B

1.9 Voltage dips

0

1

% residual voltage

Cycle

IEC 61000-4-11 Voltage shift at zero crossing

NOTE 3

B

40

10/12 at

50/60Hz

70

25/30 at

50/60Hz

% residual voltage

Cycle C

1.10 Voltage interruptions 0

250/300 at 50/60Hz

% residual voltage

Cycle IEC 61000-4-11

Voltage shift at zero crossing

NOTE 3 C

See Note 4

1.11 BCI

Amplitude modulated

20 to 200

60

80

MHz

mA (r.m.s)

% AM (1 kHz)

ISO 11452-4:

2005 + Amd

2009

Stand alone test

Vert. polarisation of the E field a

NOTE 1 & 4

A

1.12

Radio-frequency

electromagnetic field.

Amplitude modulated.

200 to 800

30

80

MHz

V/m (r.m.s)

% AM (1 kHz)

ISO 11452-2:

2004

Stand alone test

Vert. polarisation of the E field a

NOTE 1 & 4

A

1.13

Radio-frequency

electromagnetic field.

Pulse modulated.

800 to 2000

25

ton: 577

T: 4600

MHz

V/m (r.m.s)

µs

µs

ISO 11452-2:

2004

Stand alone test

Vert. polarisation of the E field a

NOTE 1

A

NOTE 1 The articles mains network to be used for this test on vehicle is defined in CISPR 16-1-2 Clause 4.3.

NOTE 2 When the CDN network cannot be used on a.c. or d.c. power lines, the capacitive coupling clamp defined in 6.3 of IEC 61000-4-4:2004, may be used

NOTE 3 Applicable only to input ports

NOTE 4 AM is peak conservation according to ISO 11451-1 or ISO 11452-1

a The field strength shall be 30 V/m rms in over 90% of the 20 to 2000 MHz frequency range and a minimum of 25 V/m over the whole 20 to 2000 MHz frequenccy range.

IEC 61851-21 Ed. 1.0 Part 21

11

IEC Product standards IEC 61581-21

With the mains plug the car manufacturer enter into a new world

Emission

Harmonic & Flicker

Conducted RF

Immunity

Burst , Surge, Power Fail

Public mains

New requirements

for car manufacturers

Chapter 7 for RESS (Vehicles and ESAs)

"RESS charging mode coupled to the power grid"

ECE

Regulation

Chapter 7 of ECE R-10 for RESS vehicles

12

Charging station

Onboard charger

Radiated Broaband electromagnetic emission

RESS Chapter 7.2, Annex 4; ESA: Chapter 7.10, Annex 7

Radiated broadband electromagnetic emissions from vehicles resp. ESAs

Test method: CISPR 12 Frequency range 30… 1000MHz.

Operating status: Vehicle in configuration "RESS charging mode coupled to the power grid". The state of charge

(SOC) of the traction battery shall be kept between 20 per cent and 80 per cent of the maximum

SOC. The current shall be set to at least 80 per cent of its nominal value.

Limits: acc. CISPR 12 for 3 m and 10 m measuring distance and Quasi‐Peak Detector.

Test setup:

State of charge (SOC):

20% - 80%

Charging current:

min. 80% of nominal current

Note: There are different setup

pictures in annex 4

Radiated Emission

13

EMC tests as per Chapter 7

RESS Chapter 7.3, Annex 11; ESA: Chapter 7.11, Annex 17

Emission of harmonics on AC power lines from vehicles resp. ESAs

Test method: Acc. IEC 61000‐3‐2 (for I ≤ 16 A /Phase) and

IEC 61000‐3‐12 (for I > 16 A and ≤ 75 A /Phase).

Operating status: Vehicle in configuration "RESS charging mode coupled to the power grid". The engine and all

devices which the driver could operate must be in OFF STATUS.

Battery charging : SOC (20% - 80% ), Charging current: min. 80% of nominal current.

Requirements: Measuring of even and odd harmonics up to 40th (I up to 16 A), resp . 13th ( I>16 A)

• Test setup:

AC Source with Impedance Zs and open circuit voltage G

Harmonics and conducted Emission

14

Example DC rectifier Voltage & Current flow in the capacitor

Frequency spectrum Time domain

Origin of harmonic currents

U

I

15

Harmonics and conducted Emission

For electric vehicle charging systems with a rated current of less than 16 A, the limits on the IEC 610003-2 for

Class A (Table 2) are defined.

The Limits for Harmonics of AC power supplies of charging systems for electric vehicles with a rated input current

more than 16 A and less than 75 A is covered by to IEC 61000-3-12 with the general test conditions.

IEC 61000-3-2 (IEC 61851-21 Ed. 2.0 Teil 21)

Table 2 – Maximum harmonic currents

(Nominal current ≤16A /Phase)

Harmonics n Limit of harmonic current [A]

Odd Harmonics

3 2,3

5 1,14

7 0,77

9 0,40

11 0,33

13 0,21

15 ≤ n ≤ 39 0,15x15/n

Even Harmonics

2 1,08

4 0,43

6 0,30

8 ≤ n ≤ 40 0,23x8/n

NetWave

3--Phasen AC/DC

programmable source

3-phase Flickerimpedance

AIF 503N75 with DPA 503

Analyser for Flicker and Harmonics

16

Harmonics and conducted Emission

Harmonic & Flicker System

100 A Harmonic and Flicker System

AC Source

Flickerimpedance

Requirements to the test system:

AC Source Voltage: + 2%

Frequency: + 0,5%

Phaseangle: 120° ± 1,5°

Peak: Between 1.40 and 1.42 x rms value

and 87° to 93° after zero crossing

Harmonische: Hamonic voltage

0.9% 3. OS

0.4% 5. OS

0.3% 7. OS

0.2% 9. OS

0.2% odd harmonic of 2nd to 10th order

0.1% harmonic of 11th to 40th order.

18

Harmonics and conducted Emission

Phänomen & Definition

Voltage fluctuations caused by varying load currents may also influence luminance or spectral distribution of

lightning systems.

The impression of unsteadies of visual sensation induced by this light stimulus is called flicker. Whereby the limits on

the voltage fluctuations are based on the equivalent levels of light flicker in a 60W incandescent bulb which is

perceived as disturbing.

The higher the voltage changes, the less frequently they may occur A.

At low voltage fluctuations flicker can high rates of change to B.

Mains voltage fluctuations, which are caused by non-

stationary operating conditions of loads, luminance

changes or changing the brightness of lighting devices

can cause.

Due to the high frequency of use, a light bulb 230V / 60W

was internationally defined as a reference lamp for flicker.

The so called flicker curve defines the graphic

representation permissible combinations relative

voltage change (V/V in %) to number changes

per minute. B

A

19

Fllicker and Voltage variations of AC power lines

Flickerimpedances

Zref: Impedance specs in IEC 61000-3-3

RA = 0,24 jXA = 0,15 at 50 Hz

RN = 0,16 jXN = 0,10 at 50 Hz

Ztest: For measurement as per IEC 61000-3-11

RA = 0,15 jXA = 0,15 at 50 Hz

RN = 0,10 jXN = 0,10 at 50 Hz

20

AIF 503N75 3-phase

Flickerimpedance with

DPA 503 Analyser

Fllicker and Voltage variations of AC power lines

3-phase Harmonic and Flicker test system

– 3- Phasen Analyser

– 3- Phasen Impedanz 32 A

– 3- Phasen Quelle 32 A

21

Fllicker and Voltage variations of AC power lines

EMC Tests as per Chapter 7

23

Emission of radiofrequency conducted disturbances on vehicle AC / DC lines

RESS Chapter 7.5, Annex 13; // ESA: Chapter 7.13, Annex 19

Emission of radiofrequency conducted disturbances on AC or DC power lines from vehicles

The test includes the requirements for residential, commercial and industrial areas.

Test method : As per. CISPR 16‐2‐1 as standard device.

Operating status: Vehicle in configuration "RESS charging mode coupled to the power grid". Engine OFF and

Motor and all other equipment which can be switched on permanently by the driver or

passenger should be OFF.

The state of charge (SOC) of the traction battery : 20% - 80%

Charging current: Rated current or at least 80% of its nominal value if adjustable.

Limits : as per IEC 61000‐6‐3 table 7 (ac) or table 8 (dc)

Different

test setup:

For RESS

application

RESS Chapter 7.6, Annex 14; ESA: Chapter 7.14, Annex 20

Emission of radiofrequency conducted disturbances on network and telecommunication access from vehicles

The test includes the requirements for residential, commercial and industrial areas.

Test method : As per CISPR 22 if not otherwise ststed

Operating status: Vehicle in configuration "RESS charging mode coupled to the power grid". Engine OFF and Motor

and all other equipment which can be switched on by the driver or passenger should be OFF.

The state of charge (SOC) of the traction battery : 20% - 80%

Charging current: Rated current or at least 80% of its nominal value if adjustable.

Limits : As per IEC 61000‐6‐3 for voltage and current, with QP and AVG‐Detector.

Ausnahme : No application of annex 14/20 if no direct connection to the telecom network exist

Test setup:

24

Different test setup

Emission of conducted RF disturbances on network and telecommunication access from

vehicles

26

Radiated Immunity

RESS Chapter 7.7, Annex 6; ESA: Chapter 7.18, Annex 9

Immunity of vehicles to electromagnetic radiation

Test method : As per ISO 11451‐2, alternativ with ESA: as per ISO 11452-2, ISO 11451‐4 (BCI).

Operating status: Vehicle in configuration "RESS charging mode coupled to the power grid". Engine OFF and

Motor and all other equipment which can be switched on by the driver or passenger should be

OFF.

The state of charge (SOC) of the traction battery : 20% - 80%

Charging current: Rated current or at least 20% of its nominal value if adjustable.

Criteria: no degradation of performance of "immunity related functions", Vehicle sets in motion.

Test: with and without charging mode

Different

test setup:

For RESS

application

RESS Chapter 7.8 Annex 15; ESA: Chapter 7.15 Annex 21

Immunität of vehicles to electrical fast transient/burst disturbances conducted along AC and DC power lines.

Test method : As per IEC 61000‐4‐4 (immunity for electric fast transients EFT/Burst).

Operating status: Vehicle in configuration "RESS charging mode coupled to the power grid". Engine OFF and Motor

and all other equipment which can be switched on by the driver or passenger should be OFF.

The state of charge (SOC) of the traction battery : 20% - 80%

Charging current: Rated current or at least 80% of its nominal value if adjustable.

Criteria: no degradation of performance of "immunity related functions", Vehicle sets in motion.

Test setup:

Immunity to electrioc fast transients EFT / Burst

27

Different test setup

Burst Test setup for vehicles in charging mode (RESS)

The vehicle shall be placed directly on the ground plane. The vehicle shall be immobilized, engine OFF and in

charging mode. All other equipment which can be switched on permanently by the driver or passenger should be

OFF.

Failure criteria: Vehicle sets in motion.

Testlevel : ± 2 kV, minimum 1 minute with all couplings at same time.

EFT Generator

AC/DC

mains

Entkoppelnetzwerk

Bezugsmasse

Cc

28

Immunity to electrioc fast transients EFT / Burst

230 V power relays

Equivalent diagram of a switching circuit

Us

Uo

S

I

R2

L2

C2 U1

L1

C1

R1

Typical voltage waveform across an opening switch

29

Burst phenomenom open a contact

Immunity to electrioc fast transients EFT / Burst

Definition of Burst impulse as per IEC 61000-4-4

30

Single pulse

Rise time tr = 5 ns

Pulse duration td = 50 ns

Pulse packet (Burst)

Repetition time tREP = 300 ms

75 pulses/Burst

Duration Burst packet tDURATTION = 15 ms

Spike frequency f = 5 kHz

Duration Burst packet tDURATION = 0,75 ms

Spike frequency f = 100 kHz

Immunity to electrioc fast transients EFT / Burst

ISO 7637-2 12 V System

Pulse 3a / 3b 220 V max.

IEC 61000-4-4

Burst EFT 2000 V

Test levels as per IEC 61000-4-4

31

Immunity to electrioc fast transients EFT / Burst

Test system for vehicles – for RESS testing

IEC 61000-4-4 (EFT/Burst)

IEC 61000-4-5 (Surge)

Coupling network for,

- AC: 3-ph. 480 V / 32 A up to 100 A

- DC: 1000V DC

- Switch AC/DC operation

- Mainswitch for AC/DC

Note: for the traditional ISO tests for the vehicle electronics

with (micro pulses, EFT, load dump), no new specific

requirements were introduced.

UCS 500N7

CNI 503x

32

Immunity to electrioc fast transients EFT / Burst

EMC tests as per Chapter 7 RESS Chapter 7.9, Annex 16; ESA: Chapter 7.16, Annex 22

Immunity of vehicles/ESAs to surge conducted along AC or DC power lines.

Test method : Gem. IEC 61000‐4‐5 (Immunity to surge impulses).

Requirements: for AC: ± 1 kV (line-line), 2 kv (lines-PE); DC: 0.5 kV. (line-line, line-PE)

Operating status: Vehicle in configuration "RESS charging mode coupled to the power grid". Engine OFF and Motor

and all other equipment which can be switched on by the driver or passenger should be OFF.

The state of charge (SOC) of the traction battery : 20% - 80%

Charging current: Current at least 20% of its nominal value if adjustable.

Failure Criteria: Vehicle sets in motion.

Coupling: The surge impulse is coupled to the AC/DC lines with :

a) coupling between lines and

b) coupling between line and earth

Test setup:

33

0.8 (+0.2 / -0) m

Cable shall be z-folded if longer

than 1m, 100 ± 25 mm above

ground and at least 100mm from

the car body

Cable shall be z-folded if

longer than 1m, 100 ±

25mm above ground and at

least 100mm from the car

body

0.8 (+0.2 / -0) m

Cable shall be z-folded if longer

than 1m, 100 ± 25 mm above

ground and at least 100mm from

the car body

Immunity to surge

Different test setup

EMC tests as per Chapter 7

RESS Chapter 7.9, Annex 16; ESA: Chapter 7.16, Annex 22

Test setup:

34

0.8 (+0.2 / -0) m

Cable shall be z-folded if longer

than 1m, 100 ± 25 mm above

ground and at least 100mm from

the car body

Cable shall be z-folded if longer

than 1m ,

(100 ± 25) mm above ground and

at least 100 mm from the car

body.

Cable shall be shortened to appropriate length,

(100 ± 25) mm above ground and

at least 100 mm from the ESA body.

Immunity to surge

Surgeimpulse definition as per IEC 61000-4-5 :Ed. 3

Open circuit voltage: 1.2/50 s

Stirnzeit: Tf = 1.67 x T= 1.2 s ± 30%

Pulsdauer: Td = Tw = 50 s ± 20%

NOTE: The pulse shape of the open circuit voltage at

the output of the coupling / decoupling network may

have a significant undershoot.

Short circuit current: 8/20 s

Front Time : Tf = 1.25xTr = 8 s 20%

Duration: Td = 1.18 x Tw =20 s 20%

NOTE: The setting for the undershoot by 30% applies

only at the generator output. For the output of the

coupling / decoupling network there is no limit in terms

of the under- or overshooting.

35

Immunity to surge

Surgeimpulse Test level as per IEC 61000-4-5 :Ed. 3

Tabelle 1 Prüfschärfegrade

0.5

0.5

1 2

1

36

Immunity to surge

Table 1 specifies in detail the test levels for the open circuit voltages for testing line to line and line to ground

The test level blue referredthe information required under the ECE 10 test requirements for AC lines.

All voltages of the lower test levels shall be satisfied

Surge Test setup for vehicles in charging mode (RESS)

If not otherwise stated in this annex the test shall be performed according to IEC 61000-4-5.

Vehicle state during tests in configuration "RESS in charging mode coupled to the power grid". The vehicle shall

be placed directly on the ground plane.

Coupling line to line

Hybrid Generator

Combination wave

Entkoppelnetzwerk

Bezugsmasse

Hybrid Generator

Combination wave

Entkopelnetzwerk

Bezugsmasse

R = 10Ω

C = 9µF

Coupling line to earth

37

Immunity to surge

39

Components in the Electrical Vehicle

Mains Supply Voltage 240 V / 16A AC

480 V / 32A AC

400 V / 125 A DC

500 V / 100A DC

HV lines

300 V up to 800 V DC

30 A up to 100 A

Simplified circuit of Electrical Vehicle

Charger (built-in)

HV Battery .

(400 Volt) .

Elec-tronic

Motor

Compressor

(Aircondition)

Inverter

DC / DC

12V

1Hz bis 150kHz

Mains Supply Voltage 230 V / 16A AC 480 V / 32A AC 400 V / 125 A DC 500 V / 100A DC

HV lines 300 V up to 800 V DC 30 A up to 100 A

ISO 7637-4

ISO 7637-4 Electrical transient conduction along shielded high voltage

supply lines only (Proposal/Early Draft)

This part of ISO 7637 specifies test methods and procedures to ensure the compatibility to

conducted electrical transients of equipment installed on passenger cars and commercial

vehicles fitted with electrical systems with voltages higher than 60 VDC and lower than

1.500 VDC and a power-supply isolated from the vehicle-body.

It describes bench tests injection of transients:

Voltage ripple (square wave) (Pulse A)

Pulsed sinusoidal disturbances (Pulse B)

Low frequency sinusoidal disturbances (Pulse C)

It is applicable to all types of electrical independent driven, road vehicles (e. g. battery

electrical vehicle [BEV] or hybrid electrical vehicle [HEV], plugin hybrid vehicle [PHEV]).

ISO 7637-4

Voltage ripple on high voltage supply lines This square wave perturbation is typically caused by switching of high currents e. g. in IGBT -

stages of electrical engine systems or DC-DC-converters. Voltage ripple produce both, line-to-

ground (HV+ or/and HV- to ground) and line-to-line (HV+ to HV-) disturbances. They can

interfere with adjacent high voltage systems like battery-controller and climate compressor.

Figure 2a ISO 7637-4: test setup for coupling between HV+ and HV-.

Generator Pulse A

Frequency range: 1kHz up - 300kHz

Frequency step: 1kHz / 10kHz

TRise and TFall <1us @ oc voltage

TRise and TFall <2.5us @ sc current

Zi = Vpp / Ipp ≤ 0.5 Ω generator output

Current capacity: ≥ 32 A(rms), ≥ 70 V(peak)

ISO 7637-4

Interferences from the inverter (rectangular signals)

ISO 7637-4

Interferences from the inverter RF interferences

ISO 7637-4

Ground connection of DUT shall

be connected to Ground plane with

a cable original length and

diameter according to the vehicle

application.

Details to ground connection and

wiring shall be agreed between

vehicle manufacturer and supplier.

Figure 2b – Transient immunity test set-up for voltage ripple (e. g. “HV+ line-to-ground”)

Voltage ripple on high voltage supply lines For coupling between HV+ and ground or HV- and ground the bottom terminal of generator

has to be connected to ground. The top terminal has to be connected to HV+ (as shown) or

to HV-. Corresponding one voltage probe terminal has to be connected to HV+ respectively

to HV-; the other voltage probe terminal has to be connected to ground.

ISO 7637-4

Pulsed sinusoidal disturbances on high voltage supply lines These disturbances come from overshoots on square wave signals caused e. g. by

interaction of switching IGBTs in high voltage systems with parasitic capacities and

inductivities of electrical engines, by DC-DC-converters and any other kind of high voltage

switching / commutation.

Generator Pulse B

Frequency range: 1-10 MHz

Impedance: 50 Ohm

Output power: 25W for 100 Vpp

225W for 300 Vpp

CNE-Balun Figure 3a – Test set-up for pulsed sinusoidal disturbances (e. g. “line-to-line”)

ISO 7637-4

Pulsed sinusoidal disturbances on high voltage supply lines For coupling between HV+ and ground or HV- and ground the bottom terminal of generator

has to be connected to ground. The top terminal has to be connected to HV+ (as shown) or

to HV-. Corresponding one voltage probe terminal has to be connected to HV+ respectively

to HV-; the other voltage probe terminal has to be connected to ground.

Ground connection of DUT shall be connected to Ground plane with a cable original length

and diameter according to the vehicle application.

Figure 3b –Set-up for pulsed sinusoidal disturbances (e. g. “HV+ line-to-ground”)

ISO 7637-4

Low frequency sinusoidal disturbances This test determines whether the equipment will accept superposed sinusoidal frequency

components.

The Figure below shows the test setup for coupling between HV+ and HV-.

A capacitor of 100uF or more shall be connected across the high voltage dc power supply.

Generator Pulse C

Frequency range: 15Hz - 400kHz

Frequency step: Linear or

logarithmic or several frequencies

per decade (dwell time 2s)

Voltage: 30VRMS up to 250kHz

20VRMS up to 400kHz

Current: 16ARMS

Figure 4a –Test set-up for low frequency sinusoidal disturbances (e. g. “line-to- line”)

ISO 7637-4

Low frequency sinusoidal disturbances This test determines whether the equipment will accept superposed sinusoidal frequency

components.

The Figure below shows the test setup for coupling between HV+ and ground or HV- and

ground the bottom terminal of the coupling transformer has to be connected to ground.

Generator Pulse C

Frequency range: 15Hz - 400kHz

Frequency step: Linear or

logarithmic or several frequencies

per decade (dwell time 2s)

Voltage: 30VRMS up to 250kHz

20VRMS up to 400kHz

Current: 16ARMS

Figure 4b –Test set-up for low frequency sinusoidal disturbances (e. g. “HV line-to- ground”)

50

Thank you!

CONDUCTED RF EQUIPMENT POWER AMPLIFIERS