{"id":18183,"date":"2026-10-13T09:00:00","date_gmt":"2026-10-13T07:00:00","guid":{"rendered":"https:\/\/tps-elektronik.com\/?p=18183"},"modified":"2026-09-21T10:12:33","modified_gmt":"2026-09-21T08:12:33","slug":"what-is-a-high-amperage-power-supply-for-wire-harness-and-connector-testing-and-why-is-it-vital-for-automotive-electrical-safety-compliance","status":"publish","type":"post","link":"https:\/\/tps-elektronik.com\/en\/what-is-a-high-amperage-power-supply-for-wire-harness-and-connector-testing-and-why-is-it-vital-for-automotive-electrical-safety-compliance\/","title":{"rendered":"What Is a High Amperage Power Supply for Wire Harness and Connector Testing? and Why Is It Vital for Automotive Electrical Safety Compliance?"},"content":{"rendered":"<article class=\"blog-post\" lang=\"en\"><header>\n<p>System integrators, panel builders, and procurement teams in the automotive supply chain rarely fail because they lack a harness design. They lose time\u2014and budget\u2014when high amperage test results do not match expectations, triggering repeated connector validation cycles and delaying PPAP or CE marking.<br \/>TPS Elektronik\u2019s approach to high amperage power supply integration for wire harness and connector testing built to reduce that risk: pre-validated test power architectures, current cycling capability up to 1008 hours. And close integration with development so that thermal and electrical margins are confirmed before formal compliance testing begins.<\/p>\n<p><a class=\"cta-primary\" href=\"https:\/\/tps-elektronik.com\/en\/services\/global-sales-partner-for-electronics\/\">Request a high amperage test power consultation \u2192<\/a><\/p>\n<\/header><nav class=\"toc\" aria-label=\"Table of contents\">\n<h2 id=\"toc\">Table of contents<\/h2>\n<ol>\n<li><a href=\"#what-is-high-amperage-psu\">What is a high amperage power supply for harness and connector testing?<\/a>\n<ol>\n<li><a href=\"#key-specifications\">Key specifications that determine test validity<\/a><\/li>\n<li><a href=\"#why-standard-psu-fails\">Why a standard lab PSU fails at high amperage<\/a><\/li>\n<\/ol>\n<\/li>\n<li><a href=\"#why-high-amperage-matters\">Why high amperage testing matters for automotive safety compliance<\/a>\n<ol>\n<li><a href=\"#lv214-uscar\">LV214 and USCAR-2: current cycling and temperature rise<\/a><\/li>\n<li><a href=\"#iso-16750\">ISO 16750-2 and ECE R10: electrical loads and EMC<\/a><\/li>\n<\/ol>\n<\/li>\n<li><a href=\"#test-applications\">Critical test applications powered by high amperage PSUs<\/a>\n<ol>\n<li><a href=\"#temperature-rise\">Temperature rise testing (harness temperature rise test PSU)<\/a><\/li>\n<li><a href=\"#current-cycling\">Current cycling and aging validation<\/a><\/li>\n<li><a href=\"#voltage-drop\">Voltage drop and contact resistance measurement<\/a><\/li>\n<\/ol>\n<\/li>\n<li><a href=\"#selecting-psu\">How to select a high amperage test power supply<\/a><\/li>\n<li><a href=\"#tps-support\">How TPS Elektronik supports high amperage test readiness<\/a><\/li>\n<li><a href=\"#faq\">FAQ<\/a><\/li>\n<\/ol>\n<\/nav>\n<section id=\"what-is-high-amperage-psu\">\n<h2>1. What is a high amperage power supply for harness and connector testing?<\/h2>\n<p>A <strong>high amperage power supply<\/strong> for wire harness and connector testing is a programmable DC source designed to deliver continuous currents typically ranging from 100 A to several thousand amperes at low output voltages (2 V to 60 V DC). Unlike general-purpose laboratory power supplies, these units engineered for the specific demands of <strong>high current wire harness testing<\/strong>: sustained thermal load, rapid current transitions, and precise measurement of voltage drop across contact interfaces.<\/p>\n<p>In automotive validation, the <strong>high amperage harness testing PSU<\/strong> is not simply a power source. It is the instrument that defines whether a connector passes or fails. A current output that drifts by 2% over a 1008-hour test, or a voltage measurement with 10 mV of noise. Which can shift a temperature rise result by several Kelvin\u2014enough to turn a compliant design into a non-compliant one.<\/p>\n<p><img decoding=\"async\" class=\"alignnone size-full wp-image-18310\" src=\"https:\/\/tps-elektronik.com\/wp-content\/uploads\/2026\/09\/High-Amperage-Power-Supply-Wire-Harness-Test-Setup-1-1.jpg\" alt=\"High Amperage Power Supply Wire Harness Test Setup Testaufbau f\u00fcr Hochstrom-Kabelb\u00e4ume von Stromversorgungen\" width=\"1920\" height=\"1079\" \/><\/p>\n<p><a class=\"cta-primary\" href=\"https:\/\/tps-elektronik.com\/en\/services\/global-sales-partner-for-electronics\/\">Discuss your high amperage test power requirements \u2192<\/a><\/p>\n<h3 id=\"key-specifications\">1.1 Key specifications that determine test validity<\/h3>\n<p>When specifying a <strong>wire harness test power supply<\/strong>, five parameters directly affect test validity:<\/p>\n<ul>\n<li><strong>Continuous current capability at low voltage<\/strong>: The PSU must sustain rated current at the actual test voltage (often 12 V, 24 V, or 48 V DC), not just at open-circuit voltage. Derating curves must checked at ambient temperatures inside the test chamber.<\/li>\n<li><strong>Current regulation accuracy<\/strong>: For <strong>harness temperature rise test PSU<\/strong> applications, current stability better than \u00b10.5% required to distinguish connector self-heating from PSU ripple.<\/li>\n<li><strong>Rise time and transient response<\/strong>: <strong>High current harness test system<\/strong> setups for ISO 16750-2 pulse testing require current rise times in the millisecond range. Standard bench supplies with 100 ms slew rates cannot reproduce load dump or inrush profiles.<\/li>\n<li><strong>Remote sensing and voltage drop measurement<\/strong>: Four-wire Kelvin sensing is mandatory for <strong>connector testing power<\/strong> applications, where the voltage drop across a 0.5 m\u03a9 contact must resolved at high current.<\/li>\n<li><strong>Parallel and master-slave operation<\/strong>: For currents beyond 500 A, modular PSUs with active current sharing allow scalable output without sacrificing regulation.<\/li>\n<\/ul>\n<h3 id=\"why-standard-psu-fails\">1.2 Why a standard lab PSU fails at high amperage<\/h3>\n<p>A 300 W bench supply rated for 10 A cannot validate a 200 A busbar joint. The failure modes are predictable: output capacitor ESR limits transient current, cable voltage drop consumes headroom, and thermal drift shifts the setpoint. The result is a test that measures the PSU\u2019s limitations rather than the connector\u2019s performance. For <strong>automotive connector test power<\/strong>, this distinction is critical. A false pass delays market entry, and a false fail triggers unnecessary design changes.<\/p>\n<p>TPS\u2019s engineering resources on <a href=\"https:\/\/tps-elektronik.com\/en\/element-material-technology-advanced-applications\/\">element and material technology<\/a> and <a href=\"https:\/\/tps-elektronik.com\/en\/element-testing-laboratories-safety-global-expansion\/\">element testing laboratories<\/a> reflect this system-level view of test power.<\/p>\n<\/section>\n<section id=\"why-high-amperage-matters\">\n<h2>2. Why high amperage testing matters for automotive safety compliance<\/h2>\n<p>Automotive electrical safety is not defined by a single test. It emerges from the interaction of connector design, wire gauge, insulation material, and the test power source used to validate them. When a <strong>high amperage cable testing<\/strong> regime poorly instrumented, the compliance evidence itself becomes unreliable.<\/p>\n<p><img decoding=\"async\" class=\"alignnone size-full wp-image-18305\" src=\"https:\/\/tps-elektronik.com\/wp-content\/uploads\/2026\/09\/High-Current-Harness-Test-System-Current-Cycling-2-1.jpg\" alt=\"High Current Harness Test System Current Cycling Hochstrom-Kabelbaum-Pr\u00fcfsystem mit Stromzyklierung\" width=\"1920\" height=\"1079\" \/><\/p>\n<h3 id=\"lv214-uscar\">2.1 LV214 and USCAR-2: current cycling and temperature rise<\/h3>\n<p>LV214 (the Volkswagen\/Audi\/Porsche\/SEAT\/Skoda joint standard) and SAE\/USCAR-2 define the core electrical validation requirements for automotive connectors. Both standards require <strong>high current wire harness testing<\/strong> under controlled conditions:<\/p>\n<ul>\n<li><strong>LV214 TG12 (current heating, derating)<\/strong>: The connector must carry a specified current without exceeding a temperature rise limit (typically 30 K for 0.35 mm\u00b2 and 0.50 mm\u00b2 conductors). The test method follows DIN EN 60512-5-1. Which specifies current-carrying capacity measurement at room temperature without exceeding a defined temperature rise.<\/li>\n<li><strong>USCAR-2 Test Sequence C (current cycling)<\/strong>: 1008 cycles at 1 hour per cycle, with test currents of 11.0 A for 0.35\/0.50 mm\u00b2 terminals. Terminal temperature must remain below 55 \u00b0C, and contact resistance limits (30 m\u03a9 for power terminals) must be maintained throughout.<\/li>\n<li><strong>USCAR-2 voltage drop<\/strong>: Maximum millivolt drop of 50 mV across mated connectors under specified current.<\/li>\n<\/ul>\n<p>Each of these requirements translates into specific demands on the <strong>high amperage power supply<\/strong>. The PSU must hold current within a tolerance tight enough that the measured temperature rise reflects the connector, not the source. It must log voltage drop continuously for 1008 hours without drift. And it must transition between current levels cleanly enough to reproduce the cycling profile.<\/p>\n<h3 id=\"iso-16750\">2.2 ISO 16750-2 and ECE R10: electrical loads and EMC<\/h3>\n<p>ISO 16750-2:2023 defines the electrical load profiles that automotive electronic systems must withstand. Which including overvoltage, reverse polarity, and load dump. The standard explicitly notes that electrical loads can vary due to the electrical impedance of the vehicle wiring harness and connection system. A <strong>high current harness test system<\/strong> used to validate ISO 16750-2 profiles must therefore deliver not only steady-state current but also the transient waveforms defined by the standard.<\/p>\n<p>For EMC compliance under ECE R10, the latest revision (R10.07, in force since June 2025) extends the immunity frequency range up to 6 GHz and updates transient immunity test methods to reference ISO 7637-2:2011 for pulses 1\u20133. While ECE R10 testing is distinct from harness current-carrying validation, the <strong>automotive electrical test PSU<\/strong> used in R10 test benches must meet similar current capability and transient response requirements.<\/p>\n<p>TPS\u2019s experience with automotive compliance documented in the <a href=\"https:\/\/tps-elektronik.com\/en\/case-studies\/quality-assurance-customer-case\/\">quality assurance customer case<\/a> and the <a href=\"https:\/\/tps-elektronik.com\/en\/metal-testing-quality-control-compliance-global-electronics\/\">metal testing and compliance guide<\/a>.<\/p>\n<\/section>\n<section id=\"test-applications\">\n<h2>3. Critical test applications powered by high amperage PSUs<\/h2>\n<p>The <strong>high amperage power supply<\/strong> is the backbone of several distinct validation workflows. Each imposes different requirements on current profile, measurement precision, and thermal management.<\/p>\n<h3 id=\"temperature-rise\">3.1 Temperature rise testing (harness temperature rise test PSU)<\/h3>\n<p>Temperature rise testing measures how much a connector or terminal heats above ambient when carrying its rated current. The test is deceptively simple: apply current, wait for thermal equilibrium, measure temperature. The difficulty lies in the power source. A <strong>harness temperature rise test PSU<\/strong> must maintain current within \u00b11% while the connector\u2019s resistance changes with temperature. A positive feedback loop that a voltage-controlled supply cannot manage. Constant-current mode with remote sensing is mandatory.<\/p>\n<p><img decoding=\"async\" class=\"alignnone size-full wp-image-18300\" src=\"https:\/\/tps-elektronik.com\/wp-content\/uploads\/2026\/09\/Harness-Temperature-Rise-Test-PSU-Measurement-3.jpg\" alt=\"Harness Temperature Rise Test PSU Measurement Messung des Temperaturanstiegs am Kabelbaum des Netzteils\" width=\"1920\" height=\"1079\" \/><\/p>\n<p>The measurement side is equally demanding. DIN EN 60512-5-1 requires ambient temperature to measured at a defined distance (typically 50 mm) from the hottest point. And the temperature rise calculation is based on the difference between terminal surface temperature and local ambient. Any PSU-induced ripple or current drift introduces thermal noise that broadens the uncertainty band of the result.<\/p>\n<h3 id=\"current-cycling\">3.2 Current cycling and aging validation<\/h3>\n<p><strong>Wire harness aging test power<\/strong> regimes subject connectors to repeated current-on\/current-off cycles that simulate real-world thermal expansion and contraction. USCAR-2\u2019s 1008-cycle requirement is the reference: one cycle per hour, with current applied for a defined on-time and then removed. Over 1008 hours, the connector experiences cumulative degradation mechanisms\u2014stress relaxation, oxidation, and micro-motion fretting\u2014that only reveal themselves under sustained high-current operation.<\/p>\n<p>For <strong>high current wire harness testing<\/strong> of this duration, the PSU must operate unattended for weeks. Protection features\u2014over-temperature shutdown, current limit foldback, and remote interlock. Which are not optional. Data logging must capture current, voltage, and temperature at intervals fine enough to resolve degradation trends, typically once per minute or better.<\/p>\n<p>TPS supports long-duration validation through its <a href=\"https:\/\/tps-elektronik.com\/en\/case-studies\/material-testing-compliance-market-entry-china\/\">material testing and compliance case study<\/a> and the <a href=\"https:\/\/tps-elektronik.com\/en\/supply-chain-optimization-for-electronics-global-sourcing-compliance\/\">supply chain optimization guide<\/a>.<\/p>\n<h3 id=\"voltage-drop\">3.3 Voltage drop and contact resistance measurement<\/h3>\n<p><strong>Cable testing high amperage<\/strong> often requires measuring the voltage drop across a connector interface at the rated current. For a 50 A load on a 2 m\u03a9 contact, the expected drop is 100 mV. Resolving a 5 mV change\u2014the threshold that indicates contact degradation. Which requires a measurement system with &lt; 1 mV noise. The <strong>connector validation power supply<\/strong> contributes to this noise budget through its output ripple and load regulation.<\/p>\n<p>Four-wire Kelvin sensing at the connector terminals eliminates cable resistance from the measurement. The PSU must provide a stable current while the nanovoltmeter or precision DMM samples the voltage. Some test setups alternate between high-current and low-current measurement phases. Which requiring the PSU to switch between levels without overshoot that could damage the contact interface.<\/p>\n<p><img decoding=\"async\" class=\"alignnone size-full wp-image-18295\" src=\"https:\/\/tps-elektronik.com\/wp-content\/uploads\/2026\/09\/Connector-Validation-Power-Supply-Voltage-Drop-Test-4-1.jpg\" alt=\"Connector Validation Power Supply Voltage Drop Test Test des Spannungsabfalls der Stromversorgung bei der Steckverbinder-Validierung\" width=\"1920\" height=\"1079\" \/><\/p>\n<p>For related validation workflows, see the <a href=\"https:\/\/tps-elektronik.com\/en\/case-studies\/quality-control-sample-generator-element-testing-ce-compliance-southeast-asia\/\">quality control sample generator case study<\/a>.<\/p>\n<\/section>\n<section id=\"selecting-psu\">\n<h2>4. How to select a high amperage test power supply<\/h2>\n<p>Selecting a <strong>wire harness test power supply<\/strong> for automotive validation is a specification exercise, not a catalog lookup. The following framework applies to both in-house test benches and outsourced laboratory validation.<\/p>\n<ul>\n<li><strong>Define the current profile first<\/strong>: Steady-state current, peak current, rise time, and duty cycle. A 200 A continuous requirement with 10 ms rise time is a different PSU class than a 200 A continuous requirement with 1 s rise time.<\/li>\n<li><strong>Calculate cable and connection losses<\/strong>: At 500 A, a 1 m copper cable with 0.1 m\u03a9 resistance drops 50 mV and dissipates 25 W. The PSU\u2019s voltage headroom must account for this.<\/li>\n<li><strong>Verify remote sensing bandwidth<\/strong>: Kelvin sense leads must be rated for the PSU\u2019s common-mode voltage and must not introduce noise. Twisted pairs with shielding are standard.<\/li>\n<li><strong>Plan for thermal management<\/strong>: A PSU operating at 80% of rated current in a 40 \u00b0C test chamber derates further. Specify PSUs with adequate margin or active cooling.<\/li>\n<li><strong>Confirm data interface and logging<\/strong>: For <strong>high current harness test system<\/strong> integration, the PSU must expose current and voltage measurements over LAN, USB, or CAN, with sample rates compatible with the degradation mechanisms being monitored.<\/li>\n<\/ul>\n<p>TPS\u2019s <a href=\"https:\/\/tps-elektronik.com\/en\/ai-driven-cost-reduction-manufacturing-simulation-elements-lab-qa\/\">AI-driven cost reduction and simulation approach<\/a> can be applied to test power sizing, reducing the risk of over-specifying or under-specifying the PSU.<\/p>\n<p><a class=\"cta-primary\" href=\"https:\/\/tps-elektronik.com\/en\/services\/global-sales-partner-for-electronics\/\">Get support selecting your high amperage test PSU \u2192<\/a><\/p>\n<\/section>\n<section id=\"tps-support\">\n<h2>5. How TPS Elektronik supports high amperage test readiness<\/h2>\n<p>TPS Elektronik operates at the intersection of EMS production, test system integration, and global market access. For system integrators and panel builders working on automotive harness and connector validation. This means access to <strong>automotive electrical test PSU<\/strong> configurations that are validated against the same standards the end customer will apply.<\/p>\n<p>TPS\u2019s global sales partner model provides structured support from production readiness through regional rollout. For high amperage test benches, this translates into:<\/p>\n<ul>\n<li><strong>PSU selection and rack integration<\/strong>: Matching current capability, sensing architecture, and thermal design to the specific test standard (LV214, USCAR-2, ISO 16750-2).<\/li>\n<li><strong>Pre-compliance validation<\/strong>: Running temperature rise and current cycling profiles on prototype connectors before formal laboratory submission, using the <a href=\"https:\/\/tps-elektronik.com\/en\/element-testing-laboratories-safety-global-expansion\/\">element testing laboratory approach<\/a>.<\/li>\n<li><strong>Documentation and compliance support<\/strong>: Preparing test reports that reference the correct clauses of LV214, USCAR-2, and DIN EN 60512-5-1 for CE marking and OEM submission.<\/li>\n<li><strong>Supply chain integration<\/strong>: Ensuring that the PSUs, cables, connectors, and measurement instruments are available across US, EU, and China production sites.<\/li>\n<\/ul>\n<p>This integrated approach detailed in the <a href=\"https:\/\/tps-elektronik.com\/en\/global-sales-partner-electronics-2026-eu-us-china\/\">global sales partner electronics 2026 guide<\/a> and the <a href=\"https:\/\/tps-elektronik.com\/en\/sales-playbook-elements-material-technology-ce-mark-readiness-asia-expansion\/\">sales playbook for CE mark readiness<\/a>.<\/p>\n<p>For a customer-facing example of how TPS handles compliance-driven projects, see the <a href=\"https:\/\/tps-elektronik.com\/en\/case-studies\/global-sales-partner-electronics-compliance-market-entry-case\/\">global sales partner compliance market entry case study<\/a>.<\/p>\n<p><a class=\"cta-primary\" href=\"https:\/\/tps-elektronik.com\/en\/services\/global-sales-partner-for-electronics\/\">Request a high amperage test power consultation with TPS \u2192<\/a><\/p>\n<\/section>\n<section id=\"faq\">\n<h2>6. FAQ<\/h2>\n<div>\n<h3>What current range does a high amperage power supply need for automotive harness testing?<\/h3>\n<div>\n<div>Typical automotive connector and harness validation requires continuous currents from 50 A to 500 A, with some busbar and high-voltage connector tests reaching 1000 A or more. The exact requirement depends on the terminal size, wire gauge, and the standard being applied (LV214 TG12, USCAR-2 Sequence C, or ISO 16750-2 load profiles).<\/div>\n<\/div>\n<h3>Can a standard laboratory power supply be used for USCAR-2 current cycling?<\/h3>\n<div>\n<div>No. USCAR-2\u2019s 1008-cycle current cycling requirement demands constant-current regulation with drift better than \u00b10.5% over 1008 hours, remote four-wire sensing, and unattended operation with data logging. Standard bench supplies typically lack the thermal stability and sensing architecture needed for this duration and precision.<\/div>\n<\/div>\n<h3>What is the difference between temperature rise testing and current cycling testing?<\/h3>\n<div>\n<div>Temperature rise testing measures the steady-state temperature increase of a connector under continuous current, verifying that it does not exceed a defined limit (e.g., 30 K per LV214 TG12). Current cycling testing applies repeated on\/off current profiles over many hours (e.g., 1008 cycles per USCAR-2) to simulate thermal fatigue and detect cumulative degradation.<\/div>\n<\/div>\n<h3>How does remote Kelvin sensing improve high amperage harness testing?<\/h3>\n<div>\n<div>Kelvin (four-wire) sensing separates the current-carrying path from the voltage measurement path. This eliminates the voltage drop across test cables and connections from the measurement, allowing the PSU to regulate the voltage at the connector terminals\u2014not at its own output\u2014and enabling accurate millivolt-level voltage drop measurement across the contact interface.<\/div>\n<\/div>\n<h3>Does TPS Elektronik provide turnkey high amperage test benches?<\/h3>\n<div>\n<div>TPS supports high amperage test bench integration through its EMS and global sales partner services, including PSU selection, rack assembly, wiring, labeling, and functional testing. The <a href=\"https:\/\/tps-elektronik.com\/en\/services\/global-sales-partner-for-electronics\/\">global sales partner service<\/a> covers the full path from production readiness to regional deployment.<\/div>\n<\/div>\n<h3>What standards should a high amperage test PSU comply with for automotive projects?<\/h3>\n<div>\n<div>The PSU itself is generally subject to EMC and safety standards (e.g., EN 55032, EN 61010), while the test methods it supports are defined by LV214 (DIN EN 60512-5-1, DIN EN 60512-5-2), SAE\/USCAR-2, and ISO 16750-2. For ECE R10 test benches, the PSU\u2019s transient response must also be compatible with ISO 7637-2 pulse profiles.<\/div>\n<\/div>\n<\/div>\n<\/section>\n<footer style=\"background: #2d5797; padding: 30px; border-radius: 14px; margin-top: 40px;\">\n<p style=\"color: #ffffff; font-size: 16px; line-height: 1.6; margin: 0;\"><strong>Ready to validate your harness and connector designs with confidence?<\/strong><br \/>Contact TPS Elektronik for high amperage test power integration, PSU selection, and compliance documentation support\u2014from prototype validation to series production.<br \/><a style=\"color: #ffffff; font-weight: 600; text-decoration: underline;\" href=\"https:\/\/tps-elektronik.com\/en\/services\/global-sales-partner-for-electronics\/\">Request your high amperage test consultation \u2192<\/a><\/p>\n<\/footer><\/article>\n\n<style 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They lose time\u2014and budget\u2014when high amperage test results do not match expectations, triggering repeated connector validation cycles and delaying PPAP or CE marking.TPS Elektronik\u2019s approach to high amperage power supply integration for wire harness and\u2026 <a href=\"https:\/\/tps-elektronik.com\/en\/what-is-a-high-amperage-power-supply-for-wire-harness-and-connector-testing-and-why-is-it-vital-for-automotive-electrical-safety-compliance\/\">Read More &raquo;<\/a><\/p>\n","protected":false},"author":9,"featured_media":18310,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"footnotes":""},"categories":[57],"tags":[],"class_list":["post-18183","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-blog-content"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v28.6 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>What Is a High Amperage Power Supply for Wire Harness and Connector Testing? and Why Is It Vital for Automotive Electrical Safety Compliance? - TPS<\/title>\n<meta name=\"description\" content=\"High amperage power supply for wire harness and connector testing ensures LV214, USCAR-2, and ECE R10 compliance. 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