ISO 21498 HV Test System & Ripple Generator

ISO 21498 HV Test System & Ripple Generator

Advanced Ripple Testing: Meets ISO 21498, LV123, VW 80300, Nissan MES PW 67602, Mazda, and emerging standards.
Series Amplifier Integration: High accuracy ripple injection, minimal distortion, and enhanced safety.
Waveform Versatility: Sine, square, trapezoidal, pulses, and triangle waveform generation.
WaveMaster Software: Fast DUT impedance measurement, automated test sequences, and dynamic voltage/current control.
High Power Capability: Ripple Voltage up to 100 Vpp, currents from 100A to 2000A+, and frequency range 10 Hz–300+ kHz.
Future-Proof Design: Modular architecture for easy upgrades and adaptation to new standards.

PARTNER:

BOLAB SYSTEMS GMBH

MARKETS:

CATEGORIES:

TEST STANDARDS:

HV Expanding Growth Diagram

SPECIFICATIONS

Systems HV Ripple Generator

Advanced High-Voltage Ripple Testing for ISO 21498-2 and Beyond

The Systems HV Ripple Generator represents the pinnacle of high-voltage ripple testing, purpose-built to ensure compliance with ISO 21498-2, LV123, VW 80300, Nissan, Mazda MES PW 67602, FORD, Stelantis, and other emerging automotive standards. Designed specifically for the rigorous demands of electric vehicle (EV) component testing, this advanced system guarantees reliability, precision, and future-proof capability.

Sec	Test	Test Parameters	Voltage Levels	Frequency Range	Operating Conditions
5.2	DC Supply Voltage Variation	Voltage variation within operational limits; Rates 2V/s; Hold ≥ 30s	Ulower_limit to Uupper_limit	DC only	Continuous operation, unlimited range
5.3	Generated Voltage Slope	Voltage slope rate; Peak power transitions; Frequency ≤ 1 kHz	Within an unlimited operating range	DC transitions	Peak/idle power transitions
5.4	Immunity to Voltage Slope	Voltage slope immunity; Rates ≥ 1, 10, 20 V/ms; OS stability	OS1 and OS2 ranges	DC transitions	Stable operation during voltage slopes
5.5	Generated Voltage Ripple	Ripple voltage measurement; 10 Hz to 150 kHz; ≤ 5% tolerance	Uinit, Umax_unlimited_op, Umin_unlimited_op	10 Hz - 150 kHz	Worst-case ripple conditions
5.6	Immunity to Voltage Ripple	Ripple immunity; Frequency sweep 10 Hz -150 kHz; Sinusoidal ripple voltage	Uupper_limit, Uinit, Ulower_limit	10 Hz - 150 kHz (sinusoidal)	Ripple tolerance under load conditions
5.7	Overvoltage	Overvoltage tolerance; Upper voltage limit; ≤ 2 V/s rate; Hold time ≥ 10 s	Above Uupper_limit to Uover_limit	DC	Component protection mode (OS3, OS4)
5.8	Undervoltage	Undervoltage tolerance; Lower voltage limit; ≤ 2 V/s rate; Hold time ≥ 20 s	Below Ulower_limit	DC	Stable under voltage drops; OS3, OS4
5.9	Voltage Offset	Offset voltage handling; Connection of HV+/HV- to ground reference; ≤2 V/s rate	Offset to ground reference	DC	Stable with offset conditions
5.1	Generated Load Dump Voltage	Load dump voltage generation; Power disruption; Peak voltage and rise time measurement	Generated by DUT, measured at disruption	Transient DC	Generated load dump event
5.11	Immunity to Load Dump Voltage	Load dump voltage immunity, Rapid voltage rise, Voltage level up to overvoltage limit	Up to Uover_limit	Transient DC	Stable under load dump voltage conditions

Unique Series Amplifier Integration

Unlike conventional ripple test setups, BOLAB's revolutionary design places the amplifier directly in series with the HV power supply, ensuring:

Superior Test Accuracy: Eliminates signal distortion, providing accurate ripple injection across all frequencies.
Increased Efficiency: Minimizes power loss and maximizes test energy delivered to the Device Under Test (DUT).
Enhanced Safety: Advanced coupling methods safeguard both personnel and equipment by effectively isolating and controlling high-voltage signals.

High Speed

Even Load Dump pulses are covered, unique in the world, high-end test systems for Electric Vehicles.

3000 V/ms for 20 V is required in VW80300 with a 7µs rising time.

BOLAB´s solution: better than 1µs!

250 V/ms increase for 150 V:

	+		=
HV supply		High Frequency 4 Quadernt Supply		Combination in series

High Voltage DC Power Supply + 4 Quadrant Amplifier In Series

Setup

As coupling network transformers (CDN) are limited in speed, frequency ranges, amplitude and especially allow only sine interferences, this solution cannot be used for Load Dump applications. Load Dump requirements are both part of LV 123 and VW 80300 standards.

Our most flexible solution is the combination of a high voltage power supply in series to our 4 quadrant amplifiers. Individual transients and even Load Dump requirements are possible.

In addition, modular design allows the adaption to almost all manufacturers of high voltage power supplies. There is no need to purchase an additional power supply if one is already available.

Advantages

Highly flexible
Transient interferences
Load Dump possible
Start from DC
High-frequency testing without losses

Disadvantages

More safety needs to be implimented

Comprehensive Testing Capabilities

The HV Ripple Generator effortlessly meets and exceeds the stringent requirements outlined in ISO 21498 and other critical automotive standards:

Frequency Range: 10 Hz to over 300 kHz
Ripple Voltage: Up to 100 V peak-to-peak (Vpp)
Ripple Current: Scalable from 100A up to 2000A+ Upgrade onsite
Injected Waveform Versatility: Sine, square, trapezoidal, pulses, and triangle waveforms

Industry-Leading WaveMaster Software

Software transforms your testing environment:

Rapid DUT Impedance Measurement: Accurately measure impedance in under one minute.
Real-Time DAQ Integration: Continuously monitor DUT performance and instantly adapt test parameters.
Automated Test Sequences: Simplify complex routines with fully customizable and repeatable test sequences.
Dynamic Compensation: Automatically adjusts voltage and current to maintain consistent test conditions, even at challenging high-frequency and low-impedance scenarios.

Built for Today, Ready for Tomorrow

Systems ensures your testing solutions remain ahead of the curve:

Future-Proof Design: Easily upgradeable hardware and software to accommodate evolving automotive standards.
Robust Construction: Engineered for intensive use in industrial environments, providing long-term reliability and consistent performance.
Extensive Standards Coverage: Compatible with ISO 21498, ISO 7637-4, LV123, VW 80300, Nissan MES PW 67602, Mazda, BMW GS 95023, Renault 36-00-811, and more.

Equipment:

Item	Discription	Picture
BLS 100-TS Series	4 Quadrent Amplifier SYSTEM Arbitrary 4-Quadrant Voltage Amplifier -30 V … +70 V \| 40 A \| 1.000 W - Arbitrary 4-Quadrant Voltage Amplifier -30 V … +70 V \| 76 A \| 2.000 W - Arbitrary 4-Quadrant Voltage Amplifier -30 V … +70 V \| 114 A \| 3.000 W - Arbitrary 4-Quadrant Voltage Amplifier -30 V … +70 V \| 152 A \| 4.000 W - Arbitrary 4-Quadrant Voltage Amplifier-30 V … +70 V \| 190 A \| 5.000 W - Arbitrary 4-Quadrant Voltage Amplifier -30 V … +70 V \| 228 A \| 6.000 W ....... Systems up to 54kW 2000+ Amps! All Systems are Fully Expandable after purchase. Or multi-unit configurations that are used independently and brought together when a higher current is needed. Options: - Internal 4 Channel Isolation Amplifier - Adjustable Internal Resistor 0 … 200 mOhm - Over Voltage Protection for serial operation of a high voltage DC power supply and a 4 quadrant amplifier system. - Voltage measurement at load including Closed-Loop-Regulation:
BLS 54/162-1000C	Single Channel High Dynamic Power Supply Bidirectional DC-Power Supply Inclusive WaveMaster Control DC Output: Voltage Umax: 1000 V Current Continuous Imax: ±162 A Device Power Pmax: 54 kW Number of output channels: 1 Voltage accuracy dynamics (values for one power supply module): Voltage rise time 10% - 90%: Voltage fall time 90% - 10%: Combine modules to reach desired Current up to 44 (<7000Amps!) Options: HMI.3 - Human Machine Interface 5'' touchscreen RPP.1 - Reverse Polarity Protection ISR.3 - Integrated Safety Relay SAFREL - Safety Relay to reach PL e SAFBUS - Safety Bus Cable PS-Rack - Cabinet 32U 2 Modules+ options
BLS 54/108-1500C	Single Channel High Dynamic Power Supply Bidirectional DC-Power Supply Inclusive WaveMaster Control DC Output: Voltage Umax: 1500 V Current Continuous Imax: ±108 A Device Power Pmax: 54 kW Number of output channels: 1 Voltage accuracy dynamics (values for one power supply module): Voltage rise time 10% - 90%: Voltage fall time 90% - 10%: Combine modules to reach desired Current up to 44 (<4500Amps!) Options: HMI.3 - Human Machine Interface 5'' touchscreen RPP.1 - Reverse Polarity Protection ISR.3 - Integrated Safety Relay SAFREL - Safety Relay to reach PL e SAFBUS - Safety Bus Cable PS-Rack - Cabinet 32U 2 Modules+ options
BLS 400-6361	AnyWave + WaveMaster External control unit solution to run waveforms with amplifiers and standard power supplies via its analog interfaces. Included WaveMaster software for waveform generation and data acquisition. • USB interface • Maximum sampling rate of analog outputs: 2.8 MS/s • 2 analog outputs • Unlimited memory data points • WaveMaster software for graphical and tabular input of waveforms and for controlling the amplifier/power supply • Graphic display of generated voltage curve in sync to measured signals of current and voltage of the monitor outputs • Integrated test pulses out of LV124 / VW80000, DIN 40839, ISO 16750, ISO 7637 as well as other manufacturer standards (Daimler, BMW, VW, etc.) • Taking over data out of oscilloscopes and run real signals • DLL´s for embedding in LabView, C#, C++, ANSI C, Python, Vector CAPL, etc. Dimension: 19“ Width, 2 U
BLS AN-V-X-200A BLS AN-V-X-400A BLS AN-V-X-600A BLS AN-V-X-800A	HV- Artificial Network 7 in 1 ISO 21498 Use Case A, B, C, Z Impedence in frequency range 10Hz bis 150 kHz according to ISO 21498. Within tolerances to ISO for full temperature and operating range. Max. voltage: 1000V Max. RMS current: 60 amp to 800 A+ Inductivities Lc 2x 1 μH Capacitors Cy 2x 1 μF Resistors Ri,HV: 2x 10 mΩ, 2x 25 mΩ, 2x 100 mΩ, 2x 50 mΩ - (also compliant according to LV 123) Connectors for direct connection of BOLAB 4-Quadrant Amplifier System Capacitor bank Cs >10 mF* built in Configered for your needs impdances you need
Cx 10000-xxx-xxx	Capacitor Cx, stand-alone ≥ 10 mF incl. active discharge 100 - 600 A AC + DC RMS 150 - 350 A AC RMS 1,000 V DC Screw terminal connectors M12 (M16 for 600A) DC power supply Ripple generator
BLS 300-SSM-TS-12	WaveMaster-Software service, support, and maintenance

Why Choose this System?

Innovative Amplifier Integration: Revolutionary series coupling delivers unprecedented test accuracy and safety.
Superior Software & Support: WaveMaster software, backed by unmatched customer support, ensures easy integration, rapid test setup, and accurate results.
Ultimate Versatility: It handles all ripple test scenarios, including advanced waveform requirements for current and future automotive standards.

Applications & Market Segments

The HV Ripple Generator is ideal for:

Automotive OEMs and Suppliers
EV Battery Manufacturers
EV and Hybrid Vehicle Testing Labs
Research and Development Facilities

When it comes to advanced high-voltage ripple testing, the choice is clear: Systems HV Ripple Generator – engineered for today's challenges, ready for tomorrow’s standards.