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High voltage electrical performance ISO 21498-2 test system

1. Introduction to the test

According to the latest ISO 21498-2:2021 version requirements, the test items that need to be met include:

6.2 DC supply voltage variation within operational range

6.3 Generated voltage slope/Generated voltage slope

6.4 Voltage slope immunity/Immunity to voltage slope

6.5 Generated voltage ripple/Generated voltage ripple

6.6 Voltage ripple immunity/Immunity to voltage ripple

6.7 Overvoltage/Overvoltage

6.8 Undervoltage / Undervoltage

6.9 Voltage offset/Voltage offset

6.10 Generated load dump voltage/Generated load dump voltage

6.11 Immunity to load dump voltage

These standards apply to high-voltage components of new energy vehicles with voltage levels in the range of DC 60V to 1500V, aiming at high-voltage battery systems (HV battery system), DC/DC high and low voltage converters (DC/DC converter HV/LV), vehicle-mounted High-voltage components such as chargers (On-board chargers) and air conditioning compressors (Air conditioning compressors) pass a series of electrical characteristic tests to verify their electrical parameters and safety.

According to the development trend of high-voltage components, increasing voltage/reducing current has become a design trend. In response to this trend, different voltage level range specifications are also defined as follows:

Voltage level	Voltage Upper Limit Specification
A(LV）	≤60 VDC/30 VAC
B(HV）	＞ 60 and ≤1500VDC;＞30 and ≤1000VAC
B_220	220V DC
B_420	420V DC
B_470	470V DC
B_750	750V DC
B_850	850V DC
B_1250	1250V DC

With the increase of the voltage level, the test for 6.11 load dump voltage immunity also poses a huge challenge to the test instrument, especially the voltage change slope du/dt. A typical case of a 400V system is proposed in Appendix C, and it is finally found that du/dt can reach 250V/ms.

A high-voltage component product may contain various power supply systems at the same time, some are high-voltage power supply systems, some are low-voltage power supply systems, and some of them may be DC power supply systems or AC power supply systems.

In the actual test, the voltage level and operating state of electronic products are divided into four states: OS1/OS2/OS3/OS4, and the distribution diagram is as follows:

These four states can be switched in different situations, as described below:

operating state	describe
OS1	The component shall provide the specified full performance(reduction pf performance not allowed) Electronic components need to meet all performances (performance degradation is not allowed) The component shall automatically change its operating status depending on the voltage relevant for the operating status Electronic components need to automatically switch operating states according to different voltage levels.
OS2	The component shall provide the specified reduced performance within its permissible deviations(reduction of performance allowed) Electronic components need to provide performance degradation within the allowable range (permitted performance degradation) The component shall automatically change its operating status depending on the voltage relevant for the operating status Electronic components need to automatically switch operating states according to different voltage levels.
OS3	The component may derate or cut-off its performance for self-protection purpose. Electronic components may degrade or cut off their performance for self-protection purposes The component shall automatically change its operating status depending on the voltage relevant for the operating status. Electronic components need to automatically switch operating states according to different voltage levels.
OS4	The component may cut-off its performance. Electronic components may interrupt their performance. Triggered by a reset or an external event(e.g. change of ignition status,restart vehicle,the component shall change its operating status depending on the voltage relevant for the operatingstatus. Triggered by a reset or an external event (e.g. ignition state change, restarting the vehicle), the component should change its operating state according to the voltage associated with the operating state.

2. Typical configuration

ISO 21498-2 Test System
serial number	product	illustrate	brand
1	Powerwave	Powerwave series products (standard 250KW/module, maximum expandable to 1000KW), meet the standards ISO 21498, VW 80300 LV 123 Mercedes MBN 11123, the highest voltage is 1500V, and the voltage slope is 1250V/ms	EMTEST/Switzerland

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