High-Voltage Safe Measurement Systems 
High-Voltage Safe Measurement Systems
The HV Breakout Modules (BM) have been specifically designed for safe measurement applications on cables carrying high voltage. Current and voltage are evaluated and the power calculated online in the module.
The voltage is measured directly. Current measurement is performed by a shunt module that includes a differential amplifier, a temperature sensor and a memory chip for calibration data for automatic online temperature compensation.
The HV BM outputs the measured data with a maximum data rate of up to 1 MHz via EtherCAT® interface and simultaneously with a data rate of up to 10 kHz via the additional CAN interface. This allows a high speed data acquisition via Ethernet and at the same time data recording via CAN data logger.
The HV BM is to be inserted into the HV power cables by feeding the cables through PG cable glands into the module and connecting them there.
For the HV BM 1.1 und 1.2 CSM offers shunt modules with different measurement ranges. The shunt modules are selected seperately and are permanently installed.
A typical application of the HV Breakout Modules Type 1.1 and 1.2 is single-phase measurement, e.g. current, voltage and power measurement between inverter and electric motor on the test bench and in driving tests.
The HV BM 1.1 is compact and ideally suited for measurement at auxiliaries powered via single live high-voltage cable.
HV BM 1.2 is ideally suited for measurement at large consumers such as electric motors powered via separate cables for HV+ and HV-.
High shield currents can have undesirable coupling effects on components in high-voltage electrical systems and impair safety and functionality.
The HV BM 1.2 has been modified to a "/S" version especially for the safe measurement of shield currents in high-voltage power lines. With the HV BM 1.2 /S, currents in the shield of a HV power line can be measured via the measurement shunt.
The HV Breakout Module Type 3.1 has been designed for three-phase evaluation of power, current and voltage of cables carrying high voltage with currents of up to ±32 A, such as supplied by public charging stations. Three-phase measurement with only one single measurement device offers enormous cost and space savings.
| Designation | Phases | Max. measurement ranges | Max. measurement data rates | ||||
|---|---|---|---|---|---|---|---|
| Nominal voltage | Peak voltage | Rated current | Peak current | ECAT | CAN | ||
| HV BM 1.1 | 1 | ±1,000 V | ±2,000 V | ±250 A | ±500 A | 1,000 kHz | 10 kHz |
| HV BM 1.2 | 1 | ±1,000 V | ±2,000 V | ±800 A | ±1,400 A | 1,000 kHz | 10 kHz |
| HV BM 1.2 /S | 1 | n.a. | n.a. | ±125 A | ±250 A | 1,000 kHz | 10 kHz |
| HV BM 3.1 | 3 | ±1,000 V | ±1,000 V | ±32 A | ±50 A | 500 kHz | 5 kHz |
XCP-Gateway is the interface between the data acquisition software (e. g. vMeasure, CANape®, INCA®, Vision® ...) and the EtherCAT® measurement modules from CSM. It includes an EtherCAT® master and an XCP-on-Ethernet slave.
HV AD4 XW1000 measurement modules provide four analog inputs and are specifically designed for the measurement of high voltages in high-voltage environments.
Electric mobility is the future of transportation. The development of modern electric and hybrid vehicles poses new challenges for measurement technology. Not only must the measurement technology for eMobility match the traditional attributes of being accurate, mobile, and easy to use, it must also be safe for the users and the system. CSM high-voltage measurement technology ensures the safety of all measurement applications by means of a HV safe measurement chain from the sensor to the data acquisition.
The EtherCAT® measurement technology from CSM offers the highest measurement performance: e.g. for multi-channel applications with more than 1,000 strain gauges - / acceleration transducers and applications with measurement data rates of up to 1 MHz per channel. Manufacturers of measurement devices have to cope with continually increasing requirements. Thus, measurement devices have to acquire and process increasingly large amounts of data. The proven CAN measurement technology is hereby often pushed to its limits. This is why the EtherCAT® field bus is setting new standards regarding bandwidth, maximum number of channels and synchronicity of measurement signals.
Read more: Fast and synchronous measurement with EtherCAT® »
