Electric Vehicle High Voltage Performance

Description

The high voltage piezoelectric performance test system for electric vehicles is suitable for the high voltage parts test of new energy vehicles in the voltage class DC 60 V ~ 1500 V. The electrical parameters and safety of high voltage components such as high voltage battery systems(HV battery system), DC/DC high and low voltage converters(DC / DC converter HV / LV), vehicle chargers(On-board charger), air conditioning compressors(Air conditioning compressor) can be verified through a series of electrical characteristic tests
EVTS 150C10 electric vehicle high voltage integrated measuring instrument supports DC 0 V ~ 1500 V voltage output, voltage slope control is greater than 250 V/ms, can complete the ISO 21498-2-2021 test project, but also can meet the LV 123 and VW 80300-2021 related test requirements. The system expansibility is strong.

Features：

Voltage slope control greater than 250 V/ms;
As per ISO 21498-2-2021、VW 80300_EN_2021 and LV 123;
simulate various complex electrical environments of high-voltage components of new energy vehicles in practical application scenarios;
Support DC 0 V ~ 1000 V / 1500 V voltage output, can edit waveform output, two-way power supply
strong expansibility, and the power supply can be extended to 1 main N slave, so that the output current can achieve 60 A, 120 A, 240 A or more.

Standard

LV 123
Mercedes MBN 11123
ISO 21498-2-2021
VW 80300_EN_2021

Specifications

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 Undervoltage		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/td>		Immunity – voltage slope change	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 The interaction between low-and-high pressure systems		Functional 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 immunity	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.
Electric vehicle high-voltage electrical performance comprehensive tester EVTS 150C10
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 range	0 ~ 1650 V
Overcurrent protection range	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.
DC Decoupling Capacitor C150C30
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	Approx. 70 kg
High Voltage Manual Network AN 1501N
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 μF
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.
High Voltage Test Device HTS 1501
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.
Coupling Transformer TPT-7637-4C100B
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.
Ripple Signal Generator RSG 40C20
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	Approx. 25 kg
Note: the power of ripple signal generator is 800 W, suitable for 100 A current system.
Pulse Interference Generator for Electric Vehicle EVPG 20
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 %
Pulse width	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.
100 A , 300 A , 700 A system configuration table :
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	100 A	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
5	Load current	100 A	300 A
6	Pulse Interference Generator for Electric Vehicle	EVPG 20
6	Load current	100 A
7	Vehicle immunity test software	Autolab
7	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.