Commission Regulation (EU) 2017/2400 of 12 December 2017 implementing Regulation (EC) No 595/2009 of the European Parliament and of the Council as regards the determination of the CO2 emissions and fuel consumption of heavy-duty vehicles and amending Directive 2007/46/EC of the European Parliament and of the Council and Commission Regulation (EU) No 582/2011 (Text with EEA relevance. )

• (e) These rotational speed setpoints shall be converted to the respective setpoints for all other gears by the following equation: nk,gear = nk,gear_iCT1 × igear_iCT1 / igear where: nk,gear = rotational speed setpoint k for a specific gear (where k = 1, 2, 3, …, maximum number of rotational speed setpoints) (where gear = 1, …, highest gear number) nk,gear_iCT1 = rotational speed setpoint k for the gear with the gear ratio closest to 1 in accordance with subpoint (d) (where k = 1, 2, 3, …, maximum number of rotational speed setpoints) igear = gear ratio of a specific gear [-] (where gear = 1, …, highest gear number) igear_iCT1 = gear ratio of the gear with the gear ratio closest to 1 in accordance with subpoint (d) [-]

In the case of an IEPC with multispeed gearbox where the torque limits were determined for each forward gear in accordance with point 4.2.2(c), a separate dataset of setpoints for rotational speed of the UUT shall be defined for each single forward gear based on the following provisions:

• (f) As setpoints for rotational speed of the UUT the same setpoints used for the measurement performed in accordance with point 4.2.2.2 for the respective voltage level and the respective forward gear shall be used.

• (g) The speed setpoint for the maximum 30 minutes continuous torque verification performed in accordance with point 4.2.4.2 for the respective voltage level shall be used in addition to the setpoints defined in subpoint (f) of this point. That rotational speed setpoint shall be converted to the respective setpoint for a specific forward gear by the equation defined in subpoint (e) of this point.

• (h) Further speed setpoints may be defined in addition to the setpoints defined in subpoints (f) and (g).

4.2.6.2.2   Setpoints for torque

The setpoints for either a standalone electric machine system or an IEPC with no shiftable gears shall be defined in accordance with the following provisions:

• (a) At least 10 setpoints for torque of the UUT shall be defined for the measurement, located both on the positive (i.e. driving) and negative (i.e. braking) torque side. The lowest and highest torque setpoint shall be defined based on the minimum and maximum torque limits determined in accordance with point 4.2.2.4 for the respective voltage level, where the lowest torque setpoint shall be the overall minimum torque, Tmin_overall, and the highest torque setpoint shall be the overall maximum torque, Tmax_overall, determined from these values.

• (b) The remaining 8 or more different torque setpoints shall be located between the lowest and highest torque setpoint. The interval between two adjacent torque setpoints shall not be larger than 22.5 % of the overall maximum torque of the UUT determined in accordance with point 4.2.2.4 for the respective voltage level.

• (c) The limit value for positive torque at a particular rotational speed shall be the maximum torque limit at this particular rotational speed setpoint determined in accordance with point 4.2.2.4 for the respective voltage level, minus 5 % of Tmax_overall. All torque setpoints at a particular rotational speed setpoint that are located higher than the limit value for positive torque at this particular rotational speed shall be replaced by one single target torque setpoint located at the maximum torque limit at this particular rotational speed setpoint.

• (d) The limit value for negative torque at a particular rotational speed shall be the minimum torque limit at this particular rotational speed setpoint determined in accordance with point 4.2.2.4 for the respective voltage level, minus 5 % of Tmin_overall. All torque setpoints at a particular rotational speed setpoint that are located lower than the limit value for negative torque at this particular rotational speed shall be replaced by one single target torque setpoint located at the minimum torque limit at this particular rotational speed setpoint.

• (e) Minimum and maximum torque limitations for a particular rotational speed setpoint shall be determined based on the data generated in accordance with point 4.2.2.4 for the respective voltage level, by using linear interpolation.

In the case of an IEPC with multispeed gearbox where the torque limits were only determined for a single gear in accordance with subpoint (a) of point 4.2.2, a separate dataset of setpoints for torque of the UUT shall be defined for each single forward gear based on the following provisions:

• (f) The torque setpoints for the gear with the gear ratio closest to 1 (where the gear ratios of two gears have the same distance to a gear ratio of 1, the test shall be performed only for the gear with the higher of the two gear ratios) determined in accordance with subpoints (a) to (e), Tj,gear_iCT1, shall be used as basis for the further step in subpoints (g) and (h).

• (g) These torque setpoints shall be converted to the respective setpoints for all other gears by the following equation: Tj,gear = Tj,gear_iCT1 / igear_iCT1 × igear where: Tj,gear = torque setpoint j for a specific gear (where j = 1, 2, 3, …, maximum number of torque setpoints) (where gear = 1, …, highest gear number) Tj,gear_iCT1 = torque setpoint j for the gear with the gear ratio closest to 1 in accordance with subpoint (f) (where j = 1, 2, 3, …, maximum number of torque setpoints) igear = gear ratio of a specific gear [-] (where gear = 1, …, highest gear number) igear_iCT1 = gear ratio of the gear with the gear ratio closest to 1 in accordance with subpoint (f) [-]

• (h) All torque setpoints Tj,gear that have an absolute value higher than 10 kNm shall not be required to be measured during the actual test run performed in accordance with point 4.2.6.4.

In the case of an IEPC with multispeed gearbox where the torque limits were determined for each forward gear in accordance with point 4.2.2(c), a separate dataset of setpoints for torque of the UUT shall be defined for each single forward gear based on the following provisions:

• (i) At least 10 setpoints for torque of the UUT shall be defined for the measurement for each single forward gear, located both on the positive (i.e. driving) and negative (i.e. braking) torque side by applying the provisions defined in subpoints (a) to (e) of this point for the specific gear.

• (j) All resulting torque setpoints that have an absolute value higher than 10 kNm shall not be required to be measured during the actual test run for the specific gear performed in accordance with point 4.2.6.4.

4.2.6.2.3   Requirements for minimum amount of torque setpoints

For each setpoint for rotational speed defined in accordance with point 4.2.6.2.1 the following requirements shall apply:

• (a) In case the number of original torque setpoints defined in accordance with point 4.2.6.2.2 located on the positive (i.e. driving) side with an absolute torque value lower than or equal to 10 kNm is 1, two additional torque setpoints shall be added in accordance with the following provisions:
• (i) If the original torque setpoint is located higher than 6,66 kNm, two new additional torque setpoints shall be defined located equidistant between the original torque setpoint and 0 kNm.
• (ii) If the original torque setpoint is located lower than 6,66 kNm:
• — a new additional torque setpoint at 9,8 kNm shall be defined.
• — if the original torque setpoint is located lower than 3,33 kNm, a new additional torque setpoint located equidistant between the original torque setpoint and 9,8 kNm shall be defined.
• — if the original torque setpoint is located higher than or equal to 3,33 kNm, a new additional torque setpoint located equidistant between the original torque setpoint and 0 kNm shall be defined.

• (b) In case the number of original torque setpoints defined in accordance with point 4.2.6.2.2 located on the positive (i.e. driving) side with an absolute torque value lower than or equal to 10 kNmis 2, the following provisions shall apply:
• (i) If no original torque setpoint located higher than 6,66 kNm exists, a new additional torque setpoint at 9,8 kNm shall be defined.
• (ii) If an original torque setpoint located higher than 6,66 kNm exists and also an original torque setpoint located lower than 3,33 kNm exists, a new additional torque setpoint shall be defined located equidistant between the lowest and highest positive (i.e. driving) original torque setpoints.
• (iii) If an original torque setpoint located higher than 6,66 kNm exists and also an original torque setpoint located higher than or equal to 3,33 kNm exists, a new additional torque setpoint shall be defined located equidistant between the lowest positive (i.e. driving) original torque setpoint and 0 kNm.

• (c) In case the number of original torque setpoints defined in accordance with point 4.2.6.2.2 located on the negative (i.e. braking) side with an absolute torque value lower than or equal to 10 kNm is 1, two additional torque setpoints shall be added in accordance with the following provisions:
• (i) If the original torque setpoint located lower than 6,66 kNm, two new additional torque setpoints shall be defined located equidistant between the original torque setpoint and 0 kNm.
• (ii) If the original torque setpoint is located lower than 6,66 kNm:
• — a new additional torque setpoint at 9,8 kNm shall be defined.
• — if the original torque setpoint is located higher than 3,33 kNm , a new additional torque setpoint shall be defined located equidistant between the original torque setpoint and 9,8 kNm.
• — if the original torque setpoint is located lower than or equal to 3,33 kNm exists, a new additional torque setpoint shall be defined located equidistant between the original torque setpoint and 0 kNm.

• (d) In case the number of original torque setpoints defined in accordance with point 4.2.6.2.2 located on the negative (i.e. braking) side with an absolute torque value lower than or equal to 10 kNmis 2, the following provisions shall apply:
• (i) If no original torque setpoint located lower than 6,66 kNm exists, a new additional torque setpoint at 9,8 kNm shall be defined.
• (ii) If an original torque setpoint located lower than 6,66 kNm exists and also an original torque setpoint located higher than 3,33 kNm exists, a new additional torque setpoint shall be defined located equidistant between the highest and lowest negative (i.e. braking) original torque setpoints.
• (iii) If an original torque setpoint located lower than 6,66 kNm exists and also an original torque setpoint located lower than or equal to 3,33 kNm exists, a new additional torque setpoint shall be defined located equidistant between the highest negative (i.e. braking) original torque setpoint and 0 kNm.

4.2.6.3   Signals to be measured

Under the operating points specified in accordance with point 4.2.6.2 the electric power to or from the inverter (or DC/DC converter if applicable) and the output torque and speed of the UUT shall be measured.

4.2.6.4   Test sequence

The test sequence consists of steady state setpoints with defined rotational speed and torque at each setpoint in accordance with point 4.2.6.2.

In case an unforeseen interruption occurs, the test sequence may be continued under the following provisions:

• — The UUT stays within the testcell, with the ambient temperature in the testcell kept within 25 ±10 °C;

• — Before continuing the test the UUT shall be run on the bench for warm-up according to the recommendations of the component manufacturer.

• — After the warm-up the test sequence shall be continued at the next lower rotational speed setpoint to the rotational speed setpoint where the interruption occurred.

• — At the next lower rotational speed setpoint the test sequence described by subpoint (a) to (m) further below shall be followed, but only for preconditioning purposes without recording any measurement data.

• — Recording of measurement data shall be done, starting from the first operating point at the rotational speed setpoint where the interruption occurred.

In the case of an IEPC, the following provisions shall apply:

• — The test sequence shall be performed for each single gear sequentially starting from the gear with the highest gear ratio to be continued with the gears in descending order of gear ratio.

• — All setpoints within a dataset for a specific gear determined in accordance with point 4.2.6.2 shall be completed before the measurement is continued in a different gear.

• — It is allowed to interrupt the test after completion of measurement for each specific gear.

• — The use of different torque meters is allowed.

Just before beginning the test at the first setpoint, the UUT shall be run on the bench for warm-up in accordance with the recommendations of the component manufacturer. The first rotational speed setpoint for the actual measured gear for starting the EPMC test is defined at the lowest rotational speed setpoint.

The remaining setpoints for the actual measured gear shall be applied in the following order:

• (a) The first operating point at a particular rotational speed setpoint is defined at the highest torque at this specific speed.

• (b) The next operating point shall be set at the same speed and the lowest positive (i.e. driving) torque setpoint.

• (c) The next operating point shall be set at the same speed and the second highest positive (i.e. driving) torque setpoint.

• (d) The next operating point shall be set at the same speed and the second lowest positive (i.e. driving) torque setpoint.

• (e) This order of switching from the remaining highest to the remaining lowest torque setpoint shall be continued until all positive (i.e. driving) torque setpoints at a particular rotational speed setpoint are measured.

• (f) Before continuing with step (g) the UUT may be cooled down in accordance with the component manufacturer’s recommendations by running at a particular setpoint defined by the component manufacturer.

• (g) Then measurement of the negative (i.e. braking) torque setpoints at the same rotational speed setpoint shall be performed starting at the lowest torque at this specific speed.

- (h) The next operating point shall be set at the same speed and the highest negative (i.e. braking) torque setpoint.

- (i) The next operating point shall be set at the same speed and the second lowest negative (i.e. braking) torque setpoint.

• (j) The next operating point shall be set at the same speed and the second highest negative (i.e. braking) torque setpoint.

- (k) This order of switching from the remaining lowest to the remaining highest torque setpoint shall be continued until all negative (i.e. braking) torque setpoints at a particular rotational speed setpoint are measured.

• (l) Before continuing with step (m) the UUT may be cooled down in accordance with the component manufacturer’s recommendations by running at a particular setpoint defined by the component manufacturer.

• (m) The test shall continue at the next higher rotational speed setpoint by repeating steps (a) to (m) of the defined test sequence above until all rotational speed setpoints for the actual measured gear were completed.

All operating points shall be held for an operating time of at least 5 seconds. During that operating time the rotational speed of the UUT shall be held at the rotational speed setpoint within a tolerance of ±1 % or 20 rpm whatever is larger. Additionally, during that operating time, except for the highest and lowest torque setpoint at each rotational speed setpoint, the average torque shall be held at the torque setpoint within a tolerance of ±1 % of the value of the torque setpoint or ±5 Nm (±2 % of the value of the torque setpoint or ±20 Nm in case of the UUT being an IEPC with either a gearbox and/or a differential included) whatever is larger.

The electric power to or from the inverter (or DC/DC converter if applicable), the output torque and rotational speed of the UUT shall be recorded as average value over the last two seconds of the operating time.

4.3.   Post-processing of measurement data of the UUT

4.3.1   General provisions for post-processing

All post-processing steps defined in points 4.3.2 to 4.3.6 shall be performed for the datasets measured for the two different voltage levels in accordance with point 4.1.3 separately.

4.3.2   Maximum and minimum torque limits

The data for maximum and minimum torque limits determined in accordance with point 4.2.2.4 shall be extended by means of linear extrapolation (using the two closest points) to zero rotational speed and to the maximum operating speed of the UUT as declared by the component manufacturer in the event that the recorded measurement data does not cover these ranges.

In the case of an IEPC with multispeed gearbox where the torque limits were determined for each forward gear in accordance with point 4.2.2(c), the manipulation step shall be done separately for each forward gear.

4.3.3   Drag curve

The data for the drag curve determined in accordance with point 4.2.3 shall be modified in accordance with the following provisions considering that drag torque shall have a negative sign in accordance with the sign conventions laid down in point 4.1.9:

• (1) Where the electric power supply to the inverter (or DC/DC converter if applicable) was set inactive or disconnected, the respective values for electric power to the inverter (or DC/DC converter if applicable) shall be set to 0.

• (2) Where the output shaft of the UUT was not connected to the load machine (i.e. dynamometer), the respective torque values shall be set to 0.

• (3) The data modified in accordance with points (1) and (2) above shall be extended by means of linear extrapolation to the maximum operating speed of the UUT as declared by the component manufacturer where the recorded measurement data does not cover these ranges.

• (4) The values of electric power to the inverter (or DC/DC converter if applicable) modified in accordance with points (1) to (3) above shall be seen as virtual mechanical loss power. These values of virtual mechanical loss power shall be converted to virtual drag torque with the respective rotational speed of the output shaft of the UUT. These values of virtual drag torque shall have a negative sign in accordance with the sign conventions defined in point 4.1.9.

• (5) At each setpoint of rotational speed of the output shaft of the UUT in the data modified in accordance with points (1) to (3) above, the value of virtual drag torque determined in accordance with point (4) above shall be added to the actual torque of the load machine (i.e. dynamometer) to define the total drag torque of the UUT as function of rotational speed.

- (6) The values of the total drag torque of the UUT at the lowest rotational speed setpoint, determined from the data modified in accordance with point (5) above, shall be copied to a new entry at 0 rpm rotational speed and added to the data modified in accordance with point (5) above.

4.3.4   EPMC

The data for the EPMC determined in accordance with point 4.2.6.4 shall be extended in accordance with the following provisions for each forward gear measured and also for each of the two voltage levels Vmin,Test and Vmax,Test separately:

• (1) The values of all data pairs for output torque and eletric inverter power determined at the lowest rotational speed setpoint shall be copied to a new entry at zero rotational speed.

• (2) The values of all data pairs for output torque and eletric inverter power determined at the highest rotational speed setpoint shall be copied to a new entry at the highest rotational speed setpoint times 1.05.

• (3) If at a specific rotational speed setpoint, including the newly introduced data in accordance with points 1 and 2 of this point, a torque setpoint determined in accordance with point 4.2.6.2.2 (a) to (g) and (i) was omitted for the actual measurement in accordance with point 4.2.6.2.2 (h) or point 4.2.6.2.2(j), a new data point representing the omitted point shall be calculated based on the following provisions:
• (a) Rotational speed: using the value of the omitted setpoint for the rotational speed.
• (b) Torque: using the value of the omitted setpoint for torque.
• (c) Inverter power: calculating a new value by means of linear extrapolation according to the subsequent provisions in this subpoint. The parameters of the least squares linear regression line (i.e. slope and y-intercept) for a specific omitted point shall be determined based on the three actually measured points (i.e. data pairs of torque and inverter power) located closest to the torque value from subpoint (b) for the corresponding rotational speed setpoint. The extrapolated value for the inverter power shall be determined by taking the inverter power of the actually measured point located closest to the torque value from subpoint (b) as a starting point and applying only the slope of the specific least squares linear regression line.
• (d) For positive torque values, extrapolated values of inverter power resulting in values lower than the measured one at the actually measured torque point located closest to the torque value from subpoint (b) shall be set to the inverter power actually measured at the torque point located closest to the torque value from subpoint (b).
• (e) For negative torque values, extrapolated values of inverter power resulting in values higher than the measured one at the actually measured torque point located closest to the torque value from subpoint (b) shall be set to the inverter power actually measured at the torque point located closest to the torque value from subpoint (b).
• (f) Notwithstanding the provisions in subpoints (d) and (e), extrapolated values of inverter power resulting in an efficiency of the total IEPC (i.e. determined based on electrical inverter power and mechanical power at component output shaft) higher than resulting from the two efficiencies set out in point (i) or (ii), as applicable, shall be replaced by a new value of inverter power that reflects exactly the efficiency:
• (i) either the resulting efficiency for this specific operating point when the provisions for determining standard values in accordance with Appendix 9 are applied
• (ii) or the efficiency of the actually measured torque point located closest to the torque value from subpoint (b) decreased by 2 percentage points (e.g. 90,5 %-2 %=88,5 %).

• (4) At each rotational speed setpoint (including the newly introduced data in points 1 to 3 above) a new data point shall be calculated based on the data at the highest torque setpoint in accordance with the following rules:
• (a) Rotational speed: using the same value for the rotational speed
• (b) Torque: using the value for torque multiplied by a factor of 1,05
• (c) Inverter power: calculating a new value in such a way that the efficiency defined as the ratio of mechanical power to inverter power stays constant

• (5) At each rotational speed setpoint (including the newly introduced data in points 1 to 3 above) a new data point shall be calculated based on the data at the lowest torque setpoint in accordance with the following rules:
• (a) Rotational speed: using the same value for the rotational speed
• (b) Torque: using the value for torque multiplied by a factor of 1.05
• (c) Inverter power: calculating a new value in such a way that the efficiency defined as the ratio of inverter power to mechanical power stays constant

4.3.5   Overload characteristics

From the data for the overload characteristics determined in accordance with point 4.2.5.3 an efficiency figure shall be determined by dividing the average mechanical output power over the period of t0_maxP by the average electric power to or from the inverter (or DC/DC converter if applicable) over the period of t0_maxP.

4.3.6   Maximum 30 minutes continuous torque

From the data determined in accordance with point 4.2.4.3 an efficiency figure shall be determined by dividing the average 30 minutes continuous power by the average electric power to or from the inverter (or DC/DC converter if applicable).

From the measurement data for the maximum 30 minutes continuous torque determined in accordance with point 4.2.4.2 the following average values shall be determined from the time-resolved values over the 1 800 -second measurement period for each cooling circuit with connection to an external heat exchanger separately:

• — cooling power

- — coolant temperature at the inlet of the cooling circuit of the UUT

The cooling power shall be determined based on the specific heat capacity of the coolant, the coolant massflow and the temperature difference over the test bed heat exchanger on the side of the UUT.

4.4   Special provisions for testing of IHPCs Type 1

IHPCs Type 1 are virtually split into two separate components for handling in the simulation tool, i.e. an electric machine system and a transmission. Therefore, two separate component data sets shall be determined by following the provisions described in this point.

For component testing of IHPCs Type 1, points 4.1 to 4.2 of this Annex shall apply.

For an IHPC Type 1 the torque and speed shall be measured at the output shaft of the system (i.e. the output side of the gearbox towards the wheels of the vehicle).

The definition of families in accordance with Appendix 13 shall not be allowed for IHPCs Type 1. Therefore, omission of test runs is not allowed and all test runs described in point 4.2 shall be performed for one specific IHPC Type 1. Notwithstanding these provisions, the test of the drag curve in accordance with point 4.2.3 shall be omitted for IHPCs Type 1.

Generating input data for IHPCs Type 1 based on standard values shall not be allowed.

4.4.1   Test runs to be performed for IHPCs Type 1

4.4.1.1   Test runs to determine the total system characteristics

This subpoint describes the details for determining the characteristics of the complete IHPC Type 1 including the losses of the gearbox part within the system.

The following test runs shall be performed in accordance with the provisions defined for IEPC with multispeed gearbox in the respective points. For all of these test runs, the input shaft for feeding propulsion torque into the system shall be either disconnected and rotating freely or shall be fixed without rotating.

Table 2a

Overview of test runs to be performed for IHPC Type 1

| Test run | Reference to point |

| --- | --- | | Maximum and minimum torque limits | 4.2.2 | | Maximum 30 minutes continuous torque | 4.2.4 | | Overload characteristics | 4.2.5 | | EPMC | 4.2.6 |

Due to the applicability of the provisions defined for IEPC with multispeed gearbox to IHPCs Type 1, the EPMC shall be measured for each single forward gear in accordance with point 4.2.6.2.

4.4.1.2   Test runs to determine the losses of the gearbox part within the system

This subpoint describes the details for determining the losses of the gearbox part within the system.

Therefore, the system shall be tested in accordance with the provisions in point 3.3 of Annex VI. Notwithstanding these provisions, the following provisions shall be applied:

• — The input shaft for feeding propulsion torque into the system shall be connected to and driven by a dynamometer in accordance with the provisions in point 3.3 of Annex VI.

• — The power supply from the electric DC powersource to the inverter(s) (or DC/DC converter(s) if applicable) shall be disconnected. In order to allow this disconnection without any parts of the system being damaged, the system may be modified in a way that dummy magnets or dummy rotors are used in the electric machine(s) part for the measurement.

• — The torque range as defined in point 3.3.6.3 of Annex VI shall be extended to cover also negative torque values in such a way that the same torque setpoints from the positive side are measured also with a negative algebraic sign.

4.4.2   Post-processing of measurement data of IHPCs Type 1

For post-processing of measurement data of IHPCs Type 1, all provisions as laid down in point 4.3 shall apply unless stated otherwise.

4.4.2.1   Post-processing of data regarding total system characteristics

All measurement data determined in accordance with point 4.4.1.1 shall be handled in accordance with the provisions as laid down in points 4.3.1 to 4.3.6. The provisions of point 4.3.3 shall be omitted since measurement of the drag curve in accordance with point 4.2.3 is not performed for IHPCs Type 1. Where there are specific provisions defined for IEPC with multispeed gearbox in the respective points, such specific provisions shall be applied.

4.4.2.2   Post-processing of data regarding losses of the gearbox part within the system

All measurement data determined in accordance with point 4.4.1.2 shall be handled in accordance with the provisions as laid down in point 3.4 of Annex VI. Notwithstanding these provisions, the following provisions shall be applied:

- — The provisions as laid down in points 3.4.2 to 3.4.5 of Annex VI shall be applied analogously also for negative torque values.

• — The provisions as laid down in point 3.4.6 of Annex VI shall not be applied.

4.4.2.3   Post-processing of data to derive the specific data of the virtual electric machine system

In order to determine the component data of the virtual electric machine system the following steps shall be applied. The following post-processing steps shall be omitted for the two efficiency figures determined in accordance with points 4.3.5 and 4.3.6 since these efficiency figures only serve for assessment of conformity of the certified CO2 emissions and fuel consumption related properties.

• (a) All speed and torque values of the measurement data handled in accordance with point 4.4.2.1 shall be converted from the output shaft to the input shaft of the IHPC Type 1 in accordance with the following equations. Where the same test run was performed for several gears, the conversion shall be performed for each gear separately. Image omitted; see official source Image omitted; see official source where: nEM,virt = rotational speed of the virtual electric machine system referring to the input shaft of the IHPC Type 1 [1/min] noutput = measured rotational speed at the output shaft of the IHPC Type 1 [1/min] igbx = ratio of rotational speed at the input shaft over the rotational speed at the output shaft of the IHPC Type 1 for a specific gear engaged during the measurement [-] TEM,virt = torque of the virtual electric machine system referring to the input shaft of the IHPC Type 1 [Nm] Toutput = measured torque at the output shaft of the IHPC Type 1 [Nm] Tloss,gbx = torque loss depending on rotational speed and torque at the input shaft of the IHPC Type 1 [Nm]. It shall be calculated by means of two-dimensional linear interpolation from the loss maps of the gearbox determined in accordance with point 4.4.2.2 for the respective gear. gear = specific gear engaged during the measurement [-]

• (b) The electric power maps determined for each forward gear in accordance with point 4.4.2.1 and converted to the input shaft in accordance with subpoint (a) of point 4.4.2.3 shall be used as basis for the following calculations. All values of electric inverter power of these electric power maps shall be converted to the respective maps for the virtual electric machine system by deducting the losses of the gearbox part in accordance with the following equation: Image omitted; see official source where: Pel,virt electric inverter power of the virtual electric machine system [W] nEM,virt rotational speed of the virtual electric machine system referring to the input shaft of the IHPC Type 1 determined in accordance with subpoint (a) of point 4.4.2.3 [1/min] TEM,virt torque of the virtual electric machine system referring to the input shaft of the IHPC Type 1 determined in accordance with subpoint (a) of point 4.4.2.3 [Nm] Pel,meas measured electric inverter power [W] Tloss,gbx torque loss depending on rotational speed and torque at the input shaft of the IHPC Type 1 [Nm]. It shall be calculated by means of two-dimensional linear interpolation from the loss maps of the gearbox determined in accordance with point 4.4.2.2 for the respective gear. gear specific gear engaged during the measurement [-]

- (c) The drag torque values of the virtual electric machine system shall be specified at the same rotational speed setpoints, nEM,virt, referring to the input shaft of the IHPC Type 1 as used for the definition of the maximum and minimum torque curve of the virtual electric machine system. Each single value of drag torque in Nm indicated at the different rotational speed setpoints shall be set to zero.

• (d) The rotational inertia of the virtual electric machine system shall be calculated by converting the inertia value(s) of the actual electric machine(s) determined in accordance with point 8 of Appendix 8 of this Annex to the corresponding value of rotational inertia referring to the input shaft of the IHPC Type 1.

4.4.3   Generation of input data for the simulation tool

Since IHPCs Type 1 are virtually split into two separate components for handling in the simulation tool, separate component input data shall be determined for an electric machine system and a transmission. The certification number indicated in the input data shall be the same for both components, electric machine system and transmission.

4.4.3.1   Input data of the virtual electric machine system

The input data for the virtual electric machine system shall be generated in accordance with the definitions for the electric machine system in Appendix 15 based on the final data resulting from following the provisions in point 4.4.2.3.

4.4.3.2   Input data of the virtual transmission

The input data for the virtual transmission shall be generated in accordance with the definitions for the transmission in Table 1 to Table 3 of Appendix 12 of Annex VI based on the final data resulting from following the provisions in point 4.4.2.2. The value of the parameter ‘TransmissionType’ in Table 1 shall be set to ‘IHPC Type 1’.

The battery UUT thermal conditioning device and the corresponding thermal conditioning loop at the test bench equipment shall be operational to satisfy the battery UUT thermal conditioning performances, according to the vehicle application and shall enable the test bench equipment to perform the requested test procedure within the battery UUT operational limits

5.1   General provisions

Battery UUT components may be distributed in different devices within the vehicle.

The battery UUT shall be controlled by the BCU, the test bench equipment shall follow the operational limits provided by the BCU via bus communication. The battery UUT thermal conditioning device and the corresponding thermal conditioning loop at the test bench equipment shall be operational in accordance with the controls by the BCU, unless otherwise specified in the given test procedure. The BCU shall enable the test bench equipment to perform the requested test procedure within the battery UUT operational limits. If necessary, the BCU program shall be adapted by the component manufacturer for the requested test procedure but within the operational and safety limits of the battery UUT.

5.1.1   Conditions for thermal equilibration

Thermal equilibration is reached if during a period of 1 hour the deviations between cell temperature as specified by the component manufacturer and temperature of all cell temperature measuring points are lower than ±7 K.

5.1.2   Sign conventions

5.1.2.1   Current

Measured values of current shall have a positive sign for discharging and a negative sign for charging.

5.1.3   Reference location for ambient temperature

The ambient temperature shall be measured within a distance of 1 m to the battery UUT at a point indicated by the component manufacturer.

5.1.4   Thermal conditions

Battery testing temperature, i.e. the target operating temperature of the battery UUT, shall be specified by the component manufacturer. The temperature of all cell temperature measuring points shall be within the limits specified by the component manufacturer during all test runs performed.

For battery UUT with liquid conditioning (i.e. heating or cooling), the temperature of the conditioning fluid shall be recorded at the battery UUT inlet and must be maintained within ±2 K of a value specified by the component manufacturer.

For air cooled battery UUT, the temperature of the battery UUT at a point indicated by the component manufacturer shall be kept within +0/-20 K of the maximum value specified by the component manufacturer.

For all test runs performed the available cooling and/or heating power on the testbench shall be limited to a value declared by the component manufacturer. This value shall be recorded together with the test data.

The available cooling and/or heating power on the testbench shall be determined based on the following procedures and recorded together with the actual component test data:

• (1) For liquid conditioning from the massflow of the conditioning fluid and the temperature difference over the heat exchanger on the side of the battery UUT.

- (2) For electric conditioning from the voltage and current. The component manufacturer may modify the electric connection of this conditioning unit for the certification of the battery UUT to enable a measurement of the battery UUT characteristics without considering the electric power required for conditioning (e.g. if the conditioning is directly implemented and connected within the battery UUT). Notwithstanding these provisions, the required electric cooling and/or heating power externally provided to the battery UUT by a conditioning unit shall be recorded.

• (3) For other types of conditioning based on good engineering judgement and discussion with the type approval authority.

5.2   Preparation cycles

The battery UUT shall be conditioned by performing maximum five cycles of full discharging followed by full charging in order to ensure stabilisation of the system’s performance before the actual testing starts.

Consecutive cycles of full discharging followed by full charging shall be performed at the component manufacturer defined operational set temperature until the ‘preconditioned’ status is reached. The criterion for a ‘preconditioned’ battery UUT is that the discharged capacity during two consecutive discharges does not change by a value greater than 3 % of the rated capacity or that five repetitions were performed.

The voltage of the battery UUT shall not fall below the minimum voltage recommended by the component manufacturer at the end of the discharge (the minimum voltage is the lowest voltage under discharge without irreversible damage done to the battery UUT). The termination criteria for the full discharging and the full charging cycles shall be defined by the component manufacturer.

5.2.1   Current levels in preparation cycles for HPBS

Discharging shall be performed at a current of 2C, charging shall be performed in accordance with the recommendations of the component manufacturer.

5.2.2   Current levels in preparation cycles Preconditioning for HEBS

Discharging shall be performed at a current of 1/3C, charging shall be performed in accordance with the recommendations of the component manufacturer.

5.3   Standard cycle

The purpose of a standard cycle (SC) is to ensure the same initial condition for each dedicated test of a battery UUT, as well as the charged energy for COP purposes in accordance with Appendix 12. It shall be performed at the component manufacturer defined operational set temperature.

5.3.1   Standard cycle for HPBS

The SC for HPBS shall consist of the following events in consecutive order: a standard discharge, a rest period, a standard charge and a second rest period.

The standard discharge procedure shall be performed at a current of 1C down to the minimum SOC in accordance with the specifications of the component manufacturer.

The rest period shall start directly after the end of discharge and shall last for 30 minutes.

The standard charge procedure shall be performed in accordance with the specifications of the component manufacturer regarding criteria for end of charge as well as applicable time limits for the overall charging procedure.

The second rest period shall start directly after the end of charge and shall last for 30 minutes.

5.3.2   Standard cycle for HEBS

The SC for HEBS shall consist of the following events in consecutive order: a standard discharge, a rest period, a standard charge and a second rest period.

The standard discharge procedure shall be performed at a current of 1/3C down to the minimum SOC in accordance with the specifications of the component manufacturer.

The rest period shall start directly after the end of discharge and shall last for 30 minutes.

The standard charge procedure shall be performed in accordance with the specifications of the component manufacturer regarding criteria for end of charge as well as applicable time limits for the overall charging procedure.

The second rest period shall start directly after the end of charge and shall last for 30 minutes.

5.4   Test runs to be performed

Before any test runs in accordance with this point are performed the battery UUT shall be subjected to the provisions in accordance with point 5.2.

5.4.1   Test procedure for rated capacity

This test measures the rated capacity of the battery UUT in Ah at constant current discharge rates.

5.4.1.1   Signals to be measured

The following signals shall be recorded during preconditioning, standard cycles performed and the actual test run:

• — Charge/Discharge current at the terminals of the battery UUT

• — Voltage across the terminals of the battery UUT

• — Temperatures of all measuring points of the battery UUT

• — Ambient temperature in the testbench

• — Heating or cooling power for battery UUT

5.4.1.2   Test run

After the battery UUT was fully charged in accordance with the specifications of the component manufacturer and thermal equilibration in accordance with point 5.1.1 was reached, a standard cycle in accordance with point 5.3 shall be performed.

The actual test run shall start within a period of 3 hours after the end of the standard cycle, otherwise the standard cycle shall be repeated.

The actual test run shall be performed at RT and consist of a constant current discharge at the following discharge rates:

• — For HPBS to the component manufacturer’s rated 1 C capacity in Ah

• — For HEBS to the component manufacturer’s rated 1/3C capacity in Ah

All discharge tests shall be terminated at the minimum conditions in accordance with the specifications of the component manufacturer.

5.4.1.3   Interpretation of results

The capacity in Ah obtained from the integrated battery current over time during the actual test run in accordance with point 5.4.1.2 shall be used as value for the rated capacity.

5.4.1.4   Data to be reported

The following data shall be reported:

• — Rated capacity determined in accordance with point 5.4.1.3

• — Average values over the actual test run of all signals recorded in accordance with point 5.4.1.1

For the purpose of conformity of production testing, also the following values shall be calculated:

• — The total charged energy, Echa, from 20 to 80 % SOC during the standard cycle performed prior to the actual test run.

• — The total discharged energy, Edis, from 80 to 20 % SOC during the actual test run.

All SOC values used shall be calculated based on the actual measured rated capacity determined in accordance with point 5.4.1.3.

The round trip efficiency ηBAT shall be calculated by dividing the total discharged energy, Edis, by the total charged energy, Echa and reported in the information document in accordance with Appendix 5.

5.4.2   Test procedure for open circuit voltage, internal resistance and current limits

This test determines the ohmic resistance for discharge and charge conditions as well as the OCV of the battery UUT as a function of SOC. In addition, the maximum current for discharging and charging as declared by the component manufacturer shall be verified.

5.4.2.1   General provisions for testing

All SOC values used shall be calculated based on the actual measured rated capacity determined in accordance with point 5.4.1.3.

Only where the battery UUT reaches the discharge voltage limit during discharge, shall the current be reduced such that the battery UUT terminal voltage is maintained at the discharge voltage limit throughout the whole discharge pulse.

Only where the battery UUT reaches during charging the charge voltage limit, shall the current be reduced such that the battery UUT terminal voltage is maintained at the charge voltage limit throughout the whole regenerative charge pulse.

If the test equipment cannot provide the current value with the requested accuracy of ±1 % of the target value within 100 ms after a change in the current profile, the respective recorded data shall be discarded and no related values for open circuit voltage and internal resistance shall be calculated from this data.

If the operational limits provided by the BCU via bus communication demand the current to be reduced in order to stay within the operational limits of the battery UUT the test bench equipment shall reduce the respective target current in accordance with the demands of the BCU.

5.4.2.2   Signals to be measured

The following signals shall be recorded during preconditioning and the actual test run:

• — Discharge current at the terminals of the battery UUT

• — Voltage across the terminals of the battery UUT

• — Temperatures of all measuring points of the battery UUT

• — Ambient temperature in the testbench

• — Heating or cooling power for battery UUT

5.4.2.3   Test run

5.4.2.3.1   Preconditioning

After the battery UUT was fully charged in accordance with the specifications of the component manufacturer and thermal equilibration in accordance with point 5.1.1 was reached, a standard cycle in accordance with point 5.3 shall be performed.

Within a period of 1 to 3 hours after the end of the standard cycle, the actual test run shall be started. Otherwise, the procedure in the preceding paragraph shall be repeated.

5.4.2.3.2   Test procedure

For HPBS, the test shall be performed at five different SOC levels: 80, 65, 50, 35 and 20 %.

For HEBS, the test shall be performed at five different SOC levels: 90, 70, 50, 35 and 20 %.

At the last step at 20 % SOC the component manufacturer may reduce the maximum discharge current of the battery UUT in order for the SOC to stay above the minimum SOC, in accordance with the specifications of the component manufacturer and avoid a deep discharge.

Before the beginning of the actual test runs at each SOC level, the battery UUT shall be preconditioned in accordance with point 5.4.2.3.1.

In order to reach the required SOC levels for testing from the initial condition of the battery UUT, it shall be discharged at a constant current rate of 1C for HPBS and of 1/3C for HEBS followed by a rest period of 30 minutes before the next measurement starts.

The component manufacturer shall prior to the test declare the maximum charge and discharge current at each different SOC level that can be applied throughout the length of the respective time increment of the current pulse defined in accordance with Table 3 for HPBS and Table 4 for HEBS.

The actual test run shall be performed at RT and shall consist of the current profile in accordance with Table 3 for HPBS and in accordance with Table 4 for HEBS.

Table 3

Current profile for HPBS

Time increment [s]	Time cumulative [s]	Target current
0	0	0
20	20	Idischg_max/33
40	60	0
20	80	Ichg_max/33
40	120	0
20	140	Idischg_max/32
40	180	0
20	200	Ichg_max/32
40	240	0
20	260	Idischg_max/3
40	300	0
20	320	Ichg_max/3
40	360	0
20	380	Idischg_max
40	420	0
20	440	Ichg_max
40	480	0

Table 4

Current profile for HEBS

Time increment [s]	Time cumulative [s]	Target current
0	0	0
120	120	Idischg_max/33
40	160	0
120	280	Ichg_max/33
40	320	0
120	440	Idischg_max/32
40	480	0
120	600	Ichg_max/32
40	640	0
120	760	Idischg_max/3
40	800	0
120	920	Ichg_max/3
40	960	0
120	1080	Idischg_max
40	1120	0
120	1240	Ichg_max
40	1280	0

Where

- Idischg_max is the absolute value of the maximum discharge current specified by the component manufacturer at the specific SOC level that can be applied throughout the length of the respective time increment of the current pulse

- Ichg_max is the absolute value of the maximum charge current specified by the component manufacturer at the specific SOC level that can be applied throughout the length of the respective time increment of the current pulse

The voltage at time zero of the test run before the first change in target current occurs, i.e. V0, shall be measured as average value over 100 ms.

For HPBS the following voltages and currents shall be measured:

• (1) For each different discharging and charging current pulse level specified in Table 3, the voltage under zero current as average value over the last second before the change in target current occurs, i.e. Vdstart for discharging and Vcstart for charging, shall be measured.

• (2) For each different discharging current pulse level specified in Table 3, the voltage at 2, 10 and 20 seconds after the change in target current occurs (Vd2, Vd10, Vd20) and the corresponding current (Id2, Id10, and Id20) shall be measured as average value over 100ms.

• (3) For each different charging current pulse level specified in Table 3, the voltage at 2, 10 and 20 seconds after the change in target current occurs (Vc2, Vc10, Vc20) and the corresponding current (Ic2, Ic10, and Ic20) shall be measured as average value over 100 ms.

Table 5 gives an overview of voltage and current values to be measured over time after the change in target current occurs for HPBS.

Table 5

Voltage measurement points for each different level of a current pulse (discharging and charging) for HPBS

Time after the change in target current occurs [s]	Discharging (D) or charging (C)	Voltage	Current
2	D	Vd2	Id2
10	D	Vd10	Id10
20	D	Vd20	Id20
2	C	Vc2	Ic2
10	C	Vc10	Ic10
20	C	Vc20	Ic20

For HEBS the following voltages and currents shall be measured:

• (1) For each different discharging and charging current pulse level specified in table 4 the voltage under zero current as average value over the last second before the change in target current occurs, i.e. Vdstart for discharging and Vcstart for charging, shall be measured.

• (2) For each different discharging current pulse level specified in table 4, the voltage at 2, 10 20 and 120 seconds after the change in target current occurs (Vd2, Vd10, Vd20 and Vd120) and the corresponding current (Id2, Id10, Id20 and Id120) shall be measured as average value over 100ms.

• (3) For each different charging current pulse level specified in table 4, the voltage at 2, 10, 20 and 120 seconds after the change in target current occurs (Vc2, Vc10, Vc20 and Vc120) and the corresponding current (Ic2, Ic10, Ic20 and Ic120) shall be measured as average value over 100 ms.

Table 6 gives an overview of voltage and current values to be measured over the time after the change in target current occurs for HEBS.

Table 6

Voltage measurement points for each different level of a current pulse (discharging and charging) for HEBS

Time after the change in target current occurs [s]	Discharging (D) or charging (C)	Voltage	Current
2	D	Vd2	Id2
10	D	Vd10	Id10
20	D	Vd20	Id20
120	D	Vd120	Id120
2	C	Vc2	Ic2
10	C	Vc10	Ic10
20	C	Vc20	Ic20
120	C	Vc120	Ic120

5.4.2.4   Interpretation of results

The following calculations shall be performed separately for each level of SOC measured in accordance with point 5.4.2.3.

5.4.2.4.1   Calculations for HPBS

• (1) For each different discharging current pulse level specified in Table 3, the values for internal resistance shall be calculated from the values of voltage and current measured in accordance with point 5.4.2.3 in accordance with the following equations:
• — RId2 = (Vdstart – Vd2) / Id2
• — RId10 = (Vdstart – Vd10) / Id10
• — RId20 = (Vdstart – Vd20) / Id20

• (2) The internal resistances for discharging RId2_avg, RId10_avg, RId20_avg shall be calculated as average over all different current pulse levels specified in Table 3 from the individual values calculated under point 1.

• (3) For each different charging current pulse level specified in Table 3, the values for internal resistance shall be calculated from the values of voltage and current measured in accordance with point 5.4.2.3 in accordance with the following equations:
• — RIc2 = (Vcstart – Vc2) / Ic2
• — RIc10 = (Vcstart – Vc10) / Ic10
• — RIc20 = (Vcstart – Vc20) / Ic20

• (4) The internal resistances for charging RIc2_avg, RIc10_avg, RIc20_avg shall be calculated as average over all different current pulse levels specified in Table 3 from the individual values calculated under point 3.

• (5) The overall internal resistances RI2, RI10 and RI20 shall be calculated as average over the respective values for discharging and charging calculated under points 2 and 4.

• (6) The open circuit voltage shall be the value of V0 measured in accordance with point 5.4.2.3 for the respective SOC level.

• (7) The limits for maximum discharging current shall be calculated as average value over 20 seconds at the target current Idischg_max for each level of SOC measured in accordance with point 5.4.2.3.

• (8) The limits for maximum charging current shall be calculated as average value over 20 seconds at the target current Ichg_max for each level of SOC measured in accordance with point 5.4.2.3. Absolute values of the results shall be reported as final values.

5.4.2.4.2   Calculations for HEBS

- (1) For each different discharging current pulse level specified in Table 4, the values for internal resistance shall be calculated from the values of voltage and current measured in accordance with point 5.4.2.3 in accordance with the following equations:

• — RId2 = (Vdstart – Vd2) / Id2
• — RId10 = (Vdstart – Vd10) / Id10
• — RId20 = (Vdstart – Vd20) / Id20
• — RId120 = (Vdstart – Vd120) / Id120

• (2) The internal resistances for discharging RId2_avg, RId10_avg, RId20_avg and RId120_avg shall be calculated as average over all different current pulse levels specified in Table 4 from the individual values calculated under point 1.

• (3) For each different charging current pulse level specified in Table 4, the values for internal resistance shall be calculated from the values of voltage and current measured in accordance with point 5.4.2.3 in accordance with the following equations:
• — RIc2 = (Vcstart – Vc2) / Ic2
• — RIc10 = (Vcstart – Vc10) / Ic10
• — RIc20 = (Vcstart – Vc20) / Ic20
• — RIc120 = (Vcstart – Vc120) / Ic120

• (4) The internal resistances for charging RIc2_avg, RIc10_avg, RIc20_avg and RIc120_avg shall be calculated as average over all different current pulse levels specified in Table 4 from the individual values calculated under point 3.

- (5) The overall internal resistances RI2, RI10, RI20 and RI120 shall be calculated as average over the respective values for discharging and charging calculated under points 2 and 4.

- (6) The open circuit voltage shall be the value of V0 measured in accordance with point 5.4.2.3 for the respective SOC level.

• (7) The limits for maximum discharging current shall be calculated as average value over 120 seconds at the target current Idischg_max for each level of SOC measured in accordance with point 5.4.2.3.

• (8) The limits for maximum charging current shall be calculated as average value over 120 seconds at the target current Ichg_max for each level of SOC measured in accordance with point 5.4.2.3. Absolute values of the results shall be reported as final values.

5.5.   Post-processing of measurement data of the battery UUT

The values of OCV dependent on SOC shall be defined based on the values determined for the different SOC levels in accordance with point 6 of point 5.4.2.4.1 for HPBS and 5.4.2.4.2 for HEBS.

The different values of internal resistances dependent on SOC shall be defined based on the values determined for the different SOC levels in accordance with point 5.4.2.4.1(5) for HPBS and 5.4.2.4.2 for HEBS.

The limits for maximum discharging current and maximum charging current shall be defined based on the values as declared by the component manufacturer prior to the test. If a specific value for the maximum discharging current or maximum charging current determined in accordance with point 5.4.2.4.1(7) and (8) for HPBS and 5.4.2.4.2 for HEBS deviates by more than ±2 % from the value declared by the component manufacturer prior to the test, the respective value determined in accordance with points 5.4.2.4.1(7) and (8) for HPBS and 5.4.2.4.2 for HEBS shall be reported.

6. Testing of capacitor systems or representative capacitor subsystems

6.1   General provisions

Capacitor system components of the capacitor UUT may also be distributed in different devices within the vehicle.

The characteristics for a capacitor are hardly dependent on its state of charge or current, respectively. Therefore, only a single test run is prescribed for the calculation of the model input parameters.

6.1.1   Sign convention for current

Measured values of current shall have a positive sign for discharging and a negative sign for charging.

6.1.2   Reference location for ambient temperature

The ambient temperature shall be measured within a distance of 1 m to the capacitor UUT at a point indicated by the component manufacturer of the capacitor UUT.

6.1.3   Thermal conditions

Capacitor testing temperature, i.e. the target operating temperature of the capacitor UUT, shall be specified by the component manufacturer. The temperature of all capacitor cell temperature measuring points shall be within the limits specified by the component manufacturer during all test runs performed.

For capacitor UUT with liquid conditioning (i.e. heating or cooling), the temperature of the conditioning fluid shall be recorded at the capacitor UUT inlet and must be maintained within ±2 K of a value specified by the component manufacturer.

For air cooled capacitor UUT, the temperature at a point indicated by the component manufacturer shall be kept within +0/–20 K of the maximum value specified by the component manufacturer.

For all test runs performed the available cooling and/or heating power on the testbench shall be limited to a value declared by the component manufacturer. This value shall be recorded together with the test data.

The available cooling and/or heating power on the testbench shall be determined based on the following procedures and recorded together with the actual component test data:

- (1) For liquid conditioning from the massflow of the conditioning fluid and the temperature difference over the heat exchanger on the side of the capacitor UUT.

• (2) For electric conditioning from the voltage and current. The component manufacturer may modify the electric connection of this conditioning unit for the certification of the capacitor UUT to enable a measurement of the capacitor UUT characteristics without considering the electric power required for conditioning (e.g. if the conditioning is directly implemented and connected within the capacitor UUT). Notwithstanding these provisions, the required electric cooling and/or heating power externally provided to the capacitor UUT by a conditioning unit shall be recorded.

• (3) For other types of conditioning based on good engineering judgement and discussion with the type approval authority.

6.2   Test conditions

• (a) The capacitor UUT shall be placed in a temperature controlled test cell. The ambient temperature shall be conditioned at 25 ±10 °C;

• (b) The voltage shall be measured at the terminals of the capacitor UUT.

• (c) The thermal conditioning system of the capacitor UUT and the corresponding thermal conditioning loop at the test bench equipment shall be fully operational in accordance with the respective controls.

- (d) The control unit shall enable the test bench equipment to perform the requested test procedure within the capacitor UUT operational limits. If necessary, the control unit program shall be adapted by the capacitor UUT component manufacturer for the requested test procedure.

6.3   Capacitor UUT characteristics test

• (a) After fully charging and then fully discharging the capacitor UUT to its lowest operating voltage in accordance with the charging method specified by the component manufacturer, it shall be soaked for at least 2 hours, but no more than 6 hours.

• (b) The capacitor UUT temperature at the start of the test shall be 25 ± 2 °C. However, 45 ± 2 °C may be selected by reporting to the type approval or certification authority that this temperature level is more representative for the conditions of the typical application.

• (c) After the soak time, a complete charge and discharge cycle in accordance with Figure 2 with a constant current Itest shall be performed. Itest shall be the maximum allowed continuous current for the capacitor UUT as specified by the component manufacturer.

• (d) After a waiting period of at least 30 seconds (t0 to t1), the capacitor UUT shall be charged with a constant current Itest until the maximum operating voltage V max is reached. Then, the charging shall be stopped and the capacitor UUT shall be soaked for 30 seconds (t2 to t3) so that the voltage can settle to its final value V b before the discharging is started. After that the capacitor UUT shall be discharged with a constant current Itest until the lowest operating voltage V min is reached. Afterwards (from t4 onwards) there shall be another waiting period of at least 30 seconds for the voltage to settle to its final value Vc.

• (e) The current and voltage over time, respectively Imeas and Vmeas, shall be recorded at a sampling frequency of at least 10 Hz.

- (f) The following characteristic values shall be determined from the measurement (illustrated in Figure 2):

V a is the no-load voltage right before start of the charge pulse V b is the no-load voltage right before start of the discharge pulse V c is the no-load voltage after the end of the discharge pulse ΔV(t 1), ΔV(t 3) are the voltage changes directly after applying the constant charging or discharging current I test at the time of t 1 and t 3, respectively. These voltage changes shall be determined by applying a linear approximation to the voltage characteristics as defined in detail A of Figure 2 by usage of the least squares method. Data sampling for the straight line approximation shall start once the change in the gradient calculated from two adjacent data points is smaller than 0.5 % when running in the direction of increasing time signal.

Figure 2

Example of voltage curve for the capacitor UUT measurement

Image omitted; see official source

ΔV(t 1) is the absolute difference of voltages between V a and the intercept value of the straight-line approximation at the time of t 1.

ΔV(t 3) is the absolute difference of voltages between V b and the intercept value of the straight-line approximation at the time of t 3.

ΔV(t 2) is the absolute difference of voltages between V max and V b.

ΔV(t 4) is the absolute difference of voltages between V min and V c.

6.4.   Post-processing of measurement data of the capacitor UUT

6.4.1   Calculation of internal resistance and capacitance

The measurement data obtained in accordance with point 6.3 shall be used to calculate the internal resistance (R) and capacitance (C) values in accordance with the following equations:

• (a) The capacitance for charging and discharging shall be calculated as follows: For charging: Image omitted; see official source For discharging: Image omitted; see official source

- (b) The maximum current for charging and discharging shall be calculated as follows:

For charging: Image omitted; see official source For discharging: Image omitted; see official source

- (c) The internal resistance for charging and discharging shall be calculated as follows:

For charging: Image omitted; see official source For discharging: Image omitted; see official source

• (d) For the model, only a single capacitance and resistance are needed and these shall be calculated as follows: Capacitance C: Image omitted; see official source Resistance R: Image omitted; see official source

• (e) The maximum voltage shall be defined as the recorded value of Vb and the minimum voltage shall be defined as the recorded value of Vc as defined in accordance with subpoint (f) of point 6.3.

7.1   Component test procedure for FCS

• 7.1.1Fuel quality

• The reference fuel as laid down in Table 8 shall be used for the test run performed in accordance with point 7.3.

Table 8

Definition of hydrogen reference fuel

Characteristics	Units	Limits	Limits	Limits	Test Method
Characteristics	Units	Minimum	Minimum	Maximum	Test Method
Hydrogen fuel index	% mole fraction	99,97	99,97		[^E0074]
Total non-hydrogen gases	μmol/mol			300
Lists of non-hydrogen gases and the specification of each contaminant [^E0079]	Lists of non-hydrogen gases and the specification of each contaminant [^E0079]	Lists of non-hydrogen gases and the specification of each contaminant [^E0079]	Lists of non-hydrogen gases and the specification of each contaminant [^E0079]	Lists of non-hydrogen gases and the specification of each contaminant [^E0079]
Water (H2O)	μmol/mol		5	5	[^E0078]
Total hydrocarbons [^E0075] except methane (C1 equivalent)	μmol/mol		2	2	[^E0078]
Methane (CH4)	μmol/mol		100	100	[^E0078]
Oxygen (O2)	μmol/mol		5	5	[^E0078]
Helium (He)	μmol/mol		300	300	[^E0078]
Total Nitrogen (N2) and Argon (Ar) [^E0075]	μmol/mol		300	300	[^E0078]
Carbon dioxide (CO2)	μmol/mol		2	2	[^E0078]
Carbon monoxide (CO) [^E0076]	μmol/mol		0,2	0,2	[^E0078]
Total sulfur compounds [^E0077] (H2S basis)	μmol/mol		0,004	0,004	[^E0078]
Formaldehyde (HCHO)	μmol/mol		0,2	0,2	[^E0078]
Formic acid (HCOOH)	μmol/mol		0,2	0,2	[^E0078]
Ammonia (NH3)	μmol/mol		0,1	0,1	[^E0078]
Total halogenated compounds [^E0078] (Halogenate ion basis)	μmol/mol		0,05	0,05	[^E0078]

The hydrogen fuel index is determined by subtracting the “total non-hydrogen gases” in this table, expressed in mole per cent, from 100 mole per cent.

Total hydrocarbons except methane include oxygenated organic species.

The sum of measured CO, HCHO and HCOOH shall not exceed 0,2 μmol/mol

As a minimum, total sulfur compounds include H2S, COS, CS2 and mercaptans, which are typically found in natural gas.

Test method shall be documented. Test methods defined in ISO21087 are preferable.

The analysis of specific contaminants depending on the production process shall be exempted. A vehicle manufacturer shall provide the responsible authority reasons for exempting specific contaminants.

7.2   System boundary of the unit under test and descriptions of specific components

• 7.2.1System boundary of the unit under test

• The FCS unit under test (‘UUT’) may comprise different BoPCs, the allowed configurations are set out in Table 9. The terminology of the different components is based on the SAE norm J2615. All configurations of FCS have two things in common:

- (a) they are tested and certified without outer cooling sub-system as a standalone power supply unit without external electric components of the vehicle connected;

- (b) all of them comprise the APS.