Teseq (Schaffner) NSG 5000 Data Sheet

EMC Test Systems for
Automotive Electronics

Automotive Solutions

www.schaffner.com

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Description

EMC Test System for Automotive Electronics .......................

Pulse Tests with the System 5000 .........................................

Pulse / Burst Generators ........................................................

High Energy Pulse Generators ...............................................

Accessories ............................................................................

Accessories ............................................................................

Modular EMC Test System ....................................................

Plug-in modules .....................................................................

Plug-in modules .....................................................................

AUTOSTAR

TM

software ............................................................

42 Volt - High Current Coupler ..............................................

Battery Simulators - Voltage Sources ....................................

Typical Configurations - Rack Systems .................................

Standards for Conducted Immunity Requirements &

System Configurations ...........................................................

RF Immunity and Emission Testing ........................................

ProfLine RF EMC Test Systems .............................................

ProfLine RF EMC Test Systems .............................................

ProfLine RF EMC Test Systems .............................................

ProfLine RF EMC Test Systems .............................................

Index by Product Number ......................................................

Introduction

NSG 5000
NSG 5001A / 5003
NSG 5005A / 5005B
INA 5025 / CDN 500
INA 5020 / 5024
System 5200
CTR 5210 / ARB 5220 / 5221
DCS 5230 / AMP 5240 / CSW 5250
AUTOSTAR

TM

CDN 5010
NSG 5004A

Standards
ProfLine 5100 series
ProfLine 5110 / 5120
ProfLine 5130 / 5140
ProfLine 5150 / 5160
ProfLine 5170 / 5180

Index

Contents

1

2

The use of electronic and electrical sub-systems in automobiles continues to
escalate as manufacturers exploit the technology to optimise performance and add
value to their products.
With automobile operation and safety increasingly dependent on the reliable
functioning of complex control and monitoring systems, integrity in the face of
electromagnetic interference is of vital importance. The electromagnetic
compatibility (EMC) test standards with which automobile manufacturers must
comply are determined by bodies such as ISO, SAE and DIN. Additionally, most
manufacturers also develop and specify their own custom EMC tests to meet a
wide-ranging - and fast evolving - set of requirements. The need for a flexible test
resource has never been greater.

Building on Strength

Schaffner has been at the forefront of the pioneering work to establish EMC tests
for motor vehicle electronics. Automotive manufacturers and suppliers world-wide
have come to trust test systems from Schaffner. Active involvement in the
standardisation committees ensures that the latest advances are continuously
reflected in our test systems.

International and In-house Standards

Well-proven system architecture and a modular concept ensure that the test
systems keep pace with changes in demands required by the standards, as well as
with the special needs of vehicle manufacturers. The system’s test specifications
exceed the conditions set down in relevant standards, which results in the requisite
flexibility for the user and the necessary test margins. The pulse parameters are so
broadly dimensioned that many company-specific test specifications are covered
automatically, eliminating the need to take any additional action.

New Requirements

Besides the classical pulse tests, variations and disturbances on a vehicle‘s power
supply lines are assuming greater significance. Currently, simulations are
insufficiently reflected in international standards with the result that a broad range of
manufacturer-specific specifications has become established.
Magnetic field tests and tests with conducted sinusoidal oscillations are becoming
important in view of the increasing utilisation of sensors and peripheral sub­assemblies.
Schaffner has expanded the test system with new components in order to fulfil
these applications in an optimal and future-secure manner. The forthcoming use of
42 Volt technology in passenger cars will have a profound influence on test
equipment. The new generation of test equipment has been appropriately specified
and adequately dimensioned to cope with the expected higher supply levels. The
software implemented is the key element in ensuring the efficient utilisation of
complex test systems.

EMC test system for

automotive electronics

Schaffner's AUTOSTAR
offers more than just a
control package.
AUTOSTAR is an open test
management platform with a
graphical interface and
flexible test report
production.
Complete customer solutions
with fully integrated
installations are possible
through the complementary
range of test systems for
radiated interference
immunity and emission
measurements.

An electronic switch to connect and disconnect the
battery supply is incorporated in the NSG 5000.
Furthermore, the processor also controls the external
battery substitute power source.

In its standard configuration, the equipment is rated for
testing objects at up to 30V / 25A dc or 48V / 10A dc.
The test rig and the power sources are protected by
built-in, over-current trip switches.
Additional inputs and outputs are located on the rear
panel for test execution control purposes and the
monitoring of error signals, oscilloscope triggers, gate
start/stop commands, etc.
Larger systems can be created by installing further
generators in an expansion chassis and these
generators are instantly recognised by the software
and are embodied automatically in the system.
Overall control is effected via a PC running under
Windows. The new version of the operating system,
AUTOSTAR, integrates all the individual components
into a uniform and clear test rig control platform.

The compact and modular System 5000 offers all the
generators necessary for tests with pulsed interference
as well as voltage variations as called for by ISO and
SAE. The established test specifications for passenger
cars together with the new standards for commercial
vehicles published by the ISO, SAE, DIN and other
bodies are fully covered, as are the many company­specific standards from larger vehicle manufacturers.
The construction adopted enables trends in the
standards and changing market requirements to be
followed consistently through the introduction of new
developments or upgrades to the generator modules.
Hence, investments in test equipment are optimally
protected.

NSG 5000 System Chassis

This compact mainframe houses the common system
components and accommodates all the standard
pulse generators. A high performance processor
controls all the real-time tasks, takes care of system
integrity, assures the monitoring of the EUT path and
handles communication with the Windows-based user
interface. Besides the control unit, the power supply,
high voltage unit and control electronics for the EUT
are all housed in a package mounted at the rear of the
mainframe. This modularity provides the flexibility to
adapt to changing requirements. The front of the
chassis is available for the insertion of various pulse
generators and for the connection and practical
handling of test objects. Interrupt-free test sequences
comprising all types of pulse at one and the same EUT
connector are made possible through the use of a high
voltage pulse bus configuration.

Pulse tests with the

System 5000

Technical Specifications

NSG 5000

0

Instrument power supply

100 to 120Vac ±10%, 47-63Hz
220 to 240Vac ±10%, 47-63Hz

Dimensions

19" benchtop housing,
can also be rack mounted
Height 31cm (12.2")
Depth 51cm (20")

EUT supply

From an external source, e.g. battery
or NSG 5004A battery simulator
48Vdc, 25A max. continuous
Sensor for voltage correction
Program-controlled switching
30A safety cut-out

Control connections

EUT failure/Start-Stop/Test end/
Trigger for oscilloscope

Computer interface

RS 232C or IEEE 488

3

4

Surge Pulse Generator NSG 5001A

Switching actions with inductive loads on the vehicle
supply harness, dc motors that operate as generators
when the vehicle supply is switched off and the effects
that occur when an ignition coil is switched off can all
create disturbances that have to be simulated and
their consequences checked. ISO and SAE have
specified these tests under pulse designation 1/2/6.
The NSG 5001A produces these test pulses in
conformance with the relevant standard. In order to
be able to cope with a company's own test methods,
the generator module also provides a much greater
range of selectable parameters, considerably higher
test voltages, additional impedances and further pulse
widths. The switch type INA 5020 provides the often
required automatic battery switch-off and restore
functions.

Technical Specifications

0

NSG 5001A

0

Pulse amplitude

10 to 600V in 1V steps

Impedance

2/4/10/50Ω and
external (pulse 1/2)
10/30Ω (pulse 6)

Pulse rise time

1/3µs (pulse 1/2)
60µs (pulse 6)

Pulse duration

50/200/500/
1000/2000µs
(pulse 1/2)
300µs (pulse 6)

Pulse modes

Single, continuous,
programmed
1 to 99999

Battery supply
activation

Program-controlled /
Voltage-controlled

Pulse Monitor

1:100, BNC

Repetition

0.2 – 15s

Technical Specifications

NSG 5003

0

Pulse amplitude

20 to 800V in
1V steps

Impedance

50Ω

Pulse rise time

5ns

Burst frequency

1 to 100kHz in

0.1kHz steps

Pulses per burst

1 - 200

Burst repetition

90ms to 99.9
seconds in 10ms
steps

Pulse modes

Single, continuous,
programmed 1 to 99999

Pulse duration

100ns (into 50Ω)

Burst Pulse Generator NSG 5003

Fast transient interference signals injected onto a
vehicle's wiring harness through switching of
associated peripheral devices can affect the correct
functioning of adjacent electronic units.
In conformance with the standards (ISO/SAE pulse
3a/3b), the NSG 5003 simulates these interference
phenomena by means of pulse bursts. The vibrant
development of electronic devices for the automotive
industry means that better and faster test methods are
required. The burst generator more than meets these
increasing demands; its technical properties
exceeding the specifications laid down in the
standards by several factors. Higher pulse voltages,
burst frequencies and pulse burst specifications are
just part of it; there are also automated functions for
weak spot analyses and long-term
trials.
The EUT connection, as well as the
separate connector for the coupling
clamp used in data line tests, has
been optimised to suit the high
frequency conditions prevailing in
such a fast pulse environment.

Pulse

generators

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5

High Energy Pulse Generator NSG 5005A

Alternators produce a high-energy (load dump) pulse
on a vehicle's power harness when the battery is
disconnected. The NSG 5005A simulates the
corresponding pulse 5, specified by both ISO and
SAE, the clamped load dump pulse 5b, as well as the
additional pulse 7 defined by the ISO.
Some vehicle manufacturers have expanded upon
these specifications - in most cases by making them
more stringent. The generator takes this into account.
Contrary to the classic concept, the unit is built around
an active amplifier circuit. This enables much greater
variability of the pulse parameters to be achieved and
facilitates better reproducibility. Impedances are
emulated electronically by dynamic current limiting,
ensuring that the required pulse energy is driven

optimally into the EUT.
An impedance box is
available as an option
(INA 5025) which sets
up the generator
impedance by means of
hardware, using power
resistors.

Technical Specifications

NSG 5005A

0

Pulse amplitude

20 to 200V in

0.5V steps

Clamping:
20-180V

Impedance

According to
resistor fitted

Pulse rise time

0.1 to 10ms

Pulse duration

30 - 700ms

Pulse repetition

15 to 600s in 0.1s
steps

INA 5025, hardware
impedance

0.5 to 10Ω in 0.25Ω
steps

Pulse modes

Single,
continuous,
programmed
1 to 99999

Pulse monitor

1:100, BNC

High Energy Pulse Generator NSG 5005B

Some American laboratories tend to prefer the current
load dump approach that is incorporated in the
standards set down by the SAE. This view is taken
because alternators are considered to behave rather
as 'hard' current sources.
This requirement is reflected in the NSG 5005B, which
offers a practical and proven solution for use in the
field of passenger vehicles and light duty trucks.
The module also employs an active amplifier circuit,
providing the user with considerable advantages in
terms of test parameter flexibility.

Generator

Ip

R

cal

0.6R

Pulse rise time

5 - 10ms

Pulse repetition

25 to 600s in 0.1s
steps

Pulse duration

40/100/150/200/
250/300/350/400ms

Pulse modes

Single, continuous,
programmed 1 to 99999

Technical Specifications

NSG 5005B

0

Energy source

200mF capacitor
charged to 60V

Pulse amplitude

20 to 120A, in 1A steps
(84A into 0.6Ω reference
load)

Pulse

generators

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S

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1

UB

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6

Capacitive Coupling Clamp CDN 500

The coupling
clamp CDN 500 is
manufactured
exactly in
accordance with
the drawings and
specifications of
ISO 7637/3. It is,
above all, the fast
nanosecond pulse
bursts (ISO 3a
and 3b) that are
injected on cable

runs. The characteristic impedance of the unit is 50Ω.

The CDN 500 coupling clamp is connected to the
generator via a coaxial cable. The far side of the

clamp has to be terminated with a 50Ω load resistor.

A suitable terminating load is available as an
accessory under the type number INA 5030 which also
provides a measurement output via a 40dB attenuator.
The coupling clamp will accept ribbon cables as well
as round cables of up to 40mm diameter. The
effective coupling capacitance depends on the cross
section and the material of the cable used; a typical
value being around 100pF.

Accessories

Technical Specifications

INA 5025

Selectable impedances 0.5 to 10Ω, programmable in steps of 0.25Ω

Dimensions W x H x D mm 225 x 311 x 220

Hardware Impedance Module

INA 5025

Enables resistors to be
added to the high-energy
pulse generator type NSG
5005A to modify the
generator's impedance.

Impedances of 0.5Ω to
10Ω, in steps of 0.25Ω are

selectable under software
control. The INA 5025
can be operated in either

the NSG 5000 basic
system chassis, the expansion chassis type INA 5000
or in a special housing type INA 5026.

Technical Specifications

CDN 500

Typical coupling capacitance 100pF approx. (200pF max.)

Active length 1000mm (39”)

Diameter of round cables 40mm (1.6”) max.

Breakdown voltage >500V
Characteristic impedance (without cable inserted) 50Ω ± 10%
Connectors 50Ω BNC (1 each side)

Dimensions L x W x H mm 1300 x 300 x 106 (51.2 x 11.8 x 4.2”)

Weight 11.5kg (25lbs) approx.

Construction Brass, with plated surface; coupling panel with roller hinges for precise positioning

Expansion Chassis INA 5000

Additional generator modules can be accommodated
in the expansion chassis to permit the assembly of
larger systems. All the control functions remain
effective and the system incorporates the modules in
the INA 5000 through an auto-configuration feature.

Interface Option INA 5002

The System 5000 is generally operated via the
RS 232 serial interface. To increase the interference
immunity of the PC interface, the connection can be
effected alternatively by means of an opto-link type
INA 30xA. The optional INA 5002 is available to
embed the System 5000 within an IEEE 488 laboratory
communications system.

7

Pulse 4 Driver Board INA 5024

This driver board is required to control external
sources for the simulation of the pulse 4 voltage
variation as specified by ISO and SAE.
When more complex and freely programmable voltage
variations are required, System 5200 should be used.

0

t

6

t

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Accessories

Battery Switch INA 5020

The INA 5020 provides a means for pulse-controlled
(as required by the ISO) or program-controlled on and
off switching of the power supply to the EUT from a
battery or an appropriate source such as the battery
simulator NSG 5004A. The switch is a rearward-facing
module in the NSG 5000 system chassis and, hence,
takes up no generator module space.

Technical Specifications

INA 5020

Input DC voltage range 0 to 30V (48V max with derated current to 10A)

DC current 30A max

Switch On/OFF time 2µs

Max. voltage drop 2.5V @ 25A

MCB rating 30A

8

Complex voltage variations
Magnetic field tests
Sinusoidal burst with

System 5200

A complementary system part is available that is
optimally designed to cope with the demands imposed
by the newer and multiple requirements met today
especially in matters of voltage variation.
Again, great importance is placed on modularity to
ensure that systems can be ideally configured,
expansions are possible at any time and a solid
platform is provided to cater for future developments
in this test arena. The software integrates the various
system components seamlessly into the overall system
concept with uniform operating procedures and user
guidance together with a comprehensive test result
reporting facility.

System 5200 Concept

A 19" system chassis serves as the basis for all test
configurations. Control of the chassis is assured by a
controller module that takes care of communication
with the PC on the one hand while, on the other hand,
it serves the bus to which all modules have access.
All the generators and function units are designed for
plug-in mounting in the front of the chassis.
As a result, all the connections to the EUT and to the
sources are brought out on the front to the test rig and
the items under test. Where necessary, the individual
modules are further modularised through a concept of
motherboards and plug-in functional units.

Basic Chassis NSG 5201 and NSG 5202

The 19" basic chassis contains all the power supply
components and, if required, the burst-transformer, the
rear-facing fans, the control and signal bus boards as
well as the common inputs and outputs for the safety
circuits and signals for the expanded control and
monitoring of the test procedures.
The CAN-bus, already well-known in automotive
technology circles, is used as the system bus.
Additionally, the NSG 5202 contains the transformer
sub-assembly required for sinusoidal-burst tests.
A chassis type NSG 5201 can also have this
transformer sub-assembly added subsequently at any
time by a Schaffner Service Center.

Technical Specifications

NSG 5200

AC Operating Voltage & Frequency Ranges 100V/120V/220V/240V 47 to 63Hz

Dimensions Width 84HP Height 6U Depth 500mm

Rack Weight 18Kg (NSG 5201) 26Kg (NSG 5202)

Control Bus CAN

Safety Interlocks Ye s

Auxiliary Input Signals DUT FAIL / EXT / PAUSE/ RESUME

Auxiliary Output Signals CRO-TRIG / TEST-END

9

Controller CTR 5210

The controller controls all the
addressing, real-time and
synchronisation tasks on the
CAN-bus as well as maintaining
communication with the PC
and, hence, with the
AUTOSTAR user-software.
RS 232C and IEEE 488
interfaces are available as
standard. Designed as a
motherboard,
the unit can have other
interfaces added as required.
As a further facility, line

waveforms can be measured
and stored on a digital oscilloscope and downloaded
to the ARB 5220 / 5221 modules for subsequent
regeneration.

Function Generators ARB 5220 / ARB 5221

The function generator is used
universally throughout the
System 5200 for the control of
sources, battery simulators and
amplifiers. The task definition in
the Autostar application software
specifies the necessary voltage/
frequency conditions. The
controller converts this
information into algorithms for
the ARB (Arbitrary waveform
generator) which creates an
image of the requirements in its
own processor and memory and
then generates the output
signals for the addressed power
modules during the test run. All
the requisite curve forms can be

created numerically from the basic functions.

By loading a bit map, e.g. a table of results from a
storage oscilloscope, the ARB also generates curve
forms that can be difficult to describe mathematically.

Every card incorporates a second channel for the
control of a further source with a programmable,
steady state voltage as well as an output for current
limiting one of the sources. The main output signal
consists of analogue voltage of -10 to + 10V - a
standard that is used by the majority of voltage
sources. Limits are only imposed by the sources used
for a particular application.

Technical Specifications

CTR 5210

Module width 8HP

Control Bus CAN

Interfaces IEEE488 (GPIB) & RS 232

Basic functions:

SINE
TRIANGLE
SQUARE
RAMP (Including DC)

Ramping Capabilities:

Amplitude
Frequency
DC offset

ARB 5220

plug-in

modules

Technical Specifications

ARB 5220

Output Voltage -10 to + 10V

Resolution 10mV

Accuracy ±10mV
Impedance 10Ω

Short circuit protection Ye s

Standard segment types Sine, Square, Triangle & Ramp (including DC)

Number of segments per waveform 1 to 100

Frequency range Sine 0.01Hz to 300KHz

Square / Triangle 0.01Hz to 100KHz

Frequency resolution 0.01Hz

Amplitude & offset ramping Linear

Frequency ramping Sine / Square / Triangle Linear, Log (Base 10)

Phase angle 0 to 360° in 15° steps

Rectification None, Positive, Negative

Test duration 1ms to 100 hours

1 to 9999 cycles

Module width 4HP

ARB 5220

The ARB 5220 is a module equipped with a function
generator board. A second board can be added
subsequently at any time. The ARB 5221 is delivered
equipped with two function generators. Two of these
modules can be used in a system, i.e. up to four
function generators are available to control the
relevant number of sources. All the generators used
are programmed separately and run synchronously
based on a master-slave relationship.

ARB 5221

Plug-in

modules

10

11

DC Switch DCS 5230

The DCS 5230
switches the voltage
source through to the
EUT connection
under program­control.
The primary input
and the auxiliary
connection enable
two sources to be
used. The DCS
switching capacity of

70V/75A is capable
of coping with high power requirements and is ready
for the 42V era.

The selectable switching conditions are:

Output (EUT) to primary source

to auxiliary source
switched off (open)
switched off (short-circuit to 0V)
dip and drop from primary to auxiliary
source and back again

to primary source with 2Ω extra

impedance (SAEJ1113/11 pulse 2b)

Current and voltage at the output can be measured at
any point during a test and be recorded in the test
report. Due to the rapid switching times, the
requirements of every standard that calls for drop-outs
and voltage jumps in the µs range can be fulfilled by
using a battery simulator and an auxiliary source.

Technical Specifications

DCS 5230

Primary Input Voltage -4V to 70V

Current 0 to 75A

(derate for inductve loads > 300mH)

Voltage Drop 1V max @ 75A

Auxiliary input voltage 0 to 70V

Current 0 to 75A

Switch time ON 0.2 to 1.5µs

OFF 0.5 to 1.5µs

(13.5 to 0V, 1KΩ load)

Pulse 2 output impedance approx.2Ω

Current 25A

Overvoltage protection 75V

Overcurrent protection >75A

Module width 40HP

Power Amplifier AMP 5240

Up to ±15V and 5A can be
delivered by the power
amplifier module which
means that for many
applications – namely for
component and sub­assembly testing – the use
of an external battery
simulator is unnecessary.
The frequency range and
bipolarity ensure that the
module will find a wide
range of applications. The

EUT current can be
measured and a program-controlled current limit can
be specified.
The AMP 5240 also serves as a power driver for the
electromagnetic coils used in magnetic field tests and
as an amplifier for conducted sinusoidal frequency
tests. Separate current measurements for the two
types of test ensure correct control of the test
conditions.

Technical Specifications

AMP 5240

Operating Modes Constant Voltage / Constant Current

Output Voltage -15 to +15V

Resolution 0.1V

Accuracy ± 0.1V

Current -5 to +5A
Impedance 0.5Ω

Current limit Range 0.1 to 5A

Resolution 0.1A

Accuracy ± 0.1A

Frequency Range 0 to 300 KHz

Resolution ± (0.1% + 1Hz)

Accuracy ± (0.1% + 1Hz)

Short circuit protection Yes

Module width 20HP

Plug-in

modules

12

Magnetic Field Tests

The 5200 system configuration is expanded by the
addition of magnetic field antennae for the execution
of magnetic field tests. Either simple current loops or
Helmholtz coils are used depending on the relevant
test standard. The AMP 5240 is equipped with a
control input for the connection of a magnetic field
measuring sensor for the precise regulation of the field
generated.

Technical Specifications

Helmholtz Coil

Coil radius 1.2m

Frequency range 0.01 to 30KHz

Magnetic field density 170dBpT

Max. DUT side length 0.8m

Technical Specifications

Radiating Loop Solution

Frequency range 0.01 to 100KHz

Magnetic field density 180dBpT (@ 10A)

Loop diameter 12cm

No. of Turns 20

Sensor diameter 4cm

No. of Turns 51

Sinusoidal-burst Module CSW 5250

Conducted sinusoidal shaped
interference simulations are
described in various
standards with differing
conditions pertaining to them.
The CSW 5250 module
contains the necessary
circuitry for pulse
superimposition, selectable
impedances and the
connection mechanism to the
transformer. The pure, non­superimposed sinusoidal
signal can be monitored at
output sockets. External
impedances can be
connected as required for
further applications.

Technical Specifications

CSW 5250

Waveform types Sine / Square / Triangle / Pulse

Amplifier frequency 0.01 to 300KHz

Resolution 1Hz

Accuracy ± (1% +1Hz)

Current -5 to +5A
Source impedance < 0.5Ω

Battery DC current 0 to 25A

Transformer turns ratio 2 :1

Connection Positive or negative lead

Bypass capacitor, switchable 100µF

MCB protection 25A

Module width 8HP

Plug-in

modules

>_

NSG

5200

Magnetic Loop

EUT

13

AUTOSTAR™

software

AUTOSTAR is more than just an operating program for
test routines – it is, in fact, a Test Management
Platform. Based on the concept of an open system, it
integrates all the generators and other circuitry present
in the installation into a consistent presentation and a
uniform graphical user interface. Additional
components can be incorporated as required
through the support of ‘Active-X’ elements and drivers.
AUTOSTAR presents the operator with a clear,
structured, visual interface with menubars, test lists,
test sequence information and, when appropriate, with
graphical pulse representations.

The test management platform AUTOSTAR sends
strings of commands to the system chassis control
computer, receives test and measurement data for
further processing and undertakes all necessary
coordination tasks. All hardware associated tasks,
together with time-critical and safety related control
matters, are managed at the chassis controller level.

Graphical presentations are particularly informative in
applications with complex supply voltage variations.
The linear or logarithmic scaling and a zoom function
ensure a clear overview of the whole test sequence
and an opportunity to check details.

Test program

Test programs are grouped together as follows:
Surge – Class 1, 2, 3
Burst
Load dump
Supply voltage variations – type 4c, 4d, 2b.
Power magnetics
Conducted sine wave

The test library contains not only the pre-programmed
test routines in accordance with international
standards such as ISO and SAE, but also test

conditions that conform to manufacturers’ in-house
standards.
The user can implement these tests directly, modify
them and store them under a new designation or
create new test definitions from the ground up and
include them in the list as well.
Sequences consisting of tests of the same or differing
categories can be arbitrarily merged and then also be
stored for later re-use.
The user-guidance facility contains not only
information regarding limiting values but also a
protective feature against prohibited parameter
combinations with appropriate warning flags.

14

Test Evaluation and Reporting

Reports concerning individual tests and test
sequences are produced automatically and are in a
form which can be used for technical files and quality
assurance documents. The user is provided with a
range of editable fields for remarks and specification of
the task in hand. The test data and results are stored
in a database form that can be retrieved by macro­programming into applications such as WORD, Excel,
Access, etc.

Auto-configuration

At start-up, the software automatically detects and
recognises the generators and other elements that are
present in the system. This auto-configuration feature
is bound up with a number of self-tests and provides
the user with all the available functions automatically.
A choice of communication mode via either the RS
232C or IEEE 488 port is provided. The test
configuration can also be created manually which is
used to make a conscious limitation on the functions
available and particularly for off-line operation. This
mode of operation enables arbitrary test routines to be
prepared in the office without having to connect up the
test system.

PC Requirements

AUTOSTAR

The recommended minimum PC configuration for working with AUTOSTAR consists of:

PC with Pentium II 233MHz or greater

Microsoft Windows 95/98/2000/NT

64MB RAM

100MB harddisk space

Super VGA - 1024 x 768 resolution

CD-ROM - drive

Microsoft mouse or compatible pointing device

1/2 free RS 232 ports or the PCI-GPIB controller from National Instruments

AUTOSTAR™

software

15

42Volt

High Current Coupler CDN 5010

There is considerable progress in the 42 Volt vehicle
supply concept and hybrid 14V/42V installations
which will soon be market-ready. The need for higher
power devices is also developing in step with the
introduction of the higher supply voltage.

The permissible EUT voltage of 45V for the NSG
5000 system chassis at a reduced current rating of
10A is sufficient for many applications concerning
component and sub-assembly tests.

The System 5000 can be expanded with a high
current coupler for pulse tests on installations with a
high current requirement.

The high current coupler type CDN 5010, equipped
with both a switch and decoupling filter rated at 48V
and 60A, is controlled by the system controller. The
pulses are fed to the CDN 5010 via a cable from the
output of the generator module in the System 5000
and are there superimposed on the battery voltage.
All the functions, such as battery switch off before
pulse triggering, etc, are also applied to the high
current path and are controlled by the software in an
unmodified manner.

The System 5200 with its rating of 70V / 75A for
the switched EUT connection is well equipped
and offers ample margins to cope with future
demands.

Technical Specifications CDN 5010 High Current Coupler

Instrument power supply

100 to 120Vac ± 10%, 47 to 63Hz
220 to 240Vac ± 10%, 47 to 63Hz

EUT power supply

From an external source
4 to 48 Vdc/60A max. continuous
Switching under software control
60A safety cut-out

Load inductance

300mH max.

Dimensions

19" benchtop housing, can also be rack-mount­ed
Height 19cm (7.5")
Depth 51cm (20")

NSG 5000

CDN 5010

DC

power

source

EUT

16

Technical Specifications

NSG 5004A Battery Simulator

Battery simulators replace the vehicle battery in the
test environment. These sources have to fulfil various
criteria concerning power rating, voltage, slew-rate,
impedance, etc. depending on the particular
application. Bi-polar current sources are called for in
certain cases. Furthermore, reactions to the EUT's
characteristics regarding such matters as in-rush
current, spikes and damping have to be taken into
account. Regulation with sense-lines in a closed loop
is often required. Simulation of rapid voltage changes
may require the use of two sources with the DCS 5230
power switch commutating between the two. This can
represent an economic solution since the sources
used need only have a modest specification, especially
the second source as it would only have to deliver a
considerably lower static power output.
The open architecture of the hardware and AUTOSTAR
software permits arbitrary sources to be integrated
with control being effected by means of a 0 - 10V
analogue signal. The control units, INA 5024 in the
System 5000 and ARB in the System 5200, are precise
and fast enough to fulfil the test requirements.

NSG 5004A

Schaffner offers a standard solution for all applications
in the classic voltage and current fields using this
battery simulator. The bipolar source, with its low
impedance, current limiting function and fast regulation
provides the maximum flexibility for tests involving
voltage variations. Sense-lines permit automatic
correction for voltage losses in the cabling. The
battery simulator NSG 5004A outputs 12.5A at -30V to
+30V and can be delivered as a cascaded unit with a
current rating of 25A.

Other Sources

Other sources can be used according to the test
requirements. This encompasses simple
power supplies as well as highly specified dc
amplifiers with extended bandwidth, extra high
current capabilities, enhanced stability or other
features.

As long as the source accepts an analogue control
signal (±10V), it can be integrated seamlessly into the
system 5200 and the AUTOSTAR software package.

The technical data published by the manufacturers
must be taken as being decisive when determining the
suitability and limits for specific tests and the particular
EUT.

Battery simulators

Current sources

Output voltage

0 to ±30Vdc, stabilized via
sensor connections

Current

12.5A/25A,
short-term 3 x I for
100ms

Impedance

0.01Ω eff.

Regulation response

≤ 30V/ms

Current limiting

0.1A to Imax.
adjustable in 0.1A
steps

17

Typical configurations

Rack systems

Typical Configurations

The modular instruments can be used either as free­standing units or they can be installed in a 19" crate or
rack/cabinet. Schaffner offers instrument housings
with suitable internal cabling and mains control panel
as accessories. Starting with three basic
configurations, the rack systems are configured and
equipped in accordance with each customer's
specifications.

System 5200 Configurations

Voltage variation configuration

NSG 5201 / CTR 5210 / ARB 5220 / DCS 5230 /
Autostar software / NSG 5004

Pulsed magnetic configuration

NSG 5201 / CTR 5210 / ARB 5220 / DCS 5230 /
AMP 5240 / Autostar software

Conducted sine wave configuration

NSG 5202 / CTR 5210 / ARB 5220 / DCS 5230 /
AMP 5240 / CSW 5250 / Autostar Software /
NSG 5004 or other DC source

Rack Systems

The modular instruments (NSG 5000 / NSG 5200 /
NSG 5004A) can be used either as free-standing
units or they can be installed in a 19" cabinet.
Schaffner offers instrument housings with suitable
internal cabling and mains control panel as
accessories. Starting with basic configurations, the
rack systems are configured and equipped in
accordance with each customer's specifications.

18

Examples of Standards for Conducted Immunity Requirements and System Configurations

Standard System Requirements Notes

ISO ISO/WD 7637-2 1999 NSG 5000, NSG 5001A, NSG 5003, NSG 5004A,

NSG 5005A, NSG 5201, CTR 5210, ARB 5220, DCS 5230

SAE J1113/11 Jun 1995 NSG 5000, NSG 5001A, NSG 5003, NSG 5004A, Passenger cars only for

NSG 5005A, NSG 5005B, NSG 5201, CTR 5210, Current Load Dump
ARB 5220, DCS 5230 (NSG 5005B)

SAE J1113-2 Sep 1996 NSG 5202, CTR 5210, ARB 5220, DCS 5230, AMP 5240,

CSW 5250, Aux Source

SAE J1113/22 Feb 1995 NSG 5201, CTR 5210, ARB 5220, DCS 5230, AMP 5240,

NSG 5004A, Helmholtz Coil

DIN DIN 40838 Part 1 NSG 5000, NSG 5001A, NSG 5003, NSG 5004A,

1992 NSG 5005A

Jaso D 001-94 1994 NSG 5202, CTR 5210, ARB 5220, DCS 5230, NSG 5004A, Except §5.7 Transient

AMP 5240, CSW 5250, Aux Source, Helmholtz Coil Voltage Characteristics

MIL MIL-STD-462 NSG 5201, CTR 5210, ARB 5220, DCS 5230, AMP 5240,

Jan 1993 NSG 5004A, Radiating Loop

BMW N 600 13.0 Part 2 NSG 5000, NSG 5001A, NSG 5003, NSG 5004A,

May 1996 NSG 5005A, NSG 5201, CTR 5210, ARB 5220, DCS 5230

Chrysler PF-9326 Rev C NSG 5000, NSG 5001A, NSG 5003, NSG 5004A,

Dec 1999 NSG 5005A, , NSG 5202, CTR 5210, ARB 5220, DCS 5230,

AMP 5240, CSW 5250, Aux Source, Helmholtz Coil

Fiat 7-Z0450 NSG 5201, CTR 5210, ARB 5220, DCS 5230, AMP 5240,

NSG 5004A, Helmholtz Coil

Ford ES-XW7T-1A278-AB NSG 5000, NSG 5001A, NSG 5003, NSG 5004A, Additional Resistor Box

Apr 1999 Rev B NSG 5005A, NSG 5201, CTR 5210, ARB 5220, DCS 5230, required

AMP 5240, Radiating Loop

General GM9105P Nov 1996 NSG 5000, NSG 5001A, NSG 5003, NSG 5004A,
Motors NSG 5005A, NSG 5005B, NSG 5201, CTR 5210,

ARB 5220, DCS 5230

GM9113P May 1993 NSG 5201, CTR 5210, ARB 5220, DCS 5230, AMP 5240,

NSG 5004A, Helmholtz Coil

GM9117P May 1993 NSG 5201, CTR 5210, ARB 5220, DCS 5230, NSG 5004A

GM9123P Jan 1997 NSG 5201, CTR 5210, ARB 5220, DCS 5230, NSG 5004A

GMW3100 Feb 2000 NSG 5000, NSG 5001A, NSG 5003, NSG 5004A,

NSG 5005A, LISN, NSG 5201, CTR 5210, ARB 5220,
DCS 5230

Mercedes A 000 000 71 99 NSG 5000, NSG 5001A, NSG 5003, NSG 5004A,

Nov 1993 NSG 5201, CTR 5210, ARB 5220, DCS 5230

Mazda MES PW 67600 NSG 5000, NSG 5001A, NSG 5003, NSG 5004A

Jul 1995 NSG 5005A, NSG 5202, CTR 5210, ARB 5220, DCS 5230,

AMP 5240, CSW 5250, Aux Source, Radiating Loop

Nissan 28400 NDS02 NSG 5201, CTR 5210, ARB 5220, DCS 5230, NSG 5004A Source for §4 to be defined

Feb 1997

Renault 36.00.400 / C NSG 5201, CTR 5210, ARB 5220, DCS 5230, NSG 5004A Source for §3.4.2.3.1 &

Jan 1998 §3.4.2.3.2 to be defined

36-00-804/ - B 1996 NSG 5000, NSG 5001A, NSG 5003, NSG 5004A,

NSG 5005A, NSG 5201, CTR 5210, ARB 5220, DCS 5230,
AMP 5240, Helmholtz Coil

Volkswagen TL-VW 820 66 NSG 5000, NSG 5001A, NSG 5003, NSG 5004A,

NSG 5005A, NSG 5201, CTR 5210, ARB 5220, DCS 5230

Volvo Doc. No. 300 NSG 5000, NSG 5001A, NSG 5003, NSG 5004A, Except §5.1 Pulses 5c (12v)

Aug 1992 NSG 5005A, NSG 5201, CTR 5210, ARB 5220, DCS 5230 and 5d (24v)

19

RF immunity and emission

testing

ProfLine Frequency Range Test Method Standard Met

ISO SAE

5110 250kHz - 500MHz Direct Injection 11452-7 J1113/3

5120 1MHz - 400MHz Bulk Current Injection 11452-4 J1113/4

5130 10kHz - 200MHz Radiated in Chamber 11452-6 J1113/21

5140 200MHz - 1GHz Radiated in Chamber 11452-2 J1113/21

5150 1GHz - 18GHz Radiated in Chamber 11452-2 J1113/21

5160 10kHz - 200MHz Strip Line 11452-5 J1113/23

5170 10kHz - 500MHz Tri Plate - J1113/25

5180 10kHz - 200MHz TEMCELL 11452-3 J1113/24

● Simple turnkey systems

● Fully automated report generation

● Integrated systems

● Compliant to international standards

● Training

To complement the test instrumentation for pulsed and
conducted tests, Schaffner also offers a complete
range of RF test systems for immunity and emission
checks. The test installations range from direct
coupling, strip transmission lines and TEM-cells right
through to various types of absorber cells and
chambers. The product range includes all the
necessary instruments such as modulators, amplifiers,
probes, couplers, networks, antennae, measuring
receivers, etc. and, naturally, the accompanying user­friendly application software providing comprehensive
test reports.

The software has been specially adapted from the
well-proven CIS9942 RF immunity IEC 61000-4-3
package to meet the specific requirements of the
automotive component standards. These include
conditional levelling on net forward power, levelling to
the peak level of the modulated signal and the
requirement to reduce the RF level during frequency
stepping.

Detailed information about the ProfLine 5000
Automotive RF EMC Test Systems is available in
separate specialist publications.

20

ProfLine RF EMC

test systems

● 250kHz - 500MHz

● Complies with ISO 11452-7 Level 6 (250kHz - 400MHz)

● Complies with SAE J1113/3 Level IV (250kHz - 500MHz)

● Turnkey system with optional report generation

Test severity level Test severity level Value Watts

SAE J1113/3 ISO 11452-7

L1 0.05

L2 I 0.1

L3 II 0.2

L4 III 0.3

L5 IV 0.4

L6 V 0.5

Test levels supported in standard package

Test severity level Test severity level Value mA

SAE J1113/4 ISO 11452-4

L1 I 25
L2 40

II 50

L3 60

III 75
L4 80
L5 IV 100

Test levels supported in standard package

● 1MHz - 400MHz

● Complies with ISO 11452-4 Level IV (1MHz - 400MHz)

● Complies with SAE J1113/4 Level L5 (1MHz - 400MHz)

● Turnkey system with optional report generation

BAN

A Broadband Artificial Network (BAN) is a network
which presents a controlled impedance to the EUT
over the specified frequency range of the test thus
ensuring repeatability and comparability of results.

Bulk Current Injection (BCI) Probe

Bulk Current Injection is a method of carrying out
immunity tests by inducing disturbance signals directly
into the wiring harness by means of a current injection
probe. The injection probe is a current transformer

through which the cabling of the EUT is passed.
Immunity tests are carried out by varying the test
severity level and frequency of the induced
disturbance. (ISO 11452-4 sect 4.1)

ProfLine 5110 Direct Injection Method

ProfLine 5120 Bulk Current Injection Method

Signal
Generator

>_

Power Meter

Amplifier

PC - NOT INCLUDED

Power Meter

Directional

Coupler

Calibration

10dB

Test

Peripheral
or Power

B.A.N.

E.U.T.

PC - NOT INCLUDED

Amplifier

Power Meter

Directional

20dB

Coupler

Signal
Generator

>_

Power Meter

Cal Jig

Load

21

The Parallel Plate Antenna

The parallel plate antenna is basically a parallel
balanced transmission line (antenna) that is capable of
generating a uniform electric field over a useful
physical area. The antenna is designed to interface to

a 50Ω power source and a 50Ω load in order to

achieve good matching characteristics. The test
configuration may be designed to test equipment with
their associated wiring harnesses.

The maximum size of the EUT should not be larger
than the width of the antenna.

The user is cautioned that, since the test apparatus
will generate undesirable electromagnetic radiation
into the environment, the test may need to be
performed in a shielded enclosure.
(ISO 11452-6 sect 4.3.1)

Test severity level Test severity level Value V/m

SAE J1113/21 ISO 11452-6

L1 I 25
L2 40
L3 II 50
L4 60

III 75
L5 80
L6 IV 100

Test levels supported in standard package

Higher levels available

● 10kHz - 200MHz

● Compliant with ISO 11452-6 to Level L6 (10kHz - 200MHz)

● Compliant with SAE J1113/21-6 to Level IV (10kHz - 200MHz)

● Turnkey system with optional report generation

Test severity level Test severity level Value V/m

SAE J1113/21 ISO 11452-2

L1 I 25
L2 40
L3 II 50
L4 60

III 75

L5 80
L6 IV 100

Test levels supported in standard package

Higher levels available

● 200MHz - 1GHz

● Complies with SAE J1113/21 Level L6 (200MHz-1GHz)

● Complies with ISO 11452-2 Level IV (200MHz-1GHz)

● Turnkey system with optional report generation

Field Generating Device

The Field Generating Device shall be an antenna.
Any commercially available antenna set (including high
power baluns if appropriate) which is capable of

radiating the specified field strengths at the EUT with
the available power may be used.
(ISO 11452 sect 4.2.1)

ProfLine 5130 Radiated in an Absorber Lined Chamber

ProfLine 5140 Radiated in a Chamber

Signal
Generator

Fibre Optic Cable

>_

PC - NOT INCLUDED

Amplifier

E Field
Probe

Screened Room

Power Meter

Directional

Load

Coupler

E Field
Generator

Signal
Generator

Fibre Optic Cable

>_

E Field
Probe

PC - NOT INCLUDED

Amplifier

Anechoic Chamber

Power Meter

Antenna

Directional

Coupler

22

Field Generating Device

The Field Generating Device shall be an antenna.
Any commercially available antenna set (including high
power baluns if appropriate) which is capable of

radiating the specified field strengths at the EUT with
the available power may be used.
(ISO 11452 sect 4.2.1)

The Strip Line

The Strip Line ideally sets up a region of uniform
electromagnetic field. The primary usage of this
stripline is to expose at least 1.5 metres of the wiring
harness to RF fields. In practice, the fields generated
will be uniform only below the TEM multi-mode

frequency. The use of a straight length of cable or
harness of 1.5 metres is required to integrate fields
above the multi-mode frequencies along the length of
the harness. (ISO 11452-5 sect 4.1)

Test severity level Test severity level Value V/m

SAE J1113/21 ISO 11452-2

L1 I 25
L2 40
L3 II 50
L4 60

III 75
L5 80
L6 IV 100

Test levels supported in standard package

Higher levels available

● 1GHz - 18GHz

● Complies with ISO 11452-2 Level IV (1GHz - 18GHz)

● Complies with SAE J1113/21 Level L6 (1GHz - 18GHz)

● Turnkey system with optional report generation

● 10kHz - 200MHz

● Complies with ISO 11452-5 to Level IV (10kHz - 200MHz)

● Complies with SAE J1113/23 to Level 4 (10kHz - 200MHz)

● Turnkey system with optional report generation

Test severity level Test severity level Value V/m

SAE J1113/23 ISO 11452-5

L1 I 50
L2 II 100
L3 III 150
L4 IV 200

Test levels supported in standard package

Higher levels available

ProfLine 5150 Radiated in a Chamber

ProfLine 5160 Strip Line Method

PC - NOT INCLUDED

Amplifier

Anechoic Chamber

Power Meter

Directional

Antenna

Coupler

Signal
Generator

Fibre Optic Cable

>_

E Field
Probe

Signal
Generator

Load

Fibre Optic Cable

>_

E Field
Probe

PC - NOT INCLUDED

Amplifier

Strip Line

Power Meter

Directional

Coupler

23

● 10kHz - 500MHz

● Complies with SAE J1113/25 Level 4 (10kHz - 500MHz)

● Turnkey system with optional report generation

Test severity level Value V/m

SAE J1113/25

L1 50
L2 100
L3 150
L4 200

Test levels supported in standard package

Higher levels available

The Tri-Plate

A Tri-Plate is a variation of a TEM cell which is
constructed without sides to a cell. The Tri-Plate sets
up a region of uniform electric and magnetic fields
between the centre septum and the top and bottom
ground plates. The lack of side walls means that the

Tri-plate must be used within a shielded room to
prevent radiation from the Tri-plate from interfering
with nearby electronic devices. The possibility of room
resonances and reflected waves distorting the
measurements must be ignored. (SAE J 1113/25)

● 10kHz - 200MHz

● Complies with ISO 11452-3 Level IV (10kHz - 200MHz)

● Complies with SAE J1113/24 Level 4 (10kHz - 200MHz)

● Turnkey system with optional report generation

Test severity level Test severity level Value V/m

SAE J1113/24 ISO 11452-3

L1 I 50
L2 II 100
L3 III 150
L4 IV 200

Test levels supported in standard package

Higher levels available

The TEM Cell

The TEM cell used in this test method is a rectangular

coaxial line with 50Ω characteristic impedance. The

EUT is exposed to a uniform TEM field. The TEM cell
method cannot be used to determine

absolute test field levels, polarization and frequency
for device immunity. Only comparative measurements
can be made. The TEM cell has the major advantage
of not radiating energy into the surrounding space.

ProfLine 5170 Tri-Plate Method

>_

Amplifier

Fibre Optic Cable

E Field
Probe

Load

Power Meter

Signal
Generator

Filter

PC - NOT INCLUDED

Directional

Coupler

TEM Cell

ProfLine 5180 TEM Cell Method

E Field
Probe

PC - NOT INCLUDED

Amplifier

Tri-Plate

Power Meter

Directional

Coupler

Signal
Generator

Load

Fibre Optic Cable

>_

24

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15
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4
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5
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19
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21
22
22
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23
8

Product Number

AMP 5240 .................................

ARB 5220 .................................

ARB 5221 .................................

AUTOSTAR ...............................

CDN 5010 .................................

CDN 500 ...................................

CSW 5250 ................................

CTR 5210 .................................

DCS 5230 .................................

INA 5020 ...................................

INA 5024 ...................................

INA 5025 ...................................

NSG 5000 .................................

NSG 5001A ..............................

NSG 5003 .................................

NSG 5004A ..............................

NSG 5005A ..............................

NSG 5005B ..............................

ProfLine 5100 series ................

ProfLine 5110 ...........................

ProfLine 5120 ...........................

ProfLine 5130 ...........................

ProfLine 5140 ...........................

ProfLine 5150 ...........................

ProfLine 5160 ...........................

ProfLine 5170 ...........................

ProfLine 5180 ...........................

System 5200 ............................

Product Index

HEADQUARTERS

Schaffner EMV AG

CH-4542 Luterbach
Switzerland
Tel: [+41] 32 6816 626
Fax: [+41] 32 6816 641
E-mail: [e-mail]

690-680A / March 2001

© 2001 Schaffner EMC Systems Specifications
subject to change without notice.

This catalogue is only intended as a guide.
For full technical specifications and up to date
information, please visit our website at;

www.schaffner.com

All trademarks recognised.

Schaffner group manufacturing companies are
ISO-registered. Their products are designed
and manufactured under the strict quality
requirements of the ISO 9000 standard.

This document has been carefully checked.
However, Schaffner does not assume any
liability for errors or inaccuracies.

China

Schaffner Beijing Liaison Office

Tel: [+86] 10 6510 1761
E-mail: [e-mail]

Japan

Schaffner EMC KK

Tel: [+81] 3 3418 5822
E-mail: [e-mail]

UK

Schaffner EMC Ltd

Tel: [+44] 118 977 0070
E-mail: [e-mail]

SALES SUBSIDIARIES

France

Schaffner EMC S.A.S.

Tel: [+33] 1 34 34 30 60
E-mail: [e-mail]

Singapore

Schaffner EMC Pte Ltd

Tel: [+65] 377 3283
E-mail: [e-mail]

USA

Schaffner EMC Inc

Tel: [+1] 732 225 9533
E-mail: [e-mail]

Germany

Schaffner EMC Systems GmbH

Tel: [+49] 30 5659 8835
E-mail: [e-mail]

Sweden

Schaffner EMC AB

Tel: [+46] 8 5792 1121
E-mail: [e-mail]

Italy

Schaffner EMC Srl

Tel: [+39] 02 66 04 30 45
E-mail: [e-mail]

Switzerland

Schaffner EMV AG

Tel: [+41] 32 6816 626
E-mail: [e-mail]

www.schaffner.com