I am looking for some feedback on what should guide my minimum test
configuration for a modular rack mount design for both emissions and
Immunity testing.  The design can have up to 10 instances of plug in
modules.  For immunity testing I believe I can test one set of each module
type but for emissions it is not clear to me what complement of modules
should be present when testing.

Details:
The rack based product similar to the configuration of Programmable Logic
Controller (PLC) where the base has the power supply and central data
gathering MCU that talks to plug in Analog power metering and Discrete 24VDC
Inputs or Outputs plus an optional communication card.  

The system is limited to one 10 slot rack which can be populated with only
one communication but the rest can be any combination of the metering
(current/voltage) or Discrete I/O cards.

I have done a lot of immunity and emission prescreening.
>From an RF radiated Immunity point of view I do not see any functional
difference if I have one of each module or the whole rack populated.
>From an emissions point of view I also do not see any significant cumulative
effect when fully populating the rack.  But if I do fully populate the rack
then the number of cable groups becomes difficult to manage.  I would really
like to reduce this down when traveling to a lab for formal emission
testing.

My gut is telling me to have one of each Digital card, the communications
module and then a couple of the metering cards.  This would cover all module
types and be configured like a typical application all though not the
maximum configuration possible.

In the PLC market this issue I am talking about becomes even larger since
these products have so many IO and can have multiple racks.  Any reflections
on how these modular beasts are reduced to manageable test configurations
and how you justify it would be appreciated.

Regards
Chris Wells
Eaton Corporation

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