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HV Breakout Modules HV Breakout-Modules
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HV Breakout Modules

Measurement of internal conductor current, shield current and voltage as well as power analysis directly in HV cables

The HV Breakout Modules (BM) are specifically designed for safely measuring directly from HV voltage power cables. Currents and voltages are measured directly and the raw data is acquired at up to 2 MHz per channel. With the Vector eMobilityAnalyzer software, which is optimally paired to the CSM HV Breakout Modules, real time power analysis is also possible.

  • Measurement of voltage (U), current (I) and shield currents in HV applications
    • Nominal Voltages up to ±1,000 V (measurement range up to ±2,000 V)
    • Currents up to ±1,000 A (nominal), ±2,000 A (peak)
    • Shield currents up to ±250 A (nominal), ±500 A (peak)
  • Simultaneous EtherCAT® and CAN bus communication or direct output of measured values via XCP-on-Ethernet
  • Output of voltage, current and instantaneous power with up to 1 MHz measurement data rate each (directly via XCP-on-Ethernet up to 2 MHz)
  • Online performance analysis with the Vector eMobilityAnalyzer software

Overview HV Breakout Modules

The HV Breakout Modules are an important component of the Vector CSM E-Mobility Measurement System and provide the basis for a wide range of measurement applications in vehicle electrification. Current and voltage are measured 100% phase-synchronously - a basic requirement for precise power calculations.

The sensors and measurement electronics of the HV Breakout Modules are well shielded in a very confined, safe space and housed together in a compact enclosure. This simplifies the instrumentation by eliminating the need for sensor cables between the sensors and the measurement device, which could be exposed to interference and thus falsify the measurement signal.

With the various connection options, the HV Breakout Modules can be easily installed into the HV power cables on test benches and in test vehicles.

The HV Breakout Modules feature an integrated shielding concept - avoiding tedious additional work for handling the cable shield. With the special HV Breakout Module 1.2 +S both the inner conductor current and the shield current can be measured simultaneously.

The robust design with an IP 67 rating and an operating temperature range -40 °C to +120 °C also allows on-vehicle installation for road tests. In this way, the same measurement system can be used to acquire data on the test bench and validate it in the road test.


Overview

Module overview

Designation Phases Measurement of Cable connection Data output
Inner conductor current Shield current Voltage Instantaneous power
HV BM 1.1 1 1 ring terminal
per side		 EtherCAT® and CAN
simultaneous
HV BM 1.2 1 2 ring terminals
per side		 EtherCAT® and CAN
simultaneous
HV BM 1.2C 1 PL500 connectors EtherCAT® and CAN
simultaneous
HV BM 1.2 +S 1 3 ring terminals
per side		 EtherCAT® and CAN
simultaneous
HV BM 3.1 3 Phoenix terminals EtherCAT® and CAN
simultaneous
HV BM 3.3 3 3 ring terminals
per side		 XCP-on-Ethernet
HV BM 3.3C 3 PL300 plug-in system XCP-on-Ethernet

Click on the corresponding module designation for more information.

Technical overview

Designation Phases Max. measurement ranges Max. measurement data rates
Nominal voltage Rated current ECAT CAN XCP-on-Ethernet
HV BM 1.1 1 ±250 A 1) ±2,000 V 2) 1,000 kHz 10 kHz -
HV BM 1.2 1 ±1,000 A 1) ±2,000 V 2) 1,000 kHz 10 kHz -
HV BM 1.2C 1 ±1,000 A 1) ±2,000 V 2) 1,000 kHz 10 kHz -
HV BM 1.2 +S 1 ±1,000 A 1)
±250 A Shield current1)		 ±2,000 V 2) 1,000 kHz 10 kHz -
HV BM 3.1 3 ±32 A ±1,000 V 500 kHz 5 kHz -
HV BM 3.3 3 ±800 A 1) ±2,000 V 2) - - 2,000 kHz
HV BM 3.3C 3 ±800 A 1) ±2,000 V 2) - - 2,000 kHz

1) Maximum size of the shunt inside the modules. Additional shunt options can be found in the data sheet.
2) For the detection of transient overvoltage the measuring range is dimensioned to ±2,000 V.