Testing HV Automotive Components

LV 123 is an electrical test standard which verifies the safety and electrical parameters of high-voltage components in cars. German original equipment manufacturers (OEMs) must comply with LV 123, notably BMW, AUDI, Daimler, Porsche and Volkswagen. Manufacturers adhering to LV 123 gain the advantage of a systematic approach to automotive testing and clear test parameter definitions, as well as the possibility of interchangeable qualification results. Another benefit of LV 123 is the ability to compare product qualifications between different OEMs, i.e. BMW and Porsche.

 

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Determining HV Status

HV operating status, a measure by which an HV component is judged to be operational, is a key element of LV 123 testing. An HV part is given one of the following status readings.
 
HV Status    Operational Details
B0 HV components operate perfectly, and without power demand.
B1 Fully operational HV components which perform as intended.
B2 Fully operational components, but with deviations permissible for B2 status.
When HV parts revert to B1 status, will perform as intended
B3 Still operational, no undefined states, will not interfere with other HV components.
Components may lower output for purposes of self-protection.
When components revert to B1 or B2, automatically perform as intended.
B4 Still operational, no undefined states. HV components may switch their output off.
When reverting to B1, B2 or B3 status, will provide intended performance via reset,
ignition status change, vehicle restart, etc.


Operational Ranges Based on Status

The operating potential of an electrical component, once given a B-status by LV 123 testing, can then be defined by the following ranges.
 
HV Operating Voltage Ranges    Range of Operation - HV Status    Units    HV 1 HV 2a HV 2b HV 3
Overvoltage at load dump B3 / B4 V pk 220 410 500 800
Upper HV circuit limit voltage B3 / B4 V pk 220 410 500 800
Maximum operating voltage B2 V d.c. 200 360 470 770
Upper limited operating capability B2 V d.c. >190-200 >340-360 >450 - 470 >750 - 770
Unlimited operating capability    B1 V d.c. 90 - 190 170 - 340 250 - 450 520 - 750
Lower limited operating capability B2 V d.c. 80 - < 90 160 - < 170 200 - < 250 450 - < 520
Highly limited operating capability B2 a / B3 b V d.c. 60 - < 80 120 - < 160 150 - < 200 X
Undervoltage B3 V d.c. 0 - < 60 0 - < 120 0 - < 150 0 - < 450