HangyuPower HY-LVSU Series High Voltage Ripple Test Power Supply for New Energy Vehicles Owner’s Manual

: August 7, 2024
: HangyuPower

Table of Contents

HangyuPower HY-LVSU Series High Voltage Ripple Test Power Supply for New
Specifications
Product Usage Instructions
Product Features
Application Area
Electrical Characteristic Testing Project
Appearance and Display
FAQ
References
Read User Manual Online (PDF format)
Download This Manual (PDF format)

HangyuPower HY-LVSU Series High Voltage Ripple Test Power Supply for New

Energy Vehicles

Specifications

Product: HY-LVSU Series High Voltage Ripple Test Power Supply for New Energy Vehicles
Manufacturer: Hangyu Power System (Shanghai) Co., Ltd.
Type: AC&DC Power Source
Output Voltage: V
Output Current: A
DC Output Power: Single machine maximum kW, can achieve higher power through parallel operation
Support: Multiple power supplies for parallel operation
Ripple Frequency: Up to HzkHz

Product Usage Instructions

Application Areas

HV battery system
Inverter
DC/DC converter HV
On-board charger
Electrical air conditioning compressor
Electrical transmission oil pump

Electrical Characteristic Testing Projects

VW/VWLV Test Content:
- LV/VW Test pulse present voltage ripple
- U_max in the corresponding operating voltage range
- UPP
- VW Cycle description with frequency distribution

Product Selection and Purchase

Product Selection Notice

Product Output series voltage
Output current
Output broadband

Standard Communication Interface

RS-
RS-
Digital I/O

All technical indicators can only be guaranteed when the equipment runs continuously for more than minutes at the specified operating temperature.

HY-LVSU Product Selection and Parameters
This series of products can choose a wide bandwidth power output Hz-kHz.

Product Features

Applicable standards: LV123, VW80303, VW80300, IS021498-2
Output voltage: 0-1500V
Output current: 0-1000A
DC output power, single machine maximum 500kW (Can achieve higher power through parallel operation)
Support multiple power supplies for parallel operation
The maximum ripple frequency can reach 10Hz~150kHz

Application Area

HV battery system
Inverter
DC/DC converter HV
On-board charger
Electrical air conditioning compressor
Electrical transmission oil pump

Electrical Characteristic Testing Project

VW80300. VW80303, LV123 Test Content

Electrical HV test

EHV-01 Performance test within the regular HV operating voltage range
EHV-02 Operation within the HV overvoltage range
EHV-03 Operation within the HV undervoltage range
EHV-05 Generated HV voltage dynamics
EHV-06 System HV voltage dynamics
EHV-08 Generated HV voltage ripple
EHV-09 System HV voltage ripple
EHV-11 HV voltage offset|
EHV-12 HV overcurrent|
EHV-13 HV service life (addenda)
EHV-14 On/off durability testing for HV components
EHV-15 Functionality of HV interlock, maintenance connector, and crash signaling

Product Selection Notice

All technical indicators can only be guaranteed when the equipment runs continuously for more than 30 minutes at the specified operating temperature.

HY-LV123SU Product selection and parameters

This series of products can choose a wide bandwidth power output: 10Hz-150kHz
If no model in the selection table meets your needs, you can propose it separately for special customization.

Output power 2.5kW series power supply selection

Output power 5kW series power supply selection

Output power 10kW series power supply selection

Output power 20kW series power supply selection

Output power 30kW series power supply selection

Output power 40kW series power supply selection

Output power 50kW series power supply selection

Output power 60kW series power supply selection.

Output power 75kW series power supply selection

Output power 100k series power supply selection output power 150kW series power supply selection

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

Purpose: Within the regular HV operating voltage range, functional state A and the maximum specified power must be
verified under various operating parameters.

Test: It includes two sub-tests:

EHV-01a for components that do not require any voltage-dependent derating in the regular operating voltage range as per the Component Performance Specification;
EHV-01b for components that perform voltage-dependent derating in the regular operating voltage range as per the Component Performance Specification.

HV voltage curve within the regular HV operating voltage range

Test parameters for EHV-01a Operation within the regular HV operating voltage range

HV voltage curve in the regular HV operating voltage range with voltage-dependent derating
HV voltage curve in the upper derating range

Test parameters for EHV-01b Operation within the regular operating voltage range

EHV-01b Test parameters within the lower and upper derating ranges

EHV-02 Operation within the HV overvoltage range

Purpose: Within the HV overvoltage range, the specified functional state and the specified power must be verified under various operating parameters.
After the voltage returns to the regular HV operating voltage range, functional state A and the maximum specified power must be fulfilled again.

HV voltage curve in HV overvoltage range
Actual measurement chart

Test parameters for EHV-02 Operation within the HV overvoltage range

EHV-01b Test parameters within the lower and upper derating ranges

EHV-02 Operation within the HV overvoltage range

HV voltage curve in HV overvoltage range
Actual measurement chart

Test parameters for EHV-02 Operation within the HV overvoltage range

EHV-03 Operation within the HV undervoltage range
Purpose: Within the HV undervoltage range, the specified functional state and the specified power must be verified under various operating parameters.

HV voltage curve in HV undervoltage range
Actual measurement chart

Test parameters for EHV-03 Operation within the HV undervoltage range

EHV-05 Generated HV voltage dynamics
Purpose : The purpose of the test is to verify that the HV voltage dynamics (rate of change) generated by the component fall within the specified limits and that the HV functional state does not change during the power jumps that are part of the test.

The control signal for the power cycle – Example
Actual measurement chart

Test parameters for EHV-05 Generated HV voltage dynamics

EHV-06 System HV voltage dynamics
Purpose : The robustness of HV components when subjected to the maximum HV voltage dynamics in the
The HV system (HV voltage rate of change) must be verified.

System HV voltage dynamics – Example
Actual measurement chart

Test parameters for EHV-06 System HV voltage dynamics

EHV-08 Generated HV voltage ripple

EHV-08 Generated HV voltage ripple

450-VDC vehicle electrical system
900-VDC vehicle electrical system

Purpose
The purpose of this test is to verify that the generated HV voltage ripple of an HV component falls within the specified limits and that its HV functional state will not change as a result of this self-generated HV ripple.

Test:
The ripple contents superimposed on the DC HV supply voltage and the DC HV supply current must be tested.
Test setup type 2 in section 4.9.2 must be used.
All measurement signals must be fed to a spectrum analyzer, data logger, or oscilloscope with a fast Fourier transform (FFT) function and must be evaluated.
To take different circuit topologies and power classes into account, this test must be evaluated in the time domain and the frequency domain. The component must meet all of the requirements individually.
Before the test, the worst-case scenario out of the possible operating and load scenarios must be determined for each HV operating voltage. The test must then be carried out using this scenario.
The contractor must agree upon the worst-case scenario test with the purchaser and add it to the test plan.

Worst-case scenarios include, for example:

Voltage ripple caused by hunting oscillation at low load, e.g., at 5% to 10% of the rated load
- Voltage ripple when fast control algorithms are activated, e.g., to damp jerking caused by mechanical vibrations in the powertrain
- Voltage ripple at maximum acceleration from a stop or from a low speed
- Low-temperature operation of a duty cycle/PWM-controlled heater
- The test must be carried out at the following HV component power levels:
The worst-case scenario determined previously
- Idling with powertrains at 5% to 10% of the rated speed
- 25%
- 50%
- 75%
- 100%
For each measurement run, a spectral amplitude distribution of the HV voltage and current ripples must be generated in the form of a diagram. In this diagram, the maximum amplitude and at least the following ?? maxima, with the corresponding frequency and amplitude, must be marked as characteristic frequencies. These characteristic frequencies must be listed in a table that also speciﬁes all relevant parameters.
If operation without an HV energy storage device is intended for the DUT, the entire test must addi tionally be run for this operating case, with the parameters adjusted accordingly.
Example of the measured voltage (VHV) in the time domain
Example of the measured voltage (VHV) in the frequency domain

Table 31 – Test parameters for EHV-08 Generated HV voltage ripple

EHV-09 System HV voltage ripple

Purpose: The robustness of HV components when subjected to the HV voltage ripple produced in the HV system must be verified.
NOTE 4: The test results flow into the System Performance Specification as feedback.

Test

An alternating voltage with a variable amplitude and frequency is superimposed on the DUT’s DC HV supply voltage.
Test setup type 2 in section 4.9.2 must be used and expanded as per the diagram.
An oscilloscope must be used to monitor the injected alternating voltage. The test parameters are specified in Table 32.
If the DUT is powered from the HV vehicle electrical system via a DC-DC converter, the curve for the system ripple must be agreed upon between the purchaser and the contractor on a project-specific basis.

Test case 1

In test case 1, the amplitude of the ripple voltage on the DUT must be set to the values specified in Table 32 and readjusted, if necessary.
During the test, it is necessary to look out for resonance phenomena between the test setup and the DUT. All peaks and sags in the ripple content of the HV voltage and HV current in the DUT must be documented together with the corresponding frequency.

Test case 2

In test case 2, the amplitude of the ripple voltage on the DUT must be set to the value specified in Table 32 at 1 kHz. After this, the required frequency range must be run through without any change to the injected amplitude.
During this process, the amplifier is only used to correct the amplitude & frequency response of the transformer used for coupling purposes.
During the test, it is necessary to look out for resonance phenomena between the test setup and the DUT. All peaks and sags in the ripple content of the HV voltage in the DUT must be documented together with the corresponding frequency.
NOTE 5 : If test case 1 showed that there is a resonance point at 1 kHz, the amplitude must be set at a frequency between 500 Hz and 1 kHz at which there is no resonance point.
DPV: Differential probe for HV voltage measurement
ADC : Oscilloscope
TR: Transformer with wide bandwidth and high DC current-carrying capacity
HY-BPSU: High-speed power supply for automotive electronic testing

Table 32 – Test parameters for EHV-09 System HV voltage ripple

EHV-11 HV voltage offset

HV afar of for test step 1 of the
HV voltage curve for test step 2 of the HV voltage offset test

Table 35 – Test parameters for EHV-11 HV voltage offset

EHV-12 HV overcurrent

Purpose: The robust behavior of the HV overcurrent protection must be verified. The overcurrent strength of electromagnetic switches, contacts, electronic outputs, and supply connections in ba- feed-capable HV components must be tested. Higher currents than in the normal load case (e.g., maximum stalling current of a motor) must also be considered.

Table 36 – Test parameters for EHV-12 HV overcurrent

In a second test step, the DUT must be switched “on”, “off”, and then back “on” once at Itest, HV under load.

EHV-13 HV service life (additional)

Purpose :
As a result of existing HV voltage ripples and HV voltage dynamics, HV components are subject to a load that has an influence on the required service life. This test uses accelerated loading on the components that represents the load during the entire vehicle service life.

Test:
In addition to test L-02 “High-temperature durability service life test” in VW 80000, the following applies: Test setup type 2 in section 4.9.2 must be used and expanded as per the diagram.

1 cycle = computed total test time / 50
The test must be carried out as per the parameters in Table 37.
In each cycle, the HV voltage ripple to which the DUT must be subjected must be set as per Table 38.
For each HV voltage ripple, the frequencies must be distributed evenly as per.

Table 37 – Test parameters for EHV-13 HV service life (additional)

Cycle description with frequency distribution

A 450-V DC vehicle electrical system
B 900-VDC vehicle electrical system
C 1/50 (-10 min) of total test duration (Arrhenius model)
D 1 cycle

VW 80000, L-02 “High-temperature durability service life test” actual waveform measurement.

EHV-14 On/off durability testing for HV components

Purpose :
The purpose of this test is to verify the reliable initialization, startup, and shutdown of the component at all voltage levels.
As a result of pre-charging, HV components are subject to a load that influences the required service life.

Test

This test must be performed as described in VW 80000.
It deviates from VW 80000 as follows: The voltages Vopmin, HV, V, H, and Vopmax,v must be distributed in equal parts to the cycles of the test as defined in VW 80000.

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

Purpose :
The functionality of the HV-specific LV signals and LV signal chains must be tested as part of the electrical tests in WW80000.

Table 39 – Additional parameters for LV signal loops

Test:

The correct functionality and signal integrity of signal generators for an interlock loop (HV interlock) and the naintenance connector must be verified during all the electrical tests in VW 80000.
The correct functionality and signal integrity of evaluation circuits for signals of an interlocking loop (HV interlock), for the maintenance connector, and for crash signaling must be verified during all the electrical tests in VW 80000.
The correct response of HV components to correctly present or transmit signals of an interlock loop (HV interlock), for the maintenance connector, and for crash signaling must be verified during all the electrical tests in VW 80000.
LV signal loops relevant to the HV system’s functionality and safety must additionally be tested with the following tests and parameters (see also table 39):
- Opening the external loop
- Opening internal DUT contacts or switches
- Excessively low impedance or short circuit in the loop
- Capacitive loading of the loop with once and twice the permissible capacitive load as per the Component Performance Specification
- Opening the signal loop with the specified capacitive loads, on each side of the loop at the inserted capacitor at a time.
- Loop short circuit to GND
- Loop short circuit to the positive terminal of all LV supplies
- Opening the loop and short circuit of a signal cable to GND, with both signal cables being connected to GND in succession
- Opening the loop and short circuit of a signal cable to the positive terminal of all LV supplies, with both signal cables being connected- ed to the positive terminal in succession
- Influences due to shunting
A signal detector in an HV component must show the specified behavior at external signal cables and internal contacts or switches during the following tests:
- Opening the external loop
- Opening internal DUT interlock contacts or switches
- Excessively low impedance or short circuit in the loop
- Loop short circuit to GND
- Loop short circuit to +12 V
- Capacitive loading of loop with once and twice the permissible capacitive load as per the Component Performance Specification
- Opening the signal loop with the specified capacitive loads, on each side of the loop at the inserted capacitor at a time
- Opening the loop and short circuit of a signal cable to GND, with both signal cables being connected to GND in succession
- Opening the loop and short circuit of a signal cable to the positive terminal of all LV supplies, with both signal cables being connected to the positive terminal in succession
- Briefly opening the loop for a duration that ensures that the opening is unambiguously detected as a discontinuity (e.g., for a detection threshold of 5 ms 10%, the brief opening must last > 6 ms and < 9 ms)
- Influences due to shunting

The DUT’s response to the influence of signal loops or signals must be monitored and documented in the test report. The time between the moment the loop exerts its influence and the DUT’s response must be recorded.

Appearance and Display

Control Panel Description
Power input circuit breaker;
7-inch LCD window display: voltage and current setting values, voltage, and current measurement values function settings menu;
Function buttons:
Used for required numerical input and parameter settings;
Voltage/current setting key
Function reuse key
Status indicator light
Chassis handle
Multi-stage shuttle adjustment knob, the inner circle adjusts one word at a time, and the outer circle is divided into ‡ 8 adjustable segments;
Lock, Enter, Esc. Local, Reset/Alarm. Output ON/OFF
19-inch standard rack mounting holes

Display screen description

Voltage measurement value display;
Current measurement value display;
Frequency setting value display;
Voltage setting value display;
Current time display;
Accumulated working time display;
Current working hours;
Set menu button for setting system parameters;
Programming button, used to set parameters during programming;
When editing the voltage and current values, quickly increase them. For example, when the voltage is 2V, pressing “+” can increase it to3, 4, 5……;
When editing voltage and current values, quickly reduce them. For example, when the voltage is 10V, press “-” to decrease it to9, 8, 7……;
When modifying the set value, you can click the arrow keys to select the number that needs to be modified.

10U 440 (W) 600(D) 445(H)mm

18U 600(W)800(D)920(H)mm

Customer Cases (Partial)

Official WeChat: hypower-cn

Contact us

Hangyu Power System (Shanghai) Co., Ltd
Mobile/Whatsapp : +8613801800699
Fax: +86-21-67285228-8009
Email: sales@hangyupower.com
neo@hangyupower.com
Address: Block B, Building 11, No. 1698 Minyi Road, Songjiang District, Shanghai
Web: www.hangyupower.com

Hangyu Power System, 2024
Hangyu Power Automotive Electronic Testing Solution Manual, Version 05.00, February 2024
All technical data and instructions are based on the actual product
If there are any changes, Hangyu Power has the final interpretation right

FAQ

Q: What are the main application areas for the HY-LVSU Series?
- A: The main application areas include HV battery systems, inverters, DC/DC converters HV, onboard chargers, electrical air conditioning compressors, and electrical transmission oil pumps.
Q: Can the output power of the HY-LVSU Series be increased through parallel operation?
- A: Yes, the single machine’s maximum output power can be increased through parallel operation.

References

航裕电源英文网站

Read User Manual Online (PDF format)

Read User Manual Online (PDF format) >>

Download This Manual (PDF format)

Download this manual >>