EMI EMC testing off board EV CHarger presentation

EMI EMC testing off board EV CHarger

1. EMI/EMC TESTING ON / OFF Board EV charger ( EVSE)

2. E MI/EMC testing on & OFF Board EV charger (EVSE ) SHANKARA MURTHY Engineering officer - Grade3 Metering & Utility Automation Division (MUAD) CENTRAL POWER RESEARCH INSTITUTE Bangalore – 560 080 Mobile : [phone] E -mail : [email protected]

3. E MI/EMC testing on & OFF Board EV charger ( EVSE) Reference standard IS 17017 ( PART 1) : 2018 – General requirement of EV Charger IS 17017 (PART 21 / SEC 2 ) : 2019 Refers Electromagnetic Compatibility (EMC) requirement for Off-board charger IS 17017 (PART 21 / SEC1 ) : 2019 Refers Electromagnetic compatibility (EMC) requirement for On-board charger

4. EV Charge or EVSE What is EV Charger or EVSE ? EV Charger : The amount of electrical energy stored in a electric vehicle’s battery. EVSE (Electric Vehicle Supply Equipment) : The equipment used to charge an electric vehicle, like a charging station or home charger . General specification of EV Charger Input voltage 230 V for single phase 430 V for 3 phase configuration. Maximum output current 16A/32A or higher depend on requirement . Output voltage - 24/48/72 VDC. Output power rating – up to 100 kw .

5. Off-Board Vs On-Board Charger charac:teristics Off Board Generally higher KW transfer. Include more sophisticated BMS(Battery Management System) system Removes Weight from vehicle On-Board Generally lower KW transfer BMS is managed by on board rectifier Adds Weight to vehicle In summary , on-board chargers are internal to the vehicle and handle the AC-to-DC conversion within the car , while off-board chargers are external systems that deliver high-speed DC power directly to the vehicle.

6. Ports of off-board charging equipment Power input port -------------------------- signal/control port -------------------------- Wired Network port ---------------------------- EUT off board charging equipment CPT PORT ---------- - AE ISN, AN or Vehicle simulators ( AE ) : Automotive Ethernet provides high-speed communication within the vehicle. ( ISN ) : In-system network refers to internal communication networks within the vehicle’s. (AN ) : Automotive network system compasses various communication protocols used for vehicle systems. (VS): Vehicle simulators : Tools used to simulate vehicle behavior for testing and development purposes.

7. Enclosure port Physical boundary of the apparatus through which electromagnetic field radiate . Power input port I nput port at which a conductor or cable carrying the electrical power needed for the functioning of apparatus . (Power can be AC or DC) Wired network port P ort of connection through which voice , data and signal transfers . signal/control port Port at which a cable or conductor is connected for the purpose of transmission of signals excluding wired network and CPT ports. CPT Port (conductive power transfer port) P ower output port of charging equipment in EV charger.

8. Test on & Off Board EVSE

9. Type of tests: Sl. No. Phenomenon Reference standard Test facility availability 1.0 Voltage dips and interruptions 1) IEC 61000-4- 11:2004 (≤ 16 A) & 2) IEC 61000-4- 34 : 2005 and IEC61000-4-34:2005/AMD1:2009 (>16A) Test is feasible with Three Phase Power Fail Simulator . (M/s. Complus System )& Test of Harmonics and flicker test system (m/s. Scientific Instrument) Power source capacity is 90KVA, 3x690VAC, Power fail simulator capacity is 3x690VAC, 100A 2.0 Conducted RF fields IEC 61000-4- 6 : 2013 Test is feasible with Conducted RF immunity test system. Max EUT rating that can be tested is Single phase 280VAC, 16A, 3 Ph. 4 wire 600VAC, 63A, 3 Ph. 5 wire 1000VAC, 63A 3.0 Magnetic fields IEC 61000-4- 8 : 2009 Test coil 1x1m for Impulse magnetic field test (MF1000-1) By using the magnetic field option for Damped oscillatory generator,

10. Operating and test condition for EUT Immunity Waiting mode: when the EUT is fully powered up and connected to EV vehicle but no charging . Charge mode: the EUT shall be operated at 20% of the maximum rated power +/_ 10 % tolerance . Emission 20% of maximum rated power +/_ 10% tolerance in charge mode. 80% of maximum rated power +/_ 10% tolerance or If any load allowing the operation of electrical vehicle suppling equipment's (EVSE )

11. Importance of conducted RF Immunity Test in EV Charger: Testing for conducted RF Immunity test ensures that the EV’s components, such as the electric drive system and battery management, operate reliably in the presence of potential electrical noise. This helps in preventing malfunction or performance degradation due to EMI . IEC 61000-4-6 : This standard specifies testing methods for evaluating a device's immunity to conducted RF disturbances induced by radio-frequency of RF fields. It ensures that electronic devices can operate correctly in interference from external RF sources . Equipment Required for test conducted RF Immunity Test : RF Signal Generator, Coupling & Decoupling Network ((CDNs ), Low-Pass Filter (LPF) and/or High-Pass Filter (HPF ) ). Frequency Sweep: The test involves sweeping frequencies from 150 kHz to 80 MHz Apply an 80% amplitude-modulated signal with a 1 kHz sine wave . Step Size : Frequency step size should not exceed 1% of the previous frequency Dwell Time : At each frequency step, the signal should be applied long enough for the EUT to respond. The minimum dwell time is 0.5 seconds, but it should be longer if needed to observe the EUT’s behavior fully.

12. After performing the conducted RF Immunity test, you will need to monitor and analyze the results according to the performance criteria defined in IEC 61000-4-6 for RF Conducted Immunity test . Performance Criteria Criterion A : Device operates normally without any impact . The EV systems such as battery management should function normally without any observable impact from the Conducted RF Immunity test . Criterion B : Temporary degradation during disturbance but recovers after . the device may experience temporary degradation or loss of performance during the disturbance but recovers to normal operation once the Conducted RF Immunity is removed. Criterion C : Temporary malfunction requiring reset or manual intervention . The device may experience temporary malfunction or loss of function during the disturbance, which requires manual intervention or reset to restore normal operation.

13. voltage dip: a sudden reduction of the voltage at a particular point of an electricity supply system below a specified dip threshold followed by its recovery after a brief interval NOTE 1 Typically, a dip is associated with the occurrence and termination of a short circuit or other extreme current increase on the system or installations connected to it. NOTE 2 A voltage dip is a two-dimensional electromagnetic disturbance, the level of which is determined by both voltage and time (duration ). short interruption: a sudden reduction of the voltage on all phases at a particular point of an electric supply system below a specified interruption threshold followed by its restoration after a brief interval NOTE Short interruptions are typically associated with switchgear operations related to the occurrence and termination of short circuits on the system or on installations connected to it. residual voltage (of voltage dip) the minimum value of r.m.s . voltage recorded during a voltage dip or short interruption

14. Voltage dips, short interruption and voltage v ariations immunity test as per (IEC 61000-4-11& IEC 61000-4-34): The purpose of IEC 61000-4-11& 34 is to ensure that electrical and electronic equipment’s, including electric vehicles (EVs), can reliably operate during voltage disturbances in the power Line. specifically, this standard addresses how equipment should handle : Voltage Dips : Temporary drops in voltage 0% Residual voltage for 0.5&1cycle , 40 % Residual voltage for 10/12 cycles, 70 % Residual voltage for 25/30 cycles, 80 % Residual voltage for 250/300 cycles, Magnitude : The depth of the voltage dip, expressed as a percentage of the nominal voltage. Example : 30% dip means the voltage drops to 70% of the nominal value . Before dip: 400 V During dip: 280 V (30% dip) After dip: 395 V Short Interruptions : The voltage interruption 0 % Residual voltage for 250/300 cycle , Less than 200 ms Voltage Variations : The test of Voltage Variation from 0 to 70% Residual voltage for 25/30 cycles in power Line . For EVs, this means that the vehicle's systems must be able to manage and recover from above electrical disturbances without failing or causing unsafe conditions.

15. • Class 1 This class applies to protected supplies and has compatibility levels lower than public network levels. It relates to the use of equipment very sensitive to disturbances in the power supply, for instance the instrumentation of technological laboratories, some automation and protection equipment, some computers, etc. NOTE Class 1 environments normally contain equipment which requires protection by such apparatus as uninterruptible power supplies (UPS), filters, or surge suppressers. • Class 2 This class applies to points of common coupling (PCC.s for consumer systems) and in-plant points of common coupling (IPC.s) in the industrial environment in general. The compatibility levels in this class are identical to those of public networks; therefore components designed for application in public networks may be used in this class of industrial environment. • Class 3 This class applies only to IPC.s in industrial environments. It has higher compatibility levels Voltage rise (and fall) time t r (and t f ), see Figures Between 1 μs and 5 considered when any of the following conditions are met:

16. Testing Methodology Simulate voltage dips in the power supply to the EV, which could involve disturbances in the vehicle’s charging system or during operation . Monitor and record the behavior of key EV systems, including : Battery Management System (BMS) : Checks how it handles voltage drops. Electric Drivetrain : Assesses performance during and after voltage disturbances. On-Board Charger : Ensures it can handle fluctuations without malfunctioning . Type of test Modes: Charging Mode: Simulate voltage dips during the charging process. Operational Mode: Test voltage dips while the vehicle is in operation to assess the impact on driving performance and safety.

17. Output: If the standard specifies that the vehicle must not experience a loss of function for dips lasting more than 200 ms, and the vehicle performs within this requirement, it is compliant . Voltage dips up to 50% for 200 ms are permissible with no critical failures . Charging rate reduction during a dip (e.g., from 50 kW to 35 kW) and recovery time is 150 ms. Voltage Dip Test Charging Performance Drivetrain Performance Dip Magnitude: 30% reduction Duration: 200 ms Battery Voltage During Dip: 280V Battery Voltage After Dip: 395 V Charging Rate During Dip: 35 kW (from 50 kW) Recovery Time: 150 ms Changes in motor performance, such as torque reduction or speed fluctuations during a dip

18. Acceptable Performance of EV charger: Acceptable Performance Criteria: Comparison of the measured values against the standard’s acceptance criteria. Output Example: If the standard specifies that the vehicle must not experience a loss of function for dips lasting more than 200 ms , and the vehicle performs within this requirement, it is compliant. Thresholds: Specific thresholds set by IEC 61000-4-11 for acceptable performance and recovery. Output Example: Voltage dips up to 50% for 200 ms are permissible with no critical failures. Example Output Values Summary: Voltage Dip Test: Dip Magnitude: 30% reduction Duration: 200 ms Battery Voltage During Dip: 280 V Battery Voltage After Dip: 395 V Charging Performance: Charging Rate During Dip: 35 kW (from 50 kW) Recovery Time: 150 ms  

19. Drivetrain Performance : Torque Reduction: 10% drop Performance Stability: No significant issues Error Codes: Code: BMS communication loss Recovery Time: 100 ms By analyzing these output values, you can assess whether the EVs meets the requirements set forth by IEC 61000-4-11 for handling voltage dips and short interruptions. This analysis helps us to ensure that the EVs operates reliably and safely under real-world electrical disturbances .

20. damped oscillatory wave immunity test as per IEC 61000-4-10: Why this test important for EVs? Reliability : The EVs have many electronic components that need to function properly even in different environments & magnetic interference. This test ensures these components remain reliable. Safety : Ensures that crucial systems like the battery management and control systems do not fail is behavior due to electromagnetic disturbances or influences. Regulatory Compliance : The Regulatory compliance helps to meet EV vehicle to international standards for electromagnetic compatibility, making it suitable for various environments . In summary: The Damped Oscillatory Magnetic Field Immunity Test makes sure that the electronic parts of electric vehicles (EVs) can operate reliably and safely when exposed to sudden and fluctuating magnetic fields influences. This is important because these magnetic fields influences can occur in real-world environments, such as near high-voltage equipment or during electrical switching operations .

21. Test levels : Frequency Range : The test typically covers frequencies from 1 MHz to 100 MHz Field Strengths : The standard specifies different levels of magnetic field strength for testing. The standard specifies different magnetic field strength levels for these tests. Common levels include: 1 A/m (for lower levels), 3 A/m, (for Medium levels), 10 A/m (for higher levels) Performance Criteria : Criterion A : The EUT should continue to operate as intended, with no degradation in performance or functionality. This means no loss of data or operational errors should occur. Criterion B : The EUT can show temporary degradation in performance but should recover to normal operation after the disturbance is removed. This might involve some transient errors but no permanent damage or malfunction. Criterion C : The EUT may experience temporary loss of function or degradation of performance but must be able to resume normal operation after the influence of Magnetic disturbance.

22. Example of test setup for table-top equipment Table-top equipment is often exposed to various electromagnetic disturbances in operational environments. These disturbances can be caused by nearby electrical devices, switching operations, or other sources of transient magnetic fields .

23. Example of test setup for floor standing EV equipment showing the horizontal coupling plane: The purpose of this test setup is to ensure that floor-standing equipment can withstand damped oscillatory magnetic fields without performance degradation. The horizontal orthogonal plane helps simulate real-world conditions where the equipment might be exposed to such electromagnetic disturbances .

24. Purpose dow Purpose The main aim of the IEC 61000-4-10 standard is to test how well equipment can withstand damped oscillatory waves, The different types of electromagnetic disturbance. These disturbances can occur due to various sources, such as switching operations in power systems or other transient phenomena.

25. THANKS FOR KIND ATTENTION