High voltage performance ISO 21498-2 test standard interpretation and solution_Century Wisdom (Suzhou) Testing Technology Co., Ltd

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High voltage performance ISO 21498-2 test standard interpretation and solution

Release time:

2022-03-09 00:00

Source:

　　1. Introduction to the test

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

　　ü 6.2 DC supply voltage variation within operational range

　　The test layout is as follows:

　　The test waveform requirements are as follows:

　　ü 6.3 Generated voltage slope/Generated voltage slope

　　The test layout is as follows:

　　The test waveform requirements are as follows:

　　ü 6.4 Immunity to voltage slope

　　The test layout is as follows:

　　The test waveform requirements are as follows:

　　ü 6.5 Generated voltage ripple/Generated voltage ripple

　　The test layout is as follows:

　　The test waveform requirements are as follows:

　　ü 6.6 Voltage ripple immunity/Immunity to voltage ripple

　　The test layout is as follows:

　　The test waveform requirements are as follows:

　　ü 6.7 Overvoltage/Overvoltage

　　The test layout is as follows:

　　The test waveform requirements are as follows:

　　ü 6.8 Undervoltage/Undervoltage

　　The test layout is as follows:

　　The test waveform requirements are as follows:

　　ü 6.9 Voltage offset/Voltage offset

　　The test layout is as follows:

　　The test waveform requirements are as follows:

　　ü 6.10 Generated load dump voltage/Generated load dump voltage

　　The test layout is as follows:

　　The test waveform requirements are as follows:

　　ü 6.11 Immunity to load dump voltage

　　The test layout is as follows:

　　The test waveform requirements are as follows:

　　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

　　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. 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.

　　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 the performance (performance is not allowed to drop) 　　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 (permissible 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

　　Powerwave series products (standard is 250KW/module, the maximum can be extended to 1000KW):

　　According to the standard:

　　ü ISO 21498

　　ü VW 80300 LV 123 Mercedes MBN 11123

　　Main Specifications:

AC output	250 kVA, 3 x 360 V ( line to neutral), 236 A per line
DC output	250 kW High Voltage Range: Max. 1500 V, Max. 333 A Low voltage range: up to 500 V, up to 1000 A See detailed power curve graph
Number of threads	3
bandwidth	1000 Hz
Frequency Range	DC - 5000 Hz
THD @ 50/60Hz, max.	0.5%
Voltage accuracy	DC: ±0.2% (set value); ±0.15% (full scale); AC: add ±0.1% (set frequency/1000)
voltage slope	1250 V/ms
isolation voltage	L-PE及 N-PE: 1000 VAC / 1500 VDC

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