Component EMC Test · Web viewUse of the product on other vehicle platforms may require...

FMC 1278 Test Plan Template 16 May, 2016

Component / Subsystem EMC Test Plan Title PageProduct Name:

Product Supplier Name: Ford Recognized EMC Test Facility(s) used:Include Lab Manager Name(s)

Product Part Number(s):List all product part numbers that this test plan is applicable to. (May be listed on separate page) Vehicles & Model Year using this product:

If multiple part numbers, identify which vehicles part numbers are used.(May be listed on separate page with part numbers)

Product Printed Circuit Board(PCB) Number(s):List all PCB numbers that this test plan is applicable to.

Product Manufacturing Location(s)Where will this product be produced?

EMC Specification Used:Identify specification and revision number being used

I certify that the information contained in this test plan is factual including description of the product operation, correct functional classifications, and acceptance criteria. I understand and agree that any subsequent changes to this test plan prior to design verification testing shall be communicated to the FMC EMC department. Any changes or revisions to this test plan after test completion shall require written technical justification and approval by the same EMC department. I understand that failure to follow this process may result in non-acceptance of the product's EMC test data by the FMC EMC department. I also understand and acknowledge that requirements validated via this test plan are relevant only to the specific vehicles that the product is to be fitted to. Use of the product on other vehicle platforms may require additional EMC performance requirements, which will necessitate additional verification testing of the product. I certify that the product samples submitted for EMC testing are of a production representative design. I authorize the EMC test laboratory to submit a summary report directly to the FMC EMC department no later than five (5) business days following completion of testing. I also authorize forwarding a copy of the EMC test laboratory's detailed test report directly to the FMC EMC department within thirty (30) business days following completion of testing. I certify to perform all tests in a Ford recognized laboratory.

Supplier Product Design Engineer Concurrence:

_________________________________________________Name Signature and Date

Supplier Product Manager Concurrence:

_________________________________________________Name Signature and Date

Ford Design & Release Engineer Concurrence:

______________________________________________________Name Signature and Date

For Internal EMC Department Use (Do not Mark)Received by FMC EMC Department

Name Telephone number

Signature and Date FMC EMC Test Plan Tracking Number

Test Plan Revision History

Date DescriptionInitial Test Plan Release

16 May, 2016 of 26 Printed copies are uncontrolled

1.0 Introduction - Scope and purpose of test plan

1.1 Product Family Description

- General Product Family Description- Differences/similarities between HW/SW Versions if any- Max complexity DUT's may be used to represent an entire product family, provide

justification/rationale for doing this.

1.2 Theory of Operation

- General Theory of Operation inclusive of how it is used in the vehicle- Functions/Features – Customer Interactions- Interaction with other vehicle systems & interfaces


Internal block diagram of the DUT

Sub-System Interfaces – Configuration(This could be a maximum system complexity configuration)

Provide FULL Block Diagram to show how the DUT will be connected in the vehicle

1.3 Physical Construction

a) What are the Product Package Material(s):Metallic ► Non-Metallic ► Conductive ► Non-Conductive ►

Provide further Material description below as necessary:

b) What is the Product Package Volume:X Dimension (mm) ► Y Dimension (mm) ► Z Dimension (mm) ►


c) Provide the Product Mechanical View:

Top – Plan View ISO View

Front View Side

d) How many separate Connectors?

Provide connector diagram and pinout detail for each connector.


Connector Diagram

Connector Diagram(s)

Connector Pinout Detail

Pin # Signal Name Wiring Detail(SW/TWP/STWP1)


1Abbreviations: SW = Single WireTWP = Twisted Wire Pair STWP = Shielded Twisted Wire Pair

1.4 Vehicle Packaging

a) Indicate the general package location of this Product in the Vehicle:

Under hood ► Under body ► Cabin ► Trunk ► External Body ►Provide further description below as necessary:

b) What is the potential CUSTOMER ACCESSIBILITY to the Product:Access from Outside Vehicle Cabin ► Access from Inside Vehicle Cabin ► No Access ►

c) What is the nature of that Access:Direct Access (Physical touching) ► Indirect Access (Remote Switch) ►

Provide further description below as necessary:

d) How is the Product connected to Power Return (GND)?

Reference (GND): Direct to Local Chassis► In Harness (remote GND/Module) ►

Which Pin(s)?

e) How is the Case connected to a Reference Level (GND)?In the Vehicle – How is the metallic case connected?

Connect (GND)to Local Chassis ► Isolated ► Unknown ►

In the Printed Circuit Board – Is there a power return connection to the Case?

Direct (DC) ► Coupled (AC) ► NO Connect ►

f) Is the Product connected internally / externally to Magnetically Sensitive / Controlled Devices?Internal ► External ► Sensitive ► Controlled ►



g) Is the Product required to meet ESA type approval requirements of ECE Regulation 10.05?Yes ► No ►


i) How is the Product connected to Vehicle Power?

Please select which Vehicle power source(s) the product is connected to?

List ALL Connector Pins that have an external connection to Vehicle Power Fu

sed?

Describe Fuse Rating for each connection

Direct Battery Connection ►

‡ Switched Power 1 ►




Regulated Power ►

† Internal Power ► † Battery source internal to the DUT

‡ Switched Power – any circuit connected to vehicle battery through a mechanical switch, electro-mechanical relay or electronic switch. Annotate the proper name for each Switched Power signal source (e.g. Run, Run/Start, Ignition, VPWR…).


2.0 EMC Requirements Analysis

2.1 Critical Interface Signals

Signal Description

Voltage/Current Level

Frequency % Duty Cycle (range)

Other

2.2 Potential Sources of Emissions

Signal Source Description

Voltage/CurrentLevel

Frequency % Duty Cycle(range)

Other

2.3 Test Sample / Surrogate Selection


3.0 Test Design and Requirements

3.1 DUT Operating Modes/Functional Classifications

DUT Mode DUT Functions Vehicle Operating ModesClass A Class B Class C Off Accessory Start Run

Mode Description(s):

Function Description(s):


3.2 Test RequirementsThe DUT component / sub-system category is assessed as being:

Passive Active

D R BM EM A AS AM AX AY AW

It is possible for multiple categories to be applicable.

Test DescriptionTest

applies (Y/N)

Functional Class &

Functional StatusInterface to be

tested S/C1 Operating Mode(s) to be used for indicated test

A B C

Radiated Immunity – RF

RI 112 Level 2 BCI

II II I

RI 112 Level 1BCI

I I I

RI 114 Level 2ALSE/Reverb

II II I

RI 114 Level 1ALSE/Reverb

I I I

RI 115 Level 2Portable Transmitter

II II I

RI 115 Level 1Portable Transmitter

I I I

Coupled Immunity - RF

RI 130Inductive Transients

I I I

RI 140Magnetic Field

I I I

RI 150Charging System

I I I

Conducted Immunity – Continuous

CI 210Continuous Disturbance

I I I



applies (Y/N)

Functional Class &



A B C

Conducted Immunity - Transients



applies (Y/N)

Functional Class &



A B C

CI 220 Pulse A1

Power Supply Circuits with Maximum Current < 5A

II II II

Control Circuits II II II

CI 220 Pulse A2-1

All Power Supply Circuits with Maximum Current< 5A

II II II


CI 220 Pulse A2-2

All Power Supply Circuits with Maximum Current< 5A

II II II


CI 220Pulse C-1

All Power Circuits < 15 A I I I

Control Circuits I I I

CI 220 Pulse C-2

All Power Circuits < 15 A I I I

Control Circuits I I I

CI 220 ISO Pulse1

All Power Supply Circuits > 5A

II II II




applies (Y/N)

Functional Class &



A B C

Conducted Immunity – Transients(required for ESA type approval)

CI 221 ISO Pulse 1

Switched Power II II II

CI 221 ISO Pulse2a

All Power Circuits I I I

CI 221 ISO Pulse 2b

Power Circuits in Parallel with an electric motor

II II II

CI 221 ISO Pulse 3a


CI 221 ISO Pulse 3b


Conducted Immunity - Transients

CI 222 ISO Pulse 5a(Normal Load Dump) III III II

CI 222 ISO Pulse 5b(Central Load Dump) III III II

Conducted Immunity - Power Cycle

CI 230 Waveform A II II II

CI 230 Waveform B II II II

Conducted Immunity - Power Cycle (required for ESA type approval)

CI 231 II II II

Conducted Immunity - Voltage Offset

CI 250 I I I

Conducted Immunity - Voltage Dropout

CI 260 Waveform A II II II

CI 260 Waveform B II II II

CI 260 Waveform C I I I

CI 260 Waveform D II II II

Conducted Immunity - Voltage Overstress

CI 270- A -14 VoltReverse Battery

III III III

CI 270- B +19 VoltOver voltage – Failed Regulator

III II II

CI 270- C BATT / IGN≥ 60 secs

III II II



applies (Y/N)

Functional Class &



A B C

+ 27 volt

Over voltage – Jump Start

START≥ 15 secs III II II

Conducted Immunity – Electrostatic Discharge

CI 280 Unpowered (Handling)Sequence 1 -3

IV IV IV

CI 280 PoweredSequence 1-3

I I I

CI 280 PoweredSequence 4-6

II II II

CI 280 PoweredSequence 7

II II II

CI 280 PoweredSequence 8

II II II

Radiated Emissions

RE 310 I I I

Conducted Emissions

CE 410 - Transient I I I

CE 420 - RF I I I

CE 421 - LF I I I

NOTES

Indicate specific DUT circuits that the test applies to. C (Combined): The circuits are to be tested simultaneously. S (Separate):The circuits are to be tested separately


3.3 Input Requirements

Electrical Input Signals/Characteristics to Operate DUT in the specified test Mode

DUT Mode

Signal Name Test Pin # Waveform

Amplitude Freq/PW/DC% Other

Non-electrical input signals/characteristics to make DUT functional:


3.4 Output Requirements

Electrical output(s) to monitor and acceptance criteria

Mode Signal Name Test Pin # Waveform Note

2 Amplitude Freq/PW/DC% Other

NANANANANA

Non-electrical output(s) to monitor and acceptance criteria

Mode Function Description Test Note 2 Acceptance criterion for function

NANANA

Note2: N = Nominal ValueA = Acceptable Value


3.5 Load Box/Test Support Requirements

Name Description Pin #

LoadValue

Input Output Simulated Actual Reference


Load Simulator Diagram


Load Simulator Schematic/Diagram


4.0 DUT Test Set-up Diagram

Generic test set-up diagram/pictureThe Generic set-up diagram shall include the following details

Interconnections between DUT, load simulator, artificial network and battery/power supply.

DUT, artificial network and load simulator bonding to ground plane DUT support equipment DUT monitoring equipment Fiber optic media used for monitoring DUT inputs and outputs


4.1 Detailed Test Setup – Informative

IT IS RECOGNISED THAT APPROVED TEST FACILITIES ARE CAPABLE OF COMPONENT/SUB-SYSTEM SETUP WITHIN THE TEST ENVIRONMENTS DELINEATED IN THE EMC SPECIFICATION EMC-CS-2009

THE APPROVED TEST FACILITY SHALL PROVIDE DETAILS OF SETUP AS PART OF THE FORMAL TEST REPORT.

SPECIFIC TEST EXCEPTIONS / DIFFERENCES TO THESE TEST REQUIREMENTS SHALL BE DOCUMENTED IN THIS SECTION.

STANDARD SETUP SHEETS HAVE BEEN PROVIDED FOR CONVENIENCE AND MAY BE USED TO DOCUMENT THIS INFORMATION.

ESD TEST POINTS SHALL BE SPECIFIED EVEN IF THERE IS NO DEVIATION FROM THE SPECIFIED TEST METHOD.

# Test ID Requirement / DescriptionDeviation from specified test method. (Y/N)

Comments

1 CI 280 (U) Electrostatic Discharge (Un-Powered / Handling)

Specify ESD test points(required)

2 CI 280 (P) Electrostatic Discharge (Powered) Specify ESD test points(required)

3 RI 112 RF Immunity - BCI

4 RI 114 RF Immunity – ALSE/Reverberation

5 RI 115 RF Immunity – Hand Portable Transmitter

6 RI 140 Magnetic Field Immunity

7 RI 130 Coupled Immunity – Inductive Transients

8 RI 150 Coupled Immunity – Charging

9 CI 210 Conducted Immunity – Continuous Disturbances

10 CI 220 Conducted Immunity – Transient Disturbances



13 CI 230 Conducted Immunity – Power Cycling

14 CI 231 Conducted Immunity – Power Cycling

15 CI 250 Conducted Immunity – Voltage Offset

16 CI 260 Conducted Immunity – Voltage Dropout

17 CI 270 Conducted Immunity – Voltage Overstress

18 RE 310 Radiated RF Emissions

19 CE 420 Conducted RF Emissions

20 CE 421 Conducted LF Emissions

21 CE 410 Conducted Transient Emissions


4.2 Electrostatic Discharge (CI 280:unpowered)

Indicate ESD discharge points (required)

Test set-up diagram (as needed)

CI 280(unpowered) Test Set-up

Test Details CommentsSpecified Test MethodDeviations from Specified Test MethodHarness ConfigurationDUT OrientationDUT Grounding (case or harness)Additional Test Specific InformationDUT Monitoring Information


4.3 Electrostatic Discharge (CI 280: powered)

Indicate ESD discharge points (required)

Test set-up diagram (as needed)

CI 280(powered) Test Set-up



4.4 RF Immunity (RI 112)

Test set-up diagram

RI 112 Test Set-up



<< Use same format for remaining test methods as needed >>

4.5 RF Immunity (RI 114)

4.6 RF Immunity to Portable Transmitters (RI115)

4.7 Coupled Transient Noise (RI 130)

4.8 Magnetic Field (RI 140)

4.9 Coupled Transient Noise (RI 150)

4.10 Conducted Sine wave (CI 210)

4.11 Conducted Transients (CI 220)



4.12 Power Cycling (CI 230)

4.13 Power Cycling (CI 231)

4.14 Ground Shift (CI 250

4.15 Power Dropout (CI260)

4.16 DC Stress (CI 270)

4.17 Radiated Emissions (RE310)

4.18 Conducted Transient (CE 410)

4.19 Conducted Emissions (CE 420)

4.20 Conducted AF (CE 421)


Component EMC Test · Web viewUse of the product on other vehicle platforms may require...

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