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FMC 1278 Test Plan Template 16 May, 2016
Component / Subsystem EMC Test Plan Title PageProduct Name:
Product Supplier Name: Ford Recognized EMC Test Facility(s) used:Include Lab Manager Name(s)
Product Part Number(s):List all product part numbers that this test plan is applicable to. (May be listed on separate page) Vehicles & Model Year using this product:
If multiple part numbers, identify which vehicles part numbers are used.(May be listed on separate page with part numbers)
Product Printed Circuit Board(PCB) Number(s):List all PCB numbers that this test plan is applicable to.
Product Manufacturing Location(s)Where will this product be produced?
EMC Specification Used:Identify specification and revision number being used
I certify that the information contained in this test plan is factual including description of the product operation, correct functional classifications, and acceptance criteria. I understand and agree that any subsequent changes to this test plan prior to design verification testing shall be communicated to the FMC EMC department. Any changes or revisions to this test plan after test completion shall require written technical justification and approval by the same EMC department. I understand that failure to follow this process may result in non-acceptance of the product's EMC test data by the FMC EMC department. I also understand and acknowledge that requirements validated via this test plan are relevant only to the specific vehicles that the product is to be fitted to. Use of the product on other vehicle platforms may require additional EMC performance requirements, which will necessitate additional verification testing of the product. I certify that the product samples submitted for EMC testing are of a production representative design. I authorize the EMC test laboratory to submit a summary report directly to the FMC EMC department no later than five (5) business days following completion of testing. I also authorize forwarding a copy of the EMC test laboratory's detailed test report directly to the FMC EMC department within thirty (30) business days following completion of testing. I certify to perform all tests in a Ford recognized laboratory.
Supplier Product Design Engineer Concurrence:
_________________________________________________Name Signature and Date
Supplier Product Manager Concurrence:
_________________________________________________Name Signature and Date
Ford Design & Release Engineer Concurrence:
______________________________________________________Name Signature and Date
For Internal EMC Department Use (Do not Mark)Received by FMC EMC Department
Name Telephone number
Signature and Date FMC EMC Test Plan Tracking Number
Test Plan Revision History
Date DescriptionInitial Test Plan Release
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1.0 Introduction - Scope and purpose of test plan
1.1 Product Family Description
- General Product Family Description- Differences/similarities between HW/SW Versions if any- Max complexity DUT's may be used to represent an entire product family, provide
justification/rationale for doing this.
1.2 Theory of Operation
- General Theory of Operation inclusive of how it is used in the vehicle- Functions/Features – Customer Interactions- Interaction with other vehicle systems & interfaces
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Internal block diagram of the DUT
Sub-System Interfaces – Configuration(This could be a maximum system complexity configuration)
Provide FULL Block Diagram to show how the DUT will be connected in the vehicle
1.3 Physical Construction
a) What are the Product Package Material(s):Metallic ► Non-Metallic ► Conductive ► Non-Conductive ►
Provide further Material description below as necessary:
b) What is the Product Package Volume:X Dimension (mm) ► Y Dimension (mm) ► Z Dimension (mm) ►
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c) Provide the Product Mechanical View:
Top – Plan View ISO View
Front View Side
d) How many separate Connectors?
Provide connector diagram and pinout detail for each connector.
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Connector Diagram
Connector Diagram(s)
Connector Pinout Detail
Pin # Signal Name Wiring Detail(SW/TWP/STWP1)
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1Abbreviations: SW = Single WireTWP = Twisted Wire Pair STWP = Shielded Twisted Wire Pair
1.4 Vehicle Packaging
a) Indicate the general package location of this Product in the Vehicle:
Under hood ► Under body ► Cabin ► Trunk ► External Body ►Provide further description below as necessary:
b) What is the potential CUSTOMER ACCESSIBILITY to the Product:Access from Outside Vehicle Cabin ► Access from Inside Vehicle Cabin ► No Access ►
c) What is the nature of that Access:Direct Access (Physical touching) ► Indirect Access (Remote Switch) ►
Provide further description below as necessary:
d) How is the Product connected to Power Return (GND)?
Reference (GND): Direct to Local Chassis► In Harness (remote GND/Module) ►
Which Pin(s)?
e) How is the Case connected to a Reference Level (GND)?In the Vehicle – How is the metallic case connected?
Connect (GND)to Local Chassis ► Isolated ► Unknown ►
In the Printed Circuit Board – Is there a power return connection to the Case?
Direct (DC) ► Coupled (AC) ► NO Connect ►
f) Is the Product connected internally / externally to Magnetically Sensitive / Controlled Devices?Internal ► External ► Sensitive ► Controlled ►
Provide further description below as necessary:
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g) Is the Product required to meet ESA type approval requirements of ECE Regulation 10.05?Yes ► No ►
Provide further description below as necessary:
i) How is the Product connected to Vehicle Power?
Please select which Vehicle power source(s) the product is connected to?
List ALL Connector Pins that have an external connection to Vehicle Power Fu
sed?
Describe Fuse Rating for each connection
Direct Battery Connection ►
‡ Switched Power 1 ►
‡ Switched Power 2 ►
‡ Switched Power 3 ►
‡ Switched Power 4 ►
Regulated Power ►
† Internal Power ► † Battery source internal to the DUT
‡ Switched Power – any circuit connected to vehicle battery through a mechanical switch, electro-mechanical relay or electronic switch. Annotate the proper name for each Switched Power signal source (e.g. Run, Run/Start, Ignition, VPWR…).
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2.0 EMC Requirements Analysis
2.1 Critical Interface Signals
Signal Description
Voltage/Current Level
Frequency % Duty Cycle (range)
Other
2.2 Potential Sources of Emissions
Signal Source Description
Voltage/CurrentLevel
Frequency % Duty Cycle(range)
Other
2.3 Test Sample / Surrogate Selection
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3.0 Test Design and Requirements
3.1 DUT Operating Modes/Functional Classifications
DUT Mode DUT Functions Vehicle Operating ModesClass A Class B Class C Off Accessory Start Run
Mode Description(s):
Function Description(s):
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3.2 Test RequirementsThe DUT component / sub-system category is assessed as being:
Passive Active
D R BM EM A AS AM AX AY AW
It is possible for multiple categories to be applicable.
Test DescriptionTest
applies (Y/N)
Functional Class &
Functional StatusInterface to be
tested S/C1 Operating Mode(s) to be used for indicated test
A B C
Radiated Immunity – RF
RI 112 Level 2 BCI
II II I
RI 112 Level 1BCI
I I I
RI 114 Level 2ALSE/Reverb
II II I
RI 114 Level 1ALSE/Reverb
I I I
RI 115 Level 2Portable Transmitter
II II I
RI 115 Level 1Portable Transmitter
I I I
Coupled Immunity - RF
RI 130Inductive Transients
I I I
RI 140Magnetic Field
I I I
RI 150Charging System
I I I
Conducted Immunity – Continuous
CI 210Continuous Disturbance
I I I
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Test DescriptionTest
applies (Y/N)
Functional Class &
Functional StatusInterface to be
tested S/C1 Operating Mode(s) to be used for indicated test
A B C
Conducted Immunity - Transients
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Test DescriptionTest
applies (Y/N)
Functional Class &
Functional StatusInterface to be
tested S/C1 Operating Mode(s) to be used for indicated test
A B C
CI 220 Pulse A1
Power Supply Circuits with Maximum Current < 5A
II II II
Control Circuits II II II
CI 220 Pulse A2-1
All Power Supply Circuits with Maximum Current< 5A
II II II
Control Circuits II II II
CI 220 Pulse A2-2
All Power Supply Circuits with Maximum Current< 5A
II II II
Control Circuits II II II
CI 220Pulse C-1
All Power Circuits < 15 A I I I
Control Circuits I I I
CI 220 Pulse C-2
All Power Circuits < 15 A I I I
Control Circuits I I I
CI 220 ISO Pulse1
All Power Supply Circuits > 5A
II II II
Control Circuits II II II
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Test DescriptionTest
applies (Y/N)
Functional Class &
Functional StatusInterface to be
tested S/C1 Operating Mode(s) to be used for indicated test
A B C
Conducted Immunity – Transients(required for ESA type approval)
CI 221 ISO Pulse 1
Switched Power II II II
CI 221 ISO Pulse2a
All Power Circuits I I I
CI 221 ISO Pulse 2b
Power Circuits in Parallel with an electric motor
II II II
CI 221 ISO Pulse 3a
All Power Circuits I I I
CI 221 ISO Pulse 3b
All Power Circuits I I I
Conducted Immunity - Transients
CI 222 ISO Pulse 5a(Normal Load Dump) III III II
CI 222 ISO Pulse 5b(Central Load Dump) III III II
Conducted Immunity - Power Cycle
CI 230 Waveform A II II II
CI 230 Waveform B II II II
Conducted Immunity - Power Cycle (required for ESA type approval)
CI 231 II II II
Conducted Immunity - Voltage Offset
CI 250 I I I
Conducted Immunity - Voltage Dropout
CI 260 Waveform A II II II
CI 260 Waveform B II II II
CI 260 Waveform C I I I
CI 260 Waveform D II II II
Conducted Immunity - Voltage Overstress
CI 270- A -14 VoltReverse Battery
III III III
CI 270- B +19 VoltOver voltage – Failed Regulator
III II II
CI 270- C BATT / IGN≥ 60 secs
III II II
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Test DescriptionTest
applies (Y/N)
Functional Class &
Functional StatusInterface to be
tested S/C1 Operating Mode(s) to be used for indicated test
A B C
+ 27 volt
Over voltage – Jump Start
START≥ 15 secs III II II
Conducted Immunity – Electrostatic Discharge
CI 280 Unpowered (Handling)Sequence 1 -3
IV IV IV
CI 280 PoweredSequence 1-3
I I I
CI 280 PoweredSequence 4-6
II II II
CI 280 PoweredSequence 7
II II II
CI 280 PoweredSequence 8
II II II
Radiated Emissions
RE 310 I I I
Conducted Emissions
CE 410 - Transient I I I
CE 420 - RF I I I
CE 421 - LF I I I
NOTES
Indicate specific DUT circuits that the test applies to. C (Combined): The circuits are to be tested simultaneously. S (Separate):The circuits are to be tested separately
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3.3 Input Requirements
Electrical Input Signals/Characteristics to Operate DUT in the specified test Mode
DUT Mode
Signal Name Test Pin # Waveform
Amplitude Freq/PW/DC% Other
Non-electrical input signals/characteristics to make DUT functional:
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3.4 Output Requirements
Electrical output(s) to monitor and acceptance criteria
Mode Signal Name Test Pin # Waveform Note
2 Amplitude Freq/PW/DC% Other
NANANANANA
Non-electrical output(s) to monitor and acceptance criteria
Mode Function Description Test Note 2 Acceptance criterion for function
NANANA
Note2: N = Nominal ValueA = Acceptable Value
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3.5 Load Box/Test Support Requirements
Name Description Pin #
LoadValue
Input Output Simulated Actual Reference
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Load Simulator Diagram
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Load Simulator Schematic/Diagram
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4.0 DUT Test Set-up Diagram
Generic test set-up diagram/pictureThe Generic set-up diagram shall include the following details
Interconnections between DUT, load simulator, artificial network and battery/power supply.
DUT, artificial network and load simulator bonding to ground plane DUT support equipment DUT monitoring equipment Fiber optic media used for monitoring DUT inputs and outputs
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4.1 Detailed Test Setup – Informative
IT IS RECOGNISED THAT APPROVED TEST FACILITIES ARE CAPABLE OF COMPONENT/SUB-SYSTEM SETUP WITHIN THE TEST ENVIRONMENTS DELINEATED IN THE EMC SPECIFICATION EMC-CS-2009
THE APPROVED TEST FACILITY SHALL PROVIDE DETAILS OF SETUP AS PART OF THE FORMAL TEST REPORT.
SPECIFIC TEST EXCEPTIONS / DIFFERENCES TO THESE TEST REQUIREMENTS SHALL BE DOCUMENTED IN THIS SECTION.
STANDARD SETUP SHEETS HAVE BEEN PROVIDED FOR CONVENIENCE AND MAY BE USED TO DOCUMENT THIS INFORMATION.
ESD TEST POINTS SHALL BE SPECIFIED EVEN IF THERE IS NO DEVIATION FROM THE SPECIFIED TEST METHOD.
# Test ID Requirement / DescriptionDeviation from specified test method. (Y/N)
Comments
1 CI 280 (U) Electrostatic Discharge (Un-Powered / Handling)
Specify ESD test points(required)
2 CI 280 (P) Electrostatic Discharge (Powered) Specify ESD test points(required)
3 RI 112 RF Immunity - BCI
4 RI 114 RF Immunity – ALSE/Reverberation
5 RI 115 RF Immunity – Hand Portable Transmitter
6 RI 140 Magnetic Field Immunity
7 RI 130 Coupled Immunity – Inductive Transients
8 RI 150 Coupled Immunity – Charging
9 CI 210 Conducted Immunity – Continuous Disturbances
10 CI 220 Conducted Immunity – Transient Disturbances
11 CI 221 Conducted Immunity – Transient Disturbances
12 CI 222 Conducted Immunity – Transient Disturbances
13 CI 230 Conducted Immunity – Power Cycling
14 CI 231 Conducted Immunity – Power Cycling
15 CI 250 Conducted Immunity – Voltage Offset
16 CI 260 Conducted Immunity – Voltage Dropout
17 CI 270 Conducted Immunity – Voltage Overstress
18 RE 310 Radiated RF Emissions
19 CE 420 Conducted RF Emissions
20 CE 421 Conducted LF Emissions
21 CE 410 Conducted Transient Emissions
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4.2 Electrostatic Discharge (CI 280:unpowered)
Indicate ESD discharge points (required)
Test set-up diagram (as needed)
CI 280(unpowered) Test Set-up
Test Details CommentsSpecified Test MethodDeviations from Specified Test MethodHarness ConfigurationDUT OrientationDUT Grounding (case or harness)Additional Test Specific InformationDUT Monitoring Information
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4.3 Electrostatic Discharge (CI 280: powered)
Indicate ESD discharge points (required)
Test set-up diagram (as needed)
CI 280(powered) Test Set-up
Test Details CommentsSpecified Test MethodDeviations from Specified Test MethodHarness ConfigurationDUT OrientationDUT Grounding (case or harness)Additional Test Specific InformationDUT Monitoring Information
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4.4 RF Immunity (RI 112)
Test set-up diagram
RI 112 Test Set-up
Test Details CommentsSpecified Test MethodDeviations from Specified Test MethodHarness ConfigurationDUT OrientationDUT Grounding (case or harness)Additional Test Specific InformationDUT Monitoring Information
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<< Use same format for remaining test methods as needed >>
4.5 RF Immunity (RI 114)
4.6 RF Immunity to Portable Transmitters (RI115)
4.7 Coupled Transient Noise (RI 130)
4.8 Magnetic Field (RI 140)
4.9 Coupled Transient Noise (RI 150)
4.10 Conducted Sine wave (CI 210)
4.11 Conducted Transients (CI 220)
4.12 Conducted Transients (CI 221)
4.13 Conducted Transients (CI 222)
4.12 Power Cycling (CI 230)
4.13 Power Cycling (CI 231)
4.14 Ground Shift (CI 250
4.15 Power Dropout (CI260)
4.16 DC Stress (CI 270)
4.17 Radiated Emissions (RE310)
4.18 Conducted Transient (CE 410)
4.19 Conducted Emissions (CE 420)
4.20 Conducted AF (CE 421)
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