CSM High-Voltage Measurement Systems Safe Measurement on High-Voltage Components
CSM HV Modules // High-Voltage Safe Measurement Systems Safe Measurement on High-Voltage Components E-mobility: enhancing eiciency, extending the range The German government plans to get one million electric vehicles out on the road, by 2020. This will only succeed if prices are cut and the range of electric vehicles is concomitantly increased, thus enhancing their attractiveness among consumers. The new development and optimization of existing vehicles and concepts play an essential role in this regard. For this purpose, powerful measurement systems which meet the increased safety requirements of the high-voltage environment and allow for eicient work are needed. High-voltage safety from the sensor to data acquisition is a key requirement for these measurement systems. Additionally, a fast installation as well as exact and reliable measurement results need to be ensured. High-voltage safe measurement module in MiniModule design Precise measurement of analog signals and temperatures in high-voltage environments The high-voltage safe CSM measurement systems enable the acquisition of analog signals and temperatures (K-type thermocouples, PT100 and PT1000 sensors) in high-voltage environments. The new measurement modules HV ADMM and HV PTMM complement the proven thermo measurement module HV THMM. With the HV ADMM CSM oers two module versions for the acquisition of analog signals of up to ±90 V in high-voltage environments. One of them disposes over a galvanically isolated and high-voltage safe sensor excitation. This allows the installation of standard sensors in combination with special sensor cables in high-voltage environments. Measurements can thus be safely performed in accordance with EN 61010. In addition, this enables the acquisition of voltage, current (via shunts), humidity, pressure, acceleration, etc. in high-voltage environments. Measurement module HV PTMM is specifically designed for high-precision temperature measurements with RTD elements (PT100 and PT1000 sensors). Due to the very thin structure, foil-pt sensors can be applied directly between battery cells. Thanks to the compact design with protection class IP67 and an operating temperature range from -40 C to +100 C, these modules can be installed directly in the engine compartment and other constrained spaces close to the high-voltage battery and power electronics. The modules feature a high degree of measurement accuracy over the entire operating temperature range. The installation close to the point of measurement also reduces interferences, which further enhances the precision of the measurement results. Moreover, the installation close to the sensor enhances safety, since the potential danger is reduced to the wear of sensor cables on highvoltage potential. As for stationary measurements, CSM oers these high-voltage modules in 19" slide-in housings for test benches as well. 2 www.csm.de
CSM measurement modules oer tested safety in accordance with EN 61010 Thanks to the safety concept, CSM systems can be used to set up high-voltage safe measurement chains from the sensor to the point of data acquisition. Part of the safety concept is the type approval testing of the entire system, consisting of the measurement modules and signal cables, in accordance with EN 61010 by an accredited test laboratory. In contrast to conventional measurement modules, each high-voltage module as well as each signal cable is individually tested in a high-voltage isolation test prior to shipment. Double-insulated 8-pin multiconnector cables are used as signal cables to connect the sensor to the module. Each cable can be used for the high-voltage safe connection of up to four points of measurement to one measurement module. This reduces cabling complexity and thus costs in comparison to the use of single-channel cables. Advantages of CSM High-Voltage Measurement Modules Tested high-voltage safety for the entire measurement system from the sensor to the point of data acquisition Reinforced insulation up to 846 V: Every module is routine-tested and comes with a testing certificate. set-up times in test benches and thus enhances test bench runtime. Modules in MiniModule housings dispose over protection class IP67 and a very wide operating temperature range from -40 C to +100 C. Extremely low power consumption and thus negligible intrinsic heating ensure the lowest possible temperature drift and high measurement accuracy over the entire operating temperature range. Available in MiniModule housings for mobile use in distributed measurement applications and as 19'' slide-in modules for measurement applications in test benches and vehicles Extremely compact and robust: MiniModules can be installed directly in the engine compartment and close to the points of measurement. This enhances safety and minimizes cabling complexity and costs. In addition, it reduces interferences to a minimum. Distributed measurement applications are also applicable for test benches: The connection and the configuration of the measurement setup can take place outside the test bench. This cuts Test bench module for temperature measurements with 8 channels: HV TH-TBM 8 3
CSM HV Modules // MiniModules High-Voltage MiniModules HV THMM 4 MiniModule HV THMM 4 is especially designed for safe temperature measurements on high-voltage live parts and is therefore very well suited for mobile and stationary use in the fields of e-mobility (electric and hybrid vehicles). 4 NiCr-Ni temperature inputs (K-type), galvanically isolated Reinforced insulation up to 846 V Internal cold junction compensation per channel Operating temperature range: -40 C to +100 C Robust and extremely compact aluminium housing, IP67 HV THMM modules allow high-voltage safe temperature measurements with thermocouples. HV PTMM 2 MiniModule HV PTMM 2 features 2 measurement inputs in 4-wire technology for PT100 and PT1000 sensors and has been specifically designed for precise temperature measurements in high-voltage environments. HV PTMM 2 is for example ideally suited for temperature measurements with very high accuracy requirements placed on the entire system, consisting of RTD sensors (PT100 / PT1000) and measurement modules. 2 inputs in 4-wire connection for PT100 and PT1000 sensors Reinforced insulation up to 846 V Operating temperature range: -40 C to +100 C Robust and extremely compact aluminium housing, IP67 HV PTMM modules for high-precision temperature measurements with PT100 / PT1000 RTD elements. 4 www.csm.de
CSM HV Modules // MiniModules HV ADMM 2+ MiniModule HV ADMM 2+ has been designed for the acquisition of analog signals in high-voltage environments. With two analog measurement inputs, each of which disposes over a galvanically isolated sensor excitation, the HV ADMM 2+ is suitable for a wide range of applications. Thanks to the galvanically isolated sensor excitation, standard sensors designed for conventional low-voltage applications, can be used in conjunction with high-voltage safe sensor cables in high-voltage environments. 2 analog inputs with reinforced insulation up to 846 V Galvanically isolated sensor excitation with reinforced insulation up to 846 V Measurement data rate up to 20 khz via (2 channels with 2 Mbit/s ) Application of standard sensors in high-voltage environments: measurement of voltage, current (via shunt), humidity, pressure, acceleration, etc. in high-voltage environments. Operating temperature range: -40 C to +100 C Robust and extremely compact aluminium housing, IP67 Integrated sensor excitation provides additional options for measurement: HV ADMM 2+ allows the safe measurement of analog signals with standard sensors in a high-voltage environment. HV ADMM 4LI MiniModule HV ADMM 4LI features four analog measurement inputs for measuring analog voltages up to ±90 V in high-voltage environments. 4 analog inputs with reinforced insulation up to 846 V Measurement data rate up to 20 khz via (2 channels with 2 Mbit/s ) Operating temperature range: -40 C to +100 C Robust and extremely compact aluminium housing, IP67 HV ADMM 4LI measures analog voltages up to ±90 V in high-voltage environments. 5
CSM High-Voltage Modules // Test Bench Modules High-Voltage Test Bench Modules HV TH-TBM 8 HV TH-TBM measurement modules have been specifically developed for safe temperature measurements with K-type thermocouples on high-voltage components in the fields of e-mobility (electric and hybrid vehicles). Designed as 19" slide-in modules, both versions are ideally suited for use in test benches and in the vehicle interior. 8 NiCr-Ni temperature inputs (K-type), galvanically isolated Reinforced insulation up to 846 V Internal cold junction compensation per channel Operating temperature range: -40 C to +85 C Robust aluminium housing (19'' 3 U / 12 HP) HV TH-TBM 8 /65: measurement modules for high-voltage safe measurements with K-type thermocouples HV PT-TBM 8 HV PT-TBM 8 features eight measurement inputs in 4-wire-connection for PT100 and PT1000 sensors and has been especially designed for precise temperature measurements in high-voltage environments. Due to the flat design of PT100 and PT1000 sensors, the HV PT-TBM 8 is ideally suited for very accurate temperature measurements between battery cells. Due to the thin-film design of foil PT sensors, it is possible to precisely monitor the temperature of battery cells, even under very confined conditions. 8 inputs in 4-wire connection for PT100 and PT1000 sensors Reinforced insulation up to 846 V Operating temperature range: -40 C to +85 C Robust aluminium housing (19'' 3 U / 19 HP) HV PT-TBM 8 is ideally suited for extremely precise and high-voltage safe temperature measurements. 6 www.csm.de
CSM High-Voltage Modules // Test Bench Modules HV AD-TBM 4+ HV AD-TBM 4+ has been specifically developed for the safe measurement of analog signals with standard sensors on high-voltage components in the fields of e-mobility. Designed as a 19" slide-in module, it is ideally suited for use in test benches and in the vehicle interior. 4 analog inputs with reinforced insulation up to 846 V Galvanically isolated sensor excitation for the use of standard sensors in high-voltage environments: for the acquisition of voltage, current (via shunts), humidity, pressure, acceleration, etc. in high-voltage environments Measurement data rate up to 20 khz via (2 channels with 2 Mbit/s ) Operating temperature range: -40 C to +85 C Robust aluminium housing (19'' 3 U / 12 HP) Integrated sensor excitation with additional options for measurement: HV AD-TBM 4+ provides options for the safe measurement of analog signals with standard sensors in high-voltage environments. HV AD-TBM 8 HV AD-TBM 8 features eight analog measurement inputs for measuring analog voltages up to ±90 V in high-voltage environments. 8 analog inputs with reinforced insulation up to 846 V Measurement data rate up to 20 khz via (2 channels with 2 Mbit/s ) Operating temperature range: -40 C to +85 C Robust aluminium housing (19'' 3 U / 12 HP) HV AD-TBM 8 measures analog voltages up to ±90 V in high-voltage environments. 7
CSM High-Voltage Modules // Safety Concept CSM Safety Concept CSM measurement systems meet high safety requirements. Part of the safety concept is the type approval test of the entire system, consisting of measurement modules and signal cables, by an accredited test laboratory. In addition, each measurement module is subjected to a routine test in accordance with the safety standard EN 61010, prior to shipment. A test protocol is accordingly issued. With these tests and in conjunction with the routine-tested signal cables of SAB Bröckskes, the user s safety can be ensured from the sensor to the data acquisition (data loggers, laptop, etc.). As for the use of standard sensors, they must be safely installed and connected in the high-voltage environment. CSM s safety concept comprises the following tests: Type approval test according to safety standard EN 61010 by an accredited test laboratory Routine test of measurement modules according to safety standard EN 61010 EMC test (CE) according to EN 61326-1 Shock and vibration testing according to EN 6006 Protection class testing according to EN 60529:2000 Routine test of pre-assembled cable according to VDE III ±90 and EN 50265-2-1 Safety features of CSM measurement systems: High-voltage safe measurement modules and specifically developed multi-connector cables with safe plug-in system for the connection of sensor to module Reinforced insulation and galvanically isolation of the modules up to 846 V in accordance with EN 61010 between: Measurement channels Measurement channels and power supply Measurement channels and Measurement channels and housing Galvanically isolated sensor excitation, adjustable per channel with reinforced insulation in accordance with EN 61010 Approved for the use in environments with pollution degree 4 (HV MiniModules) Partial potting of module components: The modules can still be repaired. Additional ground connection for connecting the ground of the car body to the ground leakage monitor of the vehicle. The use of cables and specifically developed, high-voltage safe multi-connector cables with integrated, fully isolated multi-connector concept High-voltage environment Low voltage Sensors bus data acquisition via software or data logger Example: measurement application in high-voltage environment with CSM measurement system 8 www.csm.de
SAB Bröckskes High-Voltage Safe Multi-Connector Cables The specifically developed multi-connector cables for up to four points of measurement are perfectly adapted to the characteristics of CSM measurement modules. They are protected against accidental touch (in the case of isolated sensors) and feature a rugged design. Thanks to their small cross section, they are ideally suited for space-saving applications. Since cables are often exposed to chafing on bodywork parts, these multi-connector cables dispose over a blue inner sheath. If this inner sheath becomes visible, this indicates that the cable is no longer safe for operation. Cables are available for AD, PT and TH measurement modules. All advantages at a glance Only one cable for up to four points of measurement: reduction of error sources and enhanced safety (abrasion, cable break, etc.) Reduced cabling complexity reduces costs in comparison to the use of single-channel cables. Double insulation up to 1000 V: protection against accidental touch, enhanced electrical and mechanical safety Individually designed multi-connector concept with fully isolated plastic connectors, suitable for CSM measurement modules: fire protection class V0, protection class IP67 multi-connector individual cable lengths sensor ends The multi-connector cable with its fully isolated plastic connector allows a reliable and safe cabling of the entire system. CSM High-Voltage Isolation Testing Station Operational safety test of high-voltage measurement modules The high risk potential during measurements in high-voltage environments requires an enhanced safety awareness. This means: The user s life and health should be put in the first place. CSM therefore strongly recommends to check the high-voltage isolation of these measurement modules on a regular basis in order to ensure their operational safety at all times. This applies in particular, if high-voltage measurement modules are exposed to strong external influences. For this purpose CSM developed the High-Voltage Isolation Testing Station, consisting of PC-based isolation test software, a self-test adapter and further accessories. This station provides options for testing the high-voltage isolation of CSM measurement modules directly on the customer's premises. This is cost-saving and improves the availability of the high-voltage measurement modules as it is no longer necessary to send them to the manufacturer for testing. During a high-voltage isolation test, the isolation of a measurement input is tested against all other measurement inputs, as well as against the housing, the power supply and the bus. 9
Example of Application Temperature Measurement on High-Voltage Components High-voltage battery and power electronics The ideal temperature of lithium-ion batteries as well as of active and passive elements is about 25 C. Higher and lower temperatures aect the performance and service life of the battery: Increase of the thermal resistances Cyclic service life Battery power output Power loss during charging or discharging Why are temperature measurements on high-voltage batteries important? Extended service life Better performance Dimensioning of the thermal management (cooling) in order to achieve component temperatures that are as consistent as possible Verification of simulation models Optimization of installation space and weight CSM measurement systems are also applied in the Formula E. Picture: ABT Sportsline GmbH CSM high-voltage measurement technology: the response to hazard potential in measurement applications used in high-voltage environments Dealing with the high-voltage power in electro- and hybrid vehicles, particularly in the course of the development and testing, involves a high risk potential for the life and health of the development technicians and engineers. For example, the incorrect acquisition of the safety parameters of a high-voltage battery can lead to overheating and as such to an imminent danger of an electrical fire that is diicult to extinguish. Decisive in the case of the battery development is not only the outdoor temperature, but also the reliable acquisition of the internal temperatures of the individual battery cells in all operating conditions and ambient temperatures. In order to make use of foil PT sensors which are very well suited for this purpose, CSM has developed the HV PT measurement modules. CSM high-voltage measurement systems enable the precise acquisition of all the necessary measure ment variables. The safety concept reliably separates the high-voltage measurement range (indicated by the orange color-coding of the system components) from the low-voltage range which helps preventing a transfer of high voltage to the data acquisition systems, such as laptops or data loggers. This means more safety for the user when handling high-voltage measurement applications. 10 www.csm.de
CSM HV Modules // About us About Us CSM Computer-Systeme-Messtechnik GmbH CSM is a leading and innovative manufacturer of mobile measurement equipment and data acquisition systems. For over 30 years, we set technological standards in the field of measurement technology. Our products are successfully and reliably in use worldwide, in the case of virtually all known manufacturers of automobiles and commercial vehicles as well as their suppliers and service providers. Permanent innovation in conjunction with long-term satisfied customers constitute our guarantee for success, also in the future. We constantly address new challenges, such as the need for high-voltage safe as well as synchronous high-speed measurement technology for the test and trial of electric and hybrid vehicles. The close cooperation with Vector Informatik allows us now to oer complete solutions consisting of hardware and software from one source, which is an ideal addition to our measurement technology product range. Products and Data: all Information at a Glance www.csm.de Find all information on CSM measurement modules and data loggers on our new website at www.csm.de. Make use of our solutions for the development and testing of cars, construction and agricultural machinery, cranes, commercial vehicles, trains, aircraft, boats, wind turbines, etc. Introduction to our product portfolio Examples of application The latest CSM software versions are available for download. Fast access to all datasheets and product information www.csm.de 11
V0110 CSM GmbH Computer-Systeme-Messtechnik Raieisenstraße 36 70794 Filderstadt Germany Phone: +49 711-7 79 64-20 Fax: +49 711-7 79 64-40 info@csm.de www.csm.de All trademarks mentioned are property of their respective owners. Specifications are subject to change without notice. open and CiA are registered community trade marks of in Automation e.v. EtherCAT is registered trademark and patented technology, licensed by Beckho Automation GmbH, Germany. 12 www.csm.de