Electric vehicle high voltage performance test system equipment composition

Serial

Name

Instrument type

summarize

1

High voltage integrated performance tester for electric vehicles

EVTS 150C10

Output voltage:0 ~ 1500 Vdc;Current:120 A;

Power:60 kW(single power supply:30 kW / 60 A);

Power/Current spreading : one master and N slave;

Note: Select the parallel power module according to the actual power/current requirements;

2

DC Decoupling Capacitor

C150C30

＞10 mF , MAX input voltage:1500 Vdc ;

Current:120 A;

3

High Voltage Manual Network

AN 1501N

Impedance:10 mΩ、25 mΩ、100 mΩ；

Built-in capacitor: ＞10 mF;

Output MAX voltage:1500 Vdc；Current:100 A;

Note: Select a network model based on actual requirements；

AN 150C30:300 A/1500 Vdc , no 10 mF capacitor;

AN 150C70:700 A/1500 Vdc , no 10 mF capacitor;

As per ISO 21498-2-2021;

4

High Voltage Test Device

HTS 1501

Impedance: 10 mΩ、25 mΩ、100 mΩ;

Built-in capacitor: 10 mF;

HTS 150C30:300 A/1500 Vdc , no 10 mF capacitor;

As per VW 80300_EN_2021；

5

Ripple Signal Generator

RSG 40C20

Frequency:10 Hz ~ 300kHz; Power:800 W;

Note: Select the corresponding generator model according to the actual power/current requirements;

RSG 80C50: power 5 kW;

RSG 80C100: power 10 kW;

6

Coupling Transformer

TPT-7637-4C100B

Frequency: 10 Hz ~ 300kHz;Current:100 A;

Note: Select the corresponding generator model according to the actual power/current requirements;

TPT-7637-4C300B:current 300 A / 300 Hz ~ 300kHz

TPT-7637-4C1000B:current 1000 A / 300 Hz ~ 300kHz

7

Pulse Interference Generator for Electric Vehicle

EVPG 20

As per VW 80300_EN_2021:EHV-10-02/EHV-16;

Pulse amplitude:10 V ~ 200 V;

DUT load capacity:1000 Vdc / 100 A;

8

Automotive Immunity Test  Software

Autolab

Automotive immunity test software

9

Oscilloscope

MDO 32

Bandwidth 1 GHz , sampling rate 5 GSa/s , 2 analog channels

10

High Voltage Differential Probe

THDP0200

Attenuation:50 X/500 X , bandwidth：200 MHz;

MAX voltage: 1500 Vdc ;

11

Current Probe

PT-722

Frequency：DC ~ 200 kHz ;

Current: 0.5 ~ 1000 A (4000 Ap -p)

As per ISO 21498-2 -2021

Test Item

Test Type

Match the Situation

Required equipment

6.2 DC supply voltage variation within operational range

Immunity –voltage variation

Complete satisfaction

1.MDO 32

2.PT-722

3.Autolab

4.THDP0200

5.AN 1501N

6.RSG 40C20

7.EVTS 150C10

8.TPT-7637-4C100B

6.3 Generated voltage slope

Generation

Complete satisfaction

6.4 Immunity to voltage slope

Immunity –voltage variation

Complete satisfaction

6.5 Generated voltage ripple

Generation

Complete satisfaction

6.6 Immunity to voltage ripple

Immunity –DC ripple

Complete satisfaction

6.7 Overvoltage

Immunity –voltage variation

Complete satisfaction

6.8 Under voltage

Immunity –voltage variation

Complete satisfaction

6.9 Voltage offset

Immunity –voltage variation

Complete satisfaction

6.10 Generated load dump voltage

Generation

Complete satisfaction

6.11 Immunity to load dump voltage

Immunity –voltage variation

Complete satisfaction

Note : System scheme selection configuration is divided into three categories , 100A system , 300 A system , and 700 A system. Large current can be compatible with small current test. All equipments are at the same current range . AN 1501N built-in 10 mF capacitor , so C150C10 is not needed.

As per ISO LV 123

Test Item

Test Type

Match the Situation

Required equipment

10.4.1 Range of unlimited operating capability

Immunity –voltage variation

Complete satisfaction

1.MDO 32

2.PT-722

3.Autolab

4.THDP0200

5.AN 1501N

6.RSG 40C20

7.EVTS 150C10

8.TPT-7637-4C100B

10.4.2 Range of upper limited operating capability

Immunity –voltage variation

Complete satisfaction

10.4.3 Range of lower limited operating capability

Immunity –voltage variation

Complete satisfaction

10.4.4 Range of highly limited operating capability

Immunity –voltage variation

Complete satisfaction

10.4.5 Generated voltage ripple

Immunity –voltage variation

Complete satisfaction

10.4.6 Immunity to voltage ripple

Immunity –DC ripple

Complete satisfaction

10.4.7 Overvoltage

Immunity –voltage variation

Complete satisfaction

10.4.8 Undervoltage

Immunity –voltage variation

Complete satisfaction

10.4.9 Load dump

Immunity –voltage variation

Complete satisfaction

10.4.10 Voltage offset

Immunity –voltage variation

Complete satisfaction

10.4.11 Interaction between low-pressure and high-pressure systems

Function test

Power supply only

Note: LV 123 is benchmarking ISO 21498-2-2021.

As per VW 80300

Test Item

Test Type

Match the Situation

Required equipment

EHV-01 Performance test within the regular HV operating voltage range

Immunity –voltage variation

Complete satisfaction

1.MDO 32

2.PT-722

3.Autolab

4.THDP0200

5.HTS 1501

6.RSG 40C20

7.EVTS 150C10

8.TPT-7637-4C100B

EHV-02 Operating within the HV overvoltage range

Immunity –voltage variation

Complete satisfaction

EHV-03 Operation within the HV undervoltage range

Immunity –voltage variation

Complete satisfaction

EHV-04 Pre-charging

Function test

Unsatisfied

EHV-05 Generated HV voltage dynamics

Generation

Complete satisfaction

EHV-06 System HV voltage dynamics

Immunity –voltage variation

Complete satisfaction

EHV-07 HV voltage dynamics of energy storage devices

Battery test

Unsatisfied

EHV-08 Generated HV voltage ripple

Generation

Complete satisfaction

EHV-09 System HV voltage ripple

Immunity –DC ripple

Complete satisfaction

EHV-10 System load dump

Immunity –pulse

Complete satisfaction

EHV-11 HV voltage offset

Immunity –pulse

Complete satisfaction

EHV-12 HV overcurrent

Current variation

Power supply only

EHV-13 HV service life

Periodic test

Power supply only

EHV-14 On/off durability testing for HV components

Periodic test

Power supply only

EHV-15 Functionality of HV interlock, maintenance connecter, and crash signaling

Function test

Power supply only

EHV-16 HV pulse

Immunity –pulse

Complete satisfaction

Note: 1. System scheme selection configuration is divided into three categories , 100A system , 300 A system , and 700 A system. Large current can be compatible with small current test. All equipments are at the same current  range . HTS 1501(As per VW 80300) is different from AN 1501N(As per ISO 21498).

2. EHV-04 Pre-charging: Confirmation of functional state when components of pre-charging function work.

3. EHV-07 HV voltage dynamics of energy storage devices: The sudden change of current is realized by changing the load.

4. EHV-12 HV overcurrent: Changing the output load of DUT to increase the current by 3 times.

5. EHV-13 HV service life: Programmable AC/DC power supply frequency to 40 KHz.

6. EHV-14 On/off durability testing for HV components: Reliability test.

Technical Parameters

MAX DC voltage

1500 VDC

MAV current

120 A

MAX power

60 kW

Number of power modules

2（single :30 KW / 60 A）

Overvoltage protection

0 ~ 1650 V

Overcurrent protection

0 ~ 132 A

Overpower protection

0 ~ 66 kW

Output voltage range

0 ~ 1500 V

Internal resistance

0/50/100/200 mΩ

Pulse

Sine，RAMP

Amplitude and position change

Static , line

maximum number of supported segments

99

count

1 ~ 999

Expand

Current and power are supported, 1 master and N slaves

Voltage load dump

MAX current

100 A

Size

22 U（more than 3 models for 35 U）

Note: 1. One master and one slave, MAX current 120 A , suitable for 100 A system , if you need higher current , please expand the number of power supply modules.

2. 300 A current system , internal resistance is external.

Technical Parameters

MAX input voltage

1500 VDC

MAX current

300 A

Capacitor

＞10 mF

Working Power

AC 110 V/220 V（±10 %），50 Hz /60 Hz (Default in mainland China：220 V)

Fuse

6 A

Max. Power

100 W

Size

22 U

Weight

70 kg

Technical Parameters

MAX input voltage

1500 VDC

MAX current

100 A

Transient MAX current

280 A

INPUT/OUTPUT terminal

4 mm banana or high voltage shielded

Internal resistance

10/25/100 mΩ

Inductance

1 μH

Decoupling capacitor

＞10 mF

Grounding capacitor

1 μF

Frequency

10 Hz ~ 150kHz

Working Power

AC 220 V（±10 %），50 Hz

Fuse

6 A

Max. Power

250 W

Size

22 U

Weight

178 kg

Note: High Voltage Manual Network as per ISO 21498-2-2021, a total of three impedances, it is suitable for 100 A current system.          

Technical Parameters

MAX input voltage

1500 VDC

MAX current

100 A

Decoupling capacitor

10 mF (±10 %)

Box inductance

2*1 μH (±10 %)

Internal resistance

50 mΩ ( -2/+6 mΩ )

100 mΩ (±10 %)

200 mΩ (±10 %)

Cy

100 nF (±10 %)

Voltage monitoring

Digital tube display voltage value

Frequency

10 Hz ~ 150kHz

Working Power

AC 220 V（±10 %），50 Hz

Fuse

6 A

Max. Power

500 W

Size

22 U

Weight

75 kg

Note: High Voltage Manual Network as per VW 80300_EN_2021, a total of three impedances, it is suitable for 100 A current system.          

Technical Parameters

MAX unsaturated voltage

15 V@10 Hz≤f≤3 kHz

25 V@3 kHz≤f≤30 kHz

2.5 V@30 kHz≤f≤300 kHz

Primary current

MAX 32 A

EUT current

MAX 100 A

Frequency

10 Hz ~ 300kHz

Size

4 U

Weight

60 kg

Note: the maximum EUT current is 100 A, suitable for 100 A current system.          

Technical Parameters

Frequency

10 Hz ~ 300kHz

Frequency step

3 kHz ~ 30 kHz, step: 1 kHz

30 kHz ~ 300 kHz, step:10 kHz

MAX voltage Upp

f＜50 kHz，Upp≤80 V

50 kHz ≤f＜150 kHz，Upp≤48 V

150 kHz ≤f≤300 kHz，Upp≤24 V

resolution ratio 0.1 V

Residence time

1 s ~ 10 s

resolution ratio 0.1 s

Power

800 W

Output

MAX 40 Vp /20 Ap

Working Power

AC 220 V（±10 %），50 Hz

Size

4 U

Weight

25 kg

Note: the power of ripple signal generator is 800 W, suitable for 100 A current system.          

Technical Parameters(EHV-10-02)

Pulse characteristics

Double exponential wave

Pulse voltage amplitude

10 V ~ 50 V ±20 %

50 V ~ 200 V ±10 %

Pulsewidth

≥50 μs (0 % ~ 0%)

Rise time (0 % ~ 100 %)

6.67 μs±20 % (3000 V/ms @20 V)

Impedance

2 Ω

Interval time

1 s ~ 99 s

Polarity

Positive

count

1 ~ 99

Trigger

Manual/Auto/External

Coupling method

Capacitor

Decoupling method

Diode

DUT loading capacity

1000 VDC/100 A

Note: The current of DUT loading capacity is 100 A, larger current system needs to be customized.

Technical Parameters(EHV-10-02)

Pulse characteristics

Double exponential wave

Pulse voltage amplitude

10 V ~ 50 V ±20 %

50 V ~ 200 V ±10 %

Pulsewidth

10 μs ~ 20 μs ±20 %

20 μs ~ 200 μs ±10 %

Rise time (0 % ~ 100 %)

≤300 ns  (＜5 V/ns)

Impedance

2 Ω

Interval time

0.1 s ~ 10 s

Polarity

Positive

count

1 ~ 99

Trigger

Manual/Auto/External

Coupling method

Capacitor

Decoupling method

Diode

DUT loading capacity

1000 VDC/100 A

Note: The current of DUT loading capacity is 100 A, larger current system needs to be customized.

1

Ripple Signal Generator

RSG 40C20

RSG 80C50

RSG 80C100

Frequency

DC / 10 Hz ~ 300 kHz

Power

800 W

5000 W

10000 W

Output Max

80 Vpp / 40 App

160 Vpp / 100 App

160 Vpp / 800 App

Signal Generator

Inside , one channel , frequency : 0 ~ 300 kHz

Note

This ripple generator is mainly aimed at the test requirements of high-impedance and high voltage parts of new energy.

This ripple generator is mainly aimed at low impedance and high power generators such as new energy and high voltage battery packs to meet the test requirements.

2

High Voltage Manual Network

AN 1501N

AN 150C30

AN 150C70

Output channel

2

EUT supply

100 A / 1500 Vdc

300 A / 1500 Vdc

700 A / 1500 Vdc

Frequency

(At EUT terminal)

10 Hz ~ 150 kHz

10 Hz ~ 150 kHz

10 Hz ~ 150 kHz

3

Coupling Transformer

TPT-7637-4C100B

TPT-7637-4C300B

TPT-7637-4C1000B

Frequency range

10 Hz ~ 300 kHz

300 Hz ~ 300 kHz

Coupling current

100 A

300 A

1000 A

Turn ratio

1:1

1:1

2:1 & 4:1

4

Decoupling capacitor

Built-in AN 1501N at 100 A system

C150C30

Load current

100A

300 A

Value

＞10mF(Built-in instantaneous disconnection load shedding emission test function and automatic active charge and discharge circuit)

5

High Voltage Test Device

HTS 1501

HTS 150C30

Load current

100 A

300 A

6

Pulse Interference Generator for Electric Vehicle

EVPG 20

Load current

100 A

7

Vehicle immunity test software

Autolab

Fouction

Software for remote control of ripple signal generator, including pre-programmed standard and test library, enhanced analysis and report generation. At the same time, it can be compatible with the immunity testing equipment of automobile parts.