EMC Test Standards for Automotive Electronic Components
By Martin O'Hara, Senior Design Consultant, Telematica Systems Ltd
Introduction
The electronics content of vehicles has been increasing
dramatically, particularly over the last 15 years or so and is
predicted to continue into the uext decade, some estimates
tthe value of electronics in a medium sized vehicle will
represent 30% of the total vehicle cost by 2010, The increase
in vehicle electronic components and modules has occurred
not only in electronic control units (ECU) for the vehicle itself,
but also more recently in mobile communications, information,
security and entertainment systems in the vehicle.
In light of this growth itis important that the multiple ECU's
in a vehicle are compatible electromagnetically and will not
interfere with off-board systems (especially roadside
equipment). The EMC of vehicles, especially spark ignition
engines, has been a consideration globally for much longer
than most commercial EMC standards have existed. In Europe
the first directive for the suppression of spark-ignition noise
‘was published in 1972 (72/245/EEC). In North America the
Society of Automotive Engineers (SAE) have had standards
available on EMC since the early 1990"s and the International
Standards Organisation (ISO) and CISPR have provided
automotive specific EMC standards since 1990.
Jn the European Union (EU) there is a specific directive for
automotive EMC (EU directive 95/54/EC which amends 72.
245/EEC) that covers the majority of automotive assemblies
as wellas the vehicles themselves and is embodied in legislation
(several non EU member countries in Furope also adopt this
directive under regulation ECE 10.02). There is no similar
legislative equivalent in North America (USA and Canada) or
the Rest of the World (RoW), hence automotive OEM's have
developed their own internal standards that allow them to meet
the requirements of all the geographic markets into whieh they
sell. Consequently the field of automotive EMC testing may
appear complicated having many different standards, some
specific to OEM’s, some international (CISPR/ISO), some
geographic (SAE in North America) and some legislative
requirements (95/54/EC).
‘Automotive! Issue | Applicable | Tests Covered
Standard | Date(s) | Geographic
Region
O5/6EC | 1995 European | Radiated emissions
Union and immunity
CISPR25 | 2002 Global adiated and
conducted emissions
1807637 | 1990-1005 | Global Transient immunity
150 10605 [2001 Global ESD
180 11482 [1990-1095 [Global Radiated immunity
‘SAEJIN13 | Various [North Various (see below)
America
Table I: International Automotive Stendavds for Component Testing
ENC 8 Compliance Jounal September 2003
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Components or Electronic Sub-Assemblies
The term “electronic sub-assembly” (ESA) refers to almost
any electrical or electronic device fitted to a vehicle. The
definition includes the more obvious sub-systems such as
engine management unit (EMU), body control modules (BCM)
and heating, ventilation and air-conditioning (HVAC) system:
The term ESA also includes what might be otherwise
considered as components such as manifold absolute pressure
(MAP) sensor, solid-state relays (SSR) and motors. The
international automotive EMC standards usually refer to both
components aud modules as electronic sub-assemblies and here
no difference will be made between them, although most of
the discussion will be based on modules rather than single
components
There are two categories of electrical/electronic equipment
fitted fo vehicles: those fitted by the vehicle manufacturer
(OEM fit) and after-market equipment (user fitted or
professionally installed). In many cases the same companies
are supplying the OEM and after-market product and these
‘will be tested to the same EMC standards. Equipment intended
as after-marker fit only may not be as well regulated with
respect to EMC as OEM fitted and will generally only meet
the minimum requirements for the marker.
Radiated Emissions Standards
The two radiated emissions standards in comn
95/54/EC and CISPR.25, share many common features in their
chamber (Absorber Lined Screened Enclosure; ALSE.
figure 1) test set-up and the results of each are almost
comparable, The “almost” is due to minor and often annoying
discrepancies, for example CISPR-25 tests for radiated
emissions specifies the ground plane at 0.91 from the chamber
floor, 95/S4/EC specifies Im. Itis also possible to do the tests
on an Open Area Test Site (OATS) instead of a chamber, but
the calibration for OATS is significantly more time consuming
and consequently more expensive via a test service, hence the
preference for ALSE facilities for these tests,
Figure 1: Radlated Emissions measurements from an automotive
ESA (satellite navigation display) and harness (photo courtesy of
Trafficmaster’3C Test Ltd)‘The 95/S4/EC standard covers the frequency range 30MH2 to
IGHz with fixed test levels for broadband and narrowband
emissions (figure 2). The levels are contiguous across the
frequency range and are simple pass/fail limits, although as
with most EMC test the “absolute” limits are complicated by
the standard insetting by 24B on the quoted reference levels.
‘Most people test to the quoted limits directly, itis only when
an emission is close to the reference limit that the 2dB inset
level is used, and if submitting for type approval the final word
is provided by the approval body (the VCA in the case of UK
tested products). tis not necessary to test at al the frequencies
in the range 20MHz to 1GHz, the direetive allows for the
selection of 13 test frequencies across this range (within 13
defined frequency bands), however, as these test frequencies
are selected from the largest excursions during a pre-sean, itis
usual to sweep the whole frequency range rather than select
test po
Figure 2: PSA and Ford limit lines extending the test frequency
10 2GHe
CISPR-25 covers a wider frequency range (150kHz to
960MHz) and has broadband and narrowband limits
(broadband includes peak and quasi-peak detector limits). The
test levels ate not continuous across this frequency range,
instead being applied only to utilised radio frequency bands
(figure 3), In CISPR.25 there are five classes of limi that can
be applied, often the customer will specify these, if no specific
customer requirements (ie. for the after-market) then the
‘manufacturer often performs the tests and applies whatever
limit the ESA passes.
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Figure 3: CISPR 25 Broadband peak and 95/S4/EC limit lines
CISPR-25 includes provision for testing radiated emissions in
a TEM cell, The test can be performed up to 17SMHz only
and includes seven classes of limit Lines. The levels are equal
across all the measurement bands in the TEM cell test for each
class limit. This type of testing is typically performed in-house
rather than ata test serviee, as the wider frequency range and
ability to test o.95/S4/EC at the same time makes the chamber
8
a more appealing test solution for test service providers as well
as manufacturers.
(OEM specifications are based around the CISPR-25 ebamber
set-up (some also allow the TEM test for the lower frequency
sange). Most fill i the missing measurement bands, however,
there is no consistency between OEM on how this is performed,
For example PSA fill in the intermediate measurement bands
below 30MEz with the lower limit level fiom the previous
band (i.. if class 4 is applied from 150kHz to 300KEz, class 3
limit from this band is applied from 300kHz to 530kH2), above
30MH2z the 95/54/EC limits plus 10dB is used in the gaps
Ford applies their own (non-CISPR-25) limit level and only
utilise the test set-up of the standard. Most OEM specifications
extend the upper frequeney range, going 1 2GHz to cover
GSM frequencies at 1.8GHz and 1.9GHz, a few extend further
to 2.5GHz and GHz to encompass Bluetooth technologies.
Radiated Immunity Standards
There are two radiated immunity standards in common use:
95/S4/EC for European legislative purposes and ISO 11452
for most OEM standards, There are common tests besween
the two standards and both allow a variety of methods to be
employed in the testing. One common test component is the
‘use of amplitude modulation (AM) at 1kHz to a depth of 80%
that is used for both test standards discussed here
Figure 4: Automotive ESA (EMU) radiated immunity testing in a
150mm stripline (photo courtesy of Motorola)
The EU directive 95/54/EC permits testing using both 150mm
and 800mm striplines, TEM cell (up to 200MHz), bulk current
injection (BCI) and free-field (ALSE). Each test method has