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ISO16750-2:2023 Update Overview

The ISO16750-2 standard covers the electrical loads section. As vehicles now derive power from clean energy sources such as rechargeable batteries and hydrogen, the characteristics of electrical loads have undergone significant changes in recent years. Consequently, the ISO16750-2 standard has been updated to accommodate more complex requirements.

ISO16750-2 has now been updated from the fourth edition ISO16750-2:2012 to the fifth edition ISO16750-2:2023. The latest edition was released in July 2023. Its main changes include:

Introduction of the use of electrical test operating modes;
Introduction of the concept of redundant power supplies for relevant test cases;
Addition of detailed specifications for DC supply voltage tests;
Addition of detailed specifications for overvoltage tests at room temperature;
Introduction of transient overvoltage testing;
Comprehensive update of the test method for superimposed AC voltage tests, extending the frequency range to 200kHz, etc.;
Addition of detailed specifications for supply voltage slow drop and slow rise tests;
Introduction of micro-interruption testing for supply voltage;
Addition of detailed specifications for reset characteristics in voltage drop tests;
Addition of severity level specifications for starting characteristic tests;
Addition of detailed specifications for reverse voltage tests;
Addition of detailed specifications for reference ground and supply offset tests;
Splitting the single-wire open-circuit test into two: static interruption (single open-circuit event) and dynamic interruption (multiple open-circuit events);
Changing the short-circuit protection test to short-circuit/overload protection test;
Addition of detailed specifications for load dump pulse generator verification in Appendix B;

ISO16750-2:2023 4.1 General, 4.2 DC Supply Voltage

4.1 General: New requirements added as follows

Tolerances

The original requirements specified tolerances only for frequency and time, voltage, and resistance. The updated version now includes tolerance requirements for current and inductance. Specific tolerance values are as follows:

——Frequency and time: ±5%;
——Voltage: ±0.2V;
——Current: ±2%;
——Inductance: ±10%;
——Resistance: ±10%.

DUT Quantity

In ISO 16750-2:2023, at least two DUTs must be provided. If deemed necessary based on agreement between the customer and supplier, additional samples may be used in the final verification phase (process validation).

Secondary Feed DUT

For devices and units operating on secondary feeds (e.g., sensors powered by a 5V supply from a 12V DUT), special consideration should be given to the voltage supply range. Specific tests should be adjusted according to the actual vehicle installation. Applicable tests and considerations should be agreed upon between the customer and supplier.

For devices or units performing secondary feeding, they are sometimes tested together with the 12/24 V DUT providing the secondary feed.

4.2 DC Supply Voltage: Addition of DC Supply Voltage Waveform

The entire test waveform has been updated, specifying hold times and rise/fall rates for both the maximum operating voltage USmax and the minimum operating voltage USmin. The test waveform is shown below:

Operating Modes (Refined)

During testing, the DUT needs to be operated under different conditions for testing depending on the temperature.

ISO16750-2:2023 4.3 Overvoltage

Overview

Tests are no longer divided by 12V and 24V systems but are categorized by test items, specifying which items apply to 12V or 24V systems.

4.3.1 Long Duration Overvoltage:

Alternator Fault at T_max-20℃

12V/24V systems are supplied with 18V/36V for 60 minutes. A new requirement specifies testing in Mode 3.4 (Maximum load at supply voltage U_A during generator operation).

Jump Start at Room Temperature

Test item for 12V systems. Added requirement for rise/fall time ≤10ms and added recovery time.

4.3.2 Transient Overvoltage: New Item

Applicable to 12V/24V systems, simulating the impact of DUT being affected by switched loads or loads injecting current into the distribution system. DUT test condition is Mode 3.4.

When handling redundant power supplies, test one port while keeping the other ports at U_A. Functional status should at least reach Class B, and can be relaxed to Class C with agreement between customer and supplier.

ISO16750-2:2023 4.4 Superimposed AC Voltage

Frequency

Original test frequency range: 50Hz~25kHz. Updated frequency range includes two segments: f1: 10 Hz ~ 30 kHz, f2: 30 kHz ~ 200 kHz.

The f1 band applies to DUTs powered by generators without batteries (emergency operation), generators, or DC/DC converters; the f2 band applies to DUTs powered by DC/DC converters. The new requirements not only broaden the f1 frequency range compared to the original requirements but also mandate higher frequency f2 testing for DC/DC converters to adapt to the changing power supply forms in current electric vehicles.

Injection Method

Original requirement used sweep mode for AC voltage injection, with frequency on a logarithmic scale, triangular sweep from 50Hz~25kHz, duration 120s, repeated 5 times continuously. Current requirement uses step mode, with frequency steps of 2% logarithmically, test time per frequency point ≥2s, performed only once.