Professional Documents
Culture Documents
VW80000 en PDF
VW80000 en PDF
Issue 2013-06
Class. No.: 8MA00
Descriptors: component, electric component, electronic component, electr. assembly, test condition, LV 124
Preface
NOTE 1: The component-specific requirements and tests are defined in the BT-LAH module "Reli‐
ability Testing".
NOTE 2: The component-specific EMC requirements and tests are defined in the BT-LAH module
"EMC".
This standard in the present issue is based on template LV 124, which was drawn up by represen‐
tatives of automobile manufacturers Audi AG, BMW AG, Daimler AG, Porsche AG, and Volks‐
wagen AG. Deviations from the LV 124 are listed on the cover sheet of this standard. If modifica‐
tions to individual test sections become necessary in individual cases, these must be agreed upon
separately between the appropriate department and the relevant manufacturer. Test reports are
accepted as long as the tests were performed by an independent testing institute that is accredited
according to DIN EN ISO/IEC 17025. Acceptance of the test reports does not automatically result
in a release.
Previous issues
VW 80101: 1987-06, 1988-08, 1992-01, 1993-04, 1994-05, 1995-06, 1998-01, 1999-06, 2000-09,
2001-04, 2003-05, 2004-07, 2005-06, 2006-10, 2009-03; VW 80000: 2009-10
Changes
The following changes have been made to VW 80000: 2009-10:
QUELLE: NOLIS
All rights reserved. No part of this document may be provided to third parties or reproduced without the prior consent of one of the Volkswagen Group’s Standards departments.
© Volkswagen Aktiengesellschaft VWNORM-2012-05o
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
LV 124
Page 1 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
Change history
Date of issue
2013-02 Editorial changes incorporated.
Page 2 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
Contents
Page 3 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
Part II – Environmental requirements and tests ....................................................... 55
7 Scope ................................................................................................................. 55
8 Referenced standards ...................................................................................... 56
9 Terms and definitions ....................................................................................... 57
9.1 Terms and abbreviations..................................................................................... 57
9.2 Voltages .............................................................................................................. 57
9.3 Temperatures...................................................................................................... 58
9.4 Times/durations .................................................................................................. 58
9.5 Standard tolerances ............................................................................................ 58
9.6 Standard values .................................................................................................. 58
10 General part ....................................................................................................... 59
10.1 Operating situations ............................................................................................ 59
10.2 Operating modes ................................................................................................ 60
10.3 Maintaining temperature ..................................................................................... 62
10.4 Parameter test .................................................................................................... 63
10.5 Continuous parameter monitoring with drift analysis ........................................... 64
10.6 Leak tightness test .............................................................................................. 65
10.7 Sampling rate and measured value resolution .................................................... 65
11 Use profile ......................................................................................................... 66
11.1 Service life requirements..................................................................................... 66
11.2 Temperature spectrum ........................................................................................ 66
12 Test selection .................................................................................................... 68
12.1 Test selection table ............................................................................................. 68
12.2 Test sequence plan ............................................................................................. 70
13 Mechanical requirements and tests ................................................................ 71
13.1 M-01 Free fall ...................................................................................................... 71
13.2 M-02 Stone impact test ....................................................................................... 72
13.3 M-03 Dust test ..................................................................................................... 73
13.4 M-04 Vibration test .............................................................................................. 75
13.5 M-05 Mechanical shock ...................................................................................... 86
13.6 M-06 Endurance shock test ................................................................................ 87
14 Climatic requirements and tests ...................................................................... 88
14.1 K-01 High-/low-temperature storage ................................................................... 88
14.2 K-02 Incremental temperature test ...................................................................... 89
14.3 K-03 Low-temperature operation ........................................................................ 90
14.4 K-04 Repainting temperature .............................................................................. 91
14.5 K-05 Temperature shock (component)................................................................ 92
14.6 K-06 Salt spray test with operation, exterior........................................................ 93
14.7 K-07 Salt spray test with operation, interior......................................................... 95
14.8 K-08 Damp heat, cyclic ....................................................................................... 97
14.9 K-09 Damp heat, cyclic (with frost) ..................................................................... 98
14.10 K-10 Water protection - IPX0 to IPX6K ............................................................... 99
14.11 K-11 High-pressure cleaning............................................................................. 100
14.12 K-12 Temperature shock with splash water ...................................................... 101
14.13 K-13 Temperature shock – immersion .............................................................. 104
14.14 K-14 Damp heat, constant ................................................................................ 105
14.15 K-15 Condensation and climate test ................................................................. 109
14.16 K-16 Temperature shock (without housing) ...................................................... 116
14.17 K-17 Solar radiation .......................................................................................... 117
Page 4 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
14.18 K-18 Harmful gas test ....................................................................................... 118
15 Chemical requirements and tests .................................................................. 119
15.1 C-01 Chemical tests .......................................................................................... 119
16 Service-life tests ............................................................................................. 122
16.1 L-01 Life test - mechanical/hydraulic endurance test ........................................ 122
16.2 L-02 Life test – high-temperature endurance test ............................................. 123
16.3 L-03 Life test - temperature cycle test ............................................................... 126
Appendix A (normative) Test sequence ................................................................. 130
A.1 Test sequence plan ........................................................................................... 130
A.2 Sequence tests ................................................................................................. 131
A.3 Tests outside the sequence (parallel tests) ....................................................... 133
A.4 Life tests............................................................................................................ 134
Appendix B (normative) Typical temperature spectrums for different
installation areas ....................................................................................................... 135
B.1 Temperature spectrum 1 ................................................................................... 136
B.2 Temperature spectrum 2 ................................................................................... 136
B.3 Temperature spectrum 3 ................................................................................... 136
B.4 Temperature spectrum 4 ................................................................................... 136
Appendix C (normative) Computation models for the life test "High-
temperature endurance test" .................................................................................... 137
C.1 Arrhenius model ................................................................................................ 137
C.2 Example of Arrhenius model: ............................................................................ 138
C.3 Arrhenius model for the use for components with reduced performance at
high temperatures ............................................................................................. 139
C.4 Example of Arrhenius model for use with components with reduced
performance at high temperatures: ................................................................... 140
C.5 Arrhenius model for use with components on coolant circuits........................... 142
C.6 Example of Arrhenius model for use with components on coolant circuits ........ 146
Appendix D (normative) Computation models for the "temperature cycle
test" life test ............................................................................................................... 149
D.1 Coffin-Manson model ........................................................................................ 149
D.2 Example: ........................................................................................................... 150
D.3 Coffin-Manson model for use with components on coolant circuits ................... 151
D.4 Example of Coffin-Manson model for use with components on coolant
circuits ............................................................................................................... 154
Appendix E (normative) Computation models for the test constant damp
heat – severity 2 ......................................................................................................... 156
E.1 Lawson model ................................................................................................... 156
E.2 Example: ........................................................................................................... 157
Appendix F (informative) Condensation test, chamber programming and
graphs......................................................................................................................... 158
Appendix G (informative) Sample examination methods for physical
analysis ...................................................................................................................... 161
Page 5 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
1 Scope
This document specifies requirements, test conditions, and tests for electric, electronic,
and mechatronic components and systems for use in motor vehicles with a 12 V electric
system. Unless otherwise noted, the tests are not electrical service life tests.
Additional or deviating requirements, test conditions, and tests are defined in the
corresponding Component Performance Specifications.
Note: The tests presented are used to check some of the required properties of the
component and are not used to qualify parts or qualify the production process.
2 Referenced standards
Table 1: Referenced standards
ANSI/UL 94 Standard for Tests for Flammability of Plastic Materials for
Parts in Devices and Appliances
DIN 72552-2 Terminal Markings for Vehicles:
Codes
DIN EN 13018 Non-Destructive Testing – Visual Testing – General Principles
DIN EN ISO/IEC 17025 General Requirements for the Competence of Testing and
Calibration Laboratories
Page 6 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
Page 7 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
VA, VT, VS, VR Voltage level of the start voltage pulse
3.3 Temperatures
Table 4: Abbreviations for temperatures
Tmin Minimum operating temperature
TRT Room temperature
Tmax Maximum operating temperature
Ttest Test temperature
3.4 Times/durations
Table 5: Abbreviations for times
tr Rise time (e.g., of a voltage curve)
tf Fall time (e.g., of a voltage curve)
Page 8 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
4 General requirements
4.1 Voltages and currents
The specified voltage curves are envelopes. Real voltage curves with any course within
the specified test curves and reference curves are to be expected.
All voltage and current specifications refer to the component (at its terminal). This does
not apply to tests for which the internal resistance Ri is specified. In this case, the
voltage and current specifications refer to the source (see Figure 1: Internal resistance).
Legend
VS Source
RL Line resistance and contact resistance
Ri Internal resistance observed at the terminals of
the component in the direction of the source
Page 9 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
Currents ±2%
The resolution of the measured values must be adapted to the respective test. It must
be ensured that occurring voltage peaks do not lead to an overflow or cannot be
measured in the case of an insufficient resolution. A data reduction/abstraction (e.g.,
limit monitoring, bus message evaluation) must not suppress irregularities.
Page 10 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
Page 11 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
Page 12 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
4.9.3.4 Sample operating modes
Table 10: Sample operating modes
Sample component Operating Operating mode II.b Operating mode II.c
mode II.a
Car radio with Component as Component in Component in running
navigation system in parked running vehicle. vehicle. Component
vehicle Component switched switched on (CD,
(sleep). Post- off by driver, navigation system, final
run current BUS/µC's active, stage), BUS/navigation
stopped T.15 "ON" computer active.
T.30 "ON"
Anti-theft alarm No operation Vehicle interior is monitored while vehicle is
system when vehicle parked.
is running.
Brake control system Component as Driving without brake Driving with frequent
in parked actuation. brake cycles (no
vehicle. Post- misuse, such as
run current uninterrupted brake
stopped. control operation).
On-board charger Off-grid On-grid parking (only Charging operation
parking power line
or communication, no
driving charging operation),
operation vehicle conditioning
High-voltage battery Off-grid On-grid parking with Driving operation,
pack (battery energy parking power line charging operation
management communication
system)
Page 13 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
The sequence of the electrical tests can be freely chosen. The permissible event
memory entries and the functional statuses of the component must be specified for
each test.
Unless otherwise specified in the test selection table as per section 5, all the test cases
in a test must be performed.
The electrical tests may be performed during an environmental test (see LV 124, Part II)
if this does not violate the test requirements of the electrical test and the purchaser has
approved this course of action. If the DUT exhibits irregularities during combined tests,
the tests must be repeated individually.
The key parameters to be monitored must be recorded during each test. Resets of the
component must be monitored in a suitable manner and documented.
Before and after each test, the DUTs must be subjected to a parameter test (small) as
per section 4.12.2 as per the Performance Specification.
Before the first and after the last electrical test, the parameter test (large) as per
section 4.12.3 must be performed as per the Performance Specification.
The measurement results and data of the pre-tests and post-tests must differ from each
other only within the specified permissible tolerances. Changes in the measured values
greater than the measurement accuracies must be marked. The measurement results
must be examined for trends and drifting to detect irregularities, aging, or malfunctions
of the component.
The physical analysis as per section 4.12.4 must be conducted after all electrical tests
have been completed on at least one DUT.
Page 14 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
Changes in the values of the key parameters, the functional behavior, or the event
memory entries and irregularities in the visual inspection must be evaluated regarding
the preceding test loads in comparison with the unused condition.
Page 15 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
Page 16 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
Test Applicable to To be additionally
defined by the
purchaser
E-18 Insulation resistance Components with galvanically None
isolated portions
E-19 Closed-circuit current Components that are continuously None
supplied with voltage (e.g., T.30,
T.30f, T.30g)
E-20 Dielectric strength Components with inductive parts None
(e.g., motors, relays, coils)
E-21 Backfeeds Components that are electrically None
connected to T.15 or other
terminals with wake-up function
E-22 Overcurrents Components that have an output None
Page 17 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
6.1.2 Test
Table 12: Test parameters, E-01 Long-term overvoltage
DUT operating mode Operating mode II.c
Vmax 17 V (+4%, 0%)
Vmin 13,5 V
tr <10 ms
tf <10 ms
t1 60 min
Ttest Tmax – 20 K
Number of cycles 1
Number of DUTs At least 6
Page 18 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
6.1.3 Requirement
The evaluation of the test results depends on the use of the component. A distinction is
made between:
a) Components necessary for driving operation:
Functional status B
If required, an emergency mode must be defined. The corresponding derating
strategy must be described in the Component Performance Specification.
6.2.2 Test
Table 13: Test parameters, E-02 Transient overvoltage
DUT operating mode Operating mode II.c
Vmin 16 V
U1 17 V
Vmax 18 V (+4%, 0%)
tr 1 ms
tf 1 ms
t1 400 ms
t2 600 ms
Number of DUTs At least 6
Test case 1
Ttest Tmax
Number of cycles 3
t3 2s
Test case 2
Ttest Tmin
Number of cycles 3
t3 2s
Test case 3
Ttest TRT
Number of cycles 100
t3 8s
Page 19 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
6.2.3 Requirement
Functional status A
Page 20 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
6.3.2 Test
Table 14: Test parameters, E-03 Transient undervoltage
DUT operating mode Operating mode II.c
Vmax 10,8 V (+4%, 0%)
Vmin 9 V (0%, -4%)
tr 1,8 ms
tf 1,8 ms
t1 500 ms
t2 1s
Number of DUTs At least 6
Test case 1
Ttest Tmax
Number of cycles 3
Test case 2
Ttest Tmin
Number of cycles 3
6.3.3 Requirement
Functional status A
Page 21 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
6.4.2 Test
Table 15: Test parameters, E-04 jump start
DUT operating mode Operating mode II.c
Vmin 10,8 V
Vmax 26 V (+4%, 0%)
t1 60 s
tr <10 ms
tf <10 ms
Number of cycles 1
Number of DUTs At least 6
6.4.3 Requirement
A distinction is made between:
a) Components relevant to starting (e.g., starter):
Functional status B
Sensors must provide valid values during the entire time (or be safeguarded by
means of replacement tables in the components).
Page 22 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
6.5.2 Test
Table 16: Test parameters, E-05 Load dump
DUT operating mode Operating mode II.c
Vmin 13,5 V
Vmax 27 V (+4%, 0%)
tr ≤2 ms
t1 300 ms
tf ≤30 ms
Break between cycles 1 min
Number of cycles 10
Number of DUTs At least 6
6.5.3 Requirement
A distinction is made between:
a) Safety-relevant components:
Functional status B
Page 23 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
6.6.2 Test
Table 17: Test parameters, E-06 Superimposed alternating voltage
DUT operating mode Operating mode II.c
Vmax VBmax
Ri ≤100 mΩ
Frequency range 15 Hz – 30 kHz
Wobble duration t1 2 min
Type of wobble Triangle, logarithmic
Number of cycles 15
Number of DUTs At least 6
Test case 1
VPP 2 V (+4%, 0%)
Test case 2
VPP 3 V (+4%, 0%)
only for components between battery and generator,
in particular for battery connection far from generator
Test case 3
VPP 6 V (+4%, 0%)
for all components during driving without battery
(emergency mode) or for connection close to
generator
Page 24 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
6.6.3 Requirement
Page 25 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
6.7.2 Test
Table 18: Test parameters, E-07 Slow decrease and increase of the supply voltage
DUT operating mode Operating mode II.a and II.c
Figure 8: Test pulse E-07 Slow decrease and increase of the supply voltage
Page 26 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
6.7.3 Requirement
The evaluation of the test results depends on the voltage range that is applied to the
component during the test.
Page 27 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
6.8.2 Test
Table 19: Test parameters, E-08 Slow decrease, quick increase of the supply voltage
DUT operating mode Operating mode II.a and II.c
Figure 9: Test pulse E-08 Slow decrease, quick increase of the supply voltage
Page 28 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
6.8.3 Requirement
The evaluation of the test results depends on the voltage range that is applied to the
component during the test.
Page 29 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
6.9.2 Test
Table 20: Test parameters, E-09 Reset behavior
DUT operating mode Operating mode II.a and II.c
Page 30 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
6.9.3 Requirement
Functional status A when Vmax is reached again.
It must be verified and documented that the specified threshold voltage level beyond
which the component leaves functional status A for the first time is adhered to.
Page 31 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
6.10.2 Test
Table 21: Test parameters, E-10 Short interruptions
DUT operating mode Operating mode II.c
Vtest 11 V
Z1 S1 closed
Z2 S1 open
tr ≤(0,1 * t1)
tf ≤(0,1 * t1)
Switch S1 must be switched with the t1 Intervals
following sequences: 10 µs to 100 µs 10 µs
100 µs to 1 ms 100 µs
1 ms to 10 ms 1 ms
10 ms to 100 ms 10 ms
100 ms to 2 s 100 ms
t2 >10 s
The test voltage Vtest must be held at least until
the DUT and the periphery have reached
100% operability again.
Number of cycles 1
Number of DUTs At least 6
Test case 1 S1 switched, S2 statically open
Test case 2 S1 switched, S2 opposite S1
The duration of the voltage dip increases at the intervals specified in Table 21. This
results in a diagram as shown in Figure 11.
The voltage on the DUT can be limited by the test setup to the maximum voltage of the
test E-05 Load dump (see section 6.5).
Page 32 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
S1 t2
tr
t1 t1
tf
Z1
Z2
t
The closed switch S2 including the necessary lines must have a series resistance
<100 mΩ.
Page 33 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
Then the tests as per Table 21 must be performed.
6.10.3 Requirement
It must be documented as of which time value t1 the DUT leaves functional status A for
the first time.
Page 34 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
6.11.2 Test
Table 22: Test parameters, E-11 Start pulses
DUT operating mode Operating mode II.a, II.b, and II.c
If necessary, additional operating loads must be
defined in the respective operating mode.
Test pulse - Cold start: "normal" and "severe" test pulse as per
Table 23
- Hot start: "short" and "long" test pulse as per
Table 24
Number of DUTs At least 6
Page 35 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
Legend
a T.50 off
b T.50 on
c T.50 off
ttest Cycle
Figure 13: Cold start test pulse
Page 36 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
6.11.2.2 Test case 2 – Hot start
Table 24: Test parameters, E-11 Start pulses, hot start
Parameters "Short" test "Long" test
sequence sequence
VB 11,0 V
VT 7,0 V (0%, -4%)
VS 8,0 V (0%, -4%)
VA 9,0 V (0%, -4%)
t50 ≥10 ms
tf ≤1 ms
t4 15 ms
t5 70 ms
t6 240 ms
t7 70 ms
t8 600 ms
tr ≤1 ms
Break between two
5s 20 s
cycles
Test cycles 10 100
Lege
nd
a T.50 off
b T.50 on
c T.50 off
ttest Cycle
Figure 14: Hot start test pulse
6.11.3 Requirement
Event memory entries must not occur.
It must always be possible to start the vehicle.
Page 37 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
6.11.3.1 Components relevant for starting:
Page 38 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
6.12.2 Test
Table 25: Test parameters, E-12 Voltage curve with electric system control
DUT operating mode Operating mode II.c
Vmin (11,8 V - ∆V) (0%, -4%)
Vmax (15 V - ∆V) (+4%, 0%)
t1 2s
tr ≥300 ms
tf ≥300 ms
Number of cycles 10
Number of DUTs At least 6
Test case 1
∆U 0V
Test case 2
∆V 0,7 V
Test case 3
∆V 2V
Figure 15: Test pulse, E-12 Voltage curve with electric system control
6.12.3 Requirement
Functional status A
Page 39 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
6.13.2 Test
Table 26: Test parameters, E-13 Pin interruption
DUT operating mode Operating mode II.a and II.c
Page 40 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
Pin a
t2 t3
tf
t1
tr
Z1
Z2
t
Figure 16: Test pulse, E-13 Pin interruption, test case 2
The voltage on the pin can be limited to the maximum voltage of the test E-05 Load
dump (see section 6.5).
One reference measurement each with 1 kΩ (±5%) and 1 Ω (±5%) as a DUT substitute
must be performed and documented. Verification of the edge steepness must be
provided with this test setup. Low-inductance parts must be used as resistors.
6.13.3 Requirement
Page 41 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
6.14.2 Test
Table 27: Test parameters, E-14 Connector interruption
DUT operating mode Operating mode II.a and II.c
Number of cycles Each connector must be removed once in both
operating modes.
Number of DUTs At least 6
6.14.3 Requirement
Functional status C
Page 42 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
6.15.2 Test
All relevant connections of the original circuitry must be tested.
The DUT must be addressed in the same way as it is in the vehicle circuit.
The test must be performed at various voltages between 0 V and the maximum values
specified in Table 29.
Page 43 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
Page 44 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
6.15.3 Requirement
When reverse polarity is applied, no safety-relevant functions must be triggered, e.g.,
for electric window lifts, electric sunroof, starter.
Functional status C
Page 45 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
6.16.2 Test
If the DUT has several voltage and ground connections, the test must be performed
individually for each connection point.
Legend
B Bus system
S Signal line
S1 Two-pin (a/b) change-over switch
TE Other component, e.g., test reference, test bed, simulation electronic control unit,
actuator, sensor, or load
Figure 19: Schematic circuit, E-16 Ground offset
6.16.3 Requirement
Functional status A
Page 46 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
6.17.2 Test
Table 32: Test parameters, E-17 Short circuit in signal circuit and load circuits
DUT operating mode Operating mode II.c
Test duration Short circuit of each pin individually for 60 s to ground
and to VB.
Test voltages VBmin and VBmax
Test case 1 Each pin alternately to VB and GND with voltage supply
and with ground connection
Test case 2 Each pin alternately to VB and GND without voltage
supply and with ground connection
Test case 3 Each pin alternately to VB and GND with voltage supply
and without ground connection
Number of DUTs At least 6
If the voltage supply/ground supply is provided via several pins, combinations must also
be taken into account.
Page 47 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
Legend
L Load
E Input
A Output
PWR Output VB
GND Input/output T.31
Figure 20: Schematic circuit, E-17 Short circuit in signal circuit and load circuits
6.17.3 Requirement
For inputs and outputs (E and A): functional status C
For looped-through supply voltages (PWR): functional status D
For device ground (GND): functional status E
Page 48 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
6.18.2 Test
Table 33: Test parameters, E-18 Insulation resistance
DUT operating mode Operating mode I.a
Test voltage 500 V DC
Test duration 60 s
Test points Application of the test voltage
- To terminals without galvanic connection.
- Between connection pins and conducting
housing without galvanic connection.
- Between connection pins and an electrode
around the housing if the housing is non-
conducting.
– To further test points coordinated with the
appropriate department.
Number of cycles 1 cycle must be performed, in which each of the
points defined above must be tested at least once.
Number of DUTs At least 6
6.18.3 Requirement
The insulation resistance must be at least 10 MΩ.
After the test, functional status A must be verified.
Page 49 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
6.19.2 Test
For components with an after-run function (e.g., fan), the closed-circuit current
consumption must be determined after this function has ended.
The component must be measured with the associated periphery and circuitry.
6.19.3 Requirement
The closed-circuit current consumption target for any DUT must be 0 mA.
For DUTs that must be operated after T.15 OFF, a closed-circuit current equivalent
(average over 12 h) of ≤0,1 mA corresponding to 1,2 mAh (above +40 °C ≤0,2 mA)
applies in the idle phase. This must be complied with under any conceivable at-rest
conditions of the vehicle and at any 12 h period. Otherwise, release by the department
responsible for closed-circuit current management is required.
Post-run functions must also be released by the department responsible for closed-
circuit current management.
Page 50 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
6.20.2 Test
Table 35: Test parameters, E-20 Dielectric strength
DUT operating mode Operating mode II.a
Test voltage Veff 500 V AC, 50 Hz, sinusoidal
Test duration 60 s
Test points Application of the test voltage
- To terminals without galvanic connection.
- Between connection pins and conducting
housing without galvanic connection.
- Between connection pins and an electrode
around the housing if the housing is non-
conducting.
- To further test points coordinated with the
appropriate department.
Number of cycles 1 cycle must be performed, in which each of the
points defined above must be tested at least once.
Number of DUTs At least 6
6.20.3 Requirement
Functional status C
Dielectric breakdowns and electric arcs are not permissible.
Page 51 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
6.21.2 Test
Table 36: Test parameters, E-21 Backfeeds
DUT operating mode Operating mode II.c
Vtest VBmax – 0,2 V
Test temperatures TBmax, TRT and TBmin
Number of DUTs At least 6
Legend
T Scanner head
Os Oscilloscope
K Terminal to be tested
Page 52 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
6.21.3 Requirement
Backfeed to the terminal to be tested is permissible only up to a maximum level of 1 V.
This voltage range must be achieved within t = 20 ms after cutoff.
The voltage on the unconnected terminal to be tested must drop below a voltage of 1 V
within t = 20 ms from the time of the switch-off.
The voltage curve over time must continuously fall. A discontinuity of the curve due to
positive pulses is not permitted.
Page 53 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
6.22.2 Test
Table 37: Test parameters, E-22 Overcurrents
DUT operating mode Operating mode II.c
Temperature Tmax
Test conditions for electronic The output must withstand at least the triple value
outputs of the nominal load without damage.
6.22.3 Requirement
Functional status A for mechanical components without fuse. If fuse elements are
available in the load circuit, these may be triggered.
Functional status C for electronic outputs with overload detection (current, voltage,
temperature).
In addition, no harmful changes that restrict the function or service life must be visible in
a visual inspection of all components (visual and electrical characteristics).
Page 54 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
7 Scope
This document specifies requirements, test conditions and tests for electric,
electronic and mechatronic components and systems for the use in motor vehicles up
to 3,5 t.
Additional or deviating requirements, test conditions, and tests are defined in the
corresponding Component Performance Specifications.
Note: The tests presented are not used to qualify parts or qualify the production
process.
Page 55 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
8 Referenced standards
Table 38: Referenced standards
DIN 75220 Aging of Automotive Components in Solar Simulation Units
DIN EN 13018 Non-Destructive Testing – Visual Testing – General Principles
DIN EN 60068-2-1 Environmental Testing – Part 2-1: Tests –
Test A: Cold
DIN EN 60068-2-2 Environmental Testing – Part 2-2: Tests –
Test B: Dry Heat
DIN EN 60068-2-6 Environmental Testing – Part 2-6: Tests – Test Fc: Vibration
(Sinusoidal)
DIN EN 60068-2-11 Environmental Testing – Part 2: Tests – Test Ka: Salt Mist
DIN EN 60068-2-14 Environmental Testing – Part 2-14: Tests – Test N: Change of
Temperature
DIN EN 60068-2-27 Environmental Testing – Part 2-27: Tests – Test Ea and
Guidance: Shock
DIN EN 60068-2-29 Environmental Testing – Part 2: Tests – Test Eb and
Guidance: Bump
DIN EN 60068-2-30 Environmental Testing – Part 2-30: Tests –
Test Db: Damp Heat, Cyclic (12 h +12 h Cycle)
DIN EN 60068-2-38 Environmental Testing – Part 2-38: Tests – Test Z/AD:
Composite Temperature/Humidity Cyclic Test
DIN EN 60068-2-60 Environmental Testing – Part 2: Tests – Test Ke: Flowing
Mixed Gas Corrosion Test
DIN EN 60068-2-64 Environmental Testing – Part 2-64: Tests – Test Fh: Vibration,
Broadband Random and Guidance
DIN EN 60068-2-78 Environmental Testing – Part 2-78: Tests – Test Cab: Damp
Heat, Steady State
DIN EN ISO 11124-2 Preparation of Steel Substrates Before Application of Paints
and Related Products – Specifications for Metallic Blast-
Cleaning Abrasives – Part 2: Chilled-Iron Grit
DIN EN ISO 20567-1 Paints and Varnishes -
Determination of Stone-Chip Resistance of Coatings -
Part 1: Multi-Impact Testing
DIN EN ISO 6270-2 Paints and Varnishes – Determination of Resistance to
Humidity – Part 2: Procedure for Exposing Test Specimens in
Condensation-Water Atmospheres
ISO 12103-1 Road Vehicles – Test Dust for Filter Evaluation – Part 1:
Arizona Test Dust
ISO 16750-3 Road Vehicles – Environmental Conditions and Testing for
Electrical and Electronic Equipment – Part 3: Mechanical
Loads
ISO 16750-5 Road Vehicles – Environmental Conditions and Testing for
Electrical and Electronic Equipment – Part 5: Chemical Loads
ISO 20653 Road Vehicles - Degrees of Protection (IP-Code) - Protection
of Electrical Equipment Against Foreign Objects, Water and
Access
Page 56 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
9.2 Voltages
Table 40: Abbreviations for voltage definitions
VBmin Lower operating voltage limit
VB Operating voltage
VBmax Upper operating voltage limit
Page 57 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
9.3 Temperatures
Table 41: Temperature definitions
Tmin Minimum operating temperature
TRT Room temperature
Tmax Maximum operating temperature
Top,min Minimum operating temperature for components with overload
protection/low-temperature protection
Top,max Maximum operating temperature for components with overload
protection/over-temperature protection
TTest Test temperature
9.4 Times/durations
Table 42: Time definitions
ttest Test duration
toper. Operating hours over service life
Page 58 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
10 General part
10.1 Operating situations
For vehicles with a pure engine drive train, the operating state of the vehicle
generally can be divided into the following two operating situations over its service
life:
• Driving operation
• Parking
For vehicles with alternative drive trains, it may be necessary to take additional
operating situations into account (see Table 45).
For components to which several operating situations are relevant (Figure 22), the
operating modes (see section 10.2) must be specifically defined for each operating
situation if necessary.
All operating situations relevant to the component as per Figure 22 must be taken
into account when deriving the test requirements.
Page 59 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
Page 60 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
Page 61 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
The time until this condition is achieved must be determined by the contractor
through experiments and indicated in the test documentation.
For temperature cycle tests, the DUTs must additionally be kept in the condition in
which the temperature is maintained at the specified temperature basic values for a
defined time, so that tensions in the component can be transferred to elongations.
This additional holding time must be indicated for the respective tests.
Page 62 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
Changes in the values of the key parameters, the functional behavior, or the event
memory entries and irregularities in the visual inspection must be evaluated
regarding the preceding test loads in comparison with the unused condition.
Page 63 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
Changes in the values of the key parameters, the basic functionality of the
component, or the event memory entries must be evaluated regarding the preceding
test loads.
The results must be documented in the test report.
For components with event memory, the event memory must be monitored
continuously and the entries must be documented.
The data resulting from the continuous parameter monitoring must be examined for
trends and drifting to detect irregularities, aging or malfunctions of the component.
Page 64 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
• Pressure pulsation test with 100 000 pressure changes between the minimum
and maximum specified pressure of the coolant circuit at Tmax and Tcool,max and
with 50 000 pressure changes between the minimum and maximum specified
pressure of the coolant circuit at Tmin and Tcool,min.
• Static leak tightness test at the minimum, maximum, and nominal specified
pressure of the coolant circuit, in each case at TRT with Tcool,nom, at Tmax with
Tcool,max, and at Tmin with Tcool,min.
• Vacuum test with a test pressure less than 20 mbar at TRT, provided the
component is filled in a vacuum process. Unless otherwise specified in the
Component Performance Specification, the pressure changes from ambient
pressure to test pressure and back in <5 s. The dwell time at test pressure is
at least 30 s.
• Test of the coolant flow rate at the minimum, maximum, and nominal specified
pressure of the coolant circuit, in each case at TRT with Tcool,nom, at Tmax with
Tcool,max, and at Tmin with Tcool,min.
Unless specified in the Component Performance Specification, the details of the leak
tightness test must be agreed upon between the purchaser and the contractor.
The leak tightness test must be performed after the first and after the last "parameter
test (large)" for the sequence tests (A.2), tests outside the sequence (parallel tests)
(A.3), and service life tests (A.4).
The resolution of the measured values must be adapted to the respective test.
Page 65 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
11 Use profile
11.1 Service life requirements
Table 47 shows the typical parameters for the service life requirements.
Table 47: Service life requirements
Service life 15 years
Operating hours in 8 000 h
driving operation
Mileage 300 000 km
For vehicles with alternative drive trains, it may be necessary to take additional
operating situations into account (see Table 45).
The operating times in the following additional operating situations must be defined
specifically for the component in the Component Performance Specification (see
Table 45):
• Operating hours in charging operation
• Operating hours in preconditioning
• Operating hours in on-grid parking
For vehicles with alternative drive trains, a distinction must be made between the
operating situations "driving operation," "charging operation," "preconditioning," and
"on-grid parking" and the respective temperature spectrum must be specified both for
the ambient temperature and for the coolant circuit. (See Figure 22).
Page 66 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
Page 67 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
12 Test selection
12.1 Test selection table
Table 49: Test selection table
Test Applicable to Required
specifications
M-01 Free fall All components None
For components that will obviously be
damaged in this test (e.g. glass bodies, highly
sensitive sensors), this test may be omitted in
coordination with the purchaser. This must be
documented.
M-02 Stone impact test Components installed in areas that may be None
affected by stone impact
M-03 Dust test All components
Degree of protection Components for which the ingress of dust is None
IP6KX not allowed
Degree of protection Components for which the ingress of dust is
IP5KX allowed as long as functionality and safety are
not impaired
Page 68 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
Test Applicable to Required
specifications
K-07 Salt spray test with Components installed in exposed positions in None
operation, interior the interior (e.g. side pockets in the trunk, door
wet space, spare wheel well)
K-08 Damp heat, cyclic All components None
K-09 Damp heat, cyclic All components None
(with frost)
K-10 Water protection - IPX0 to All components None
IPX6K
- Degree of protection Components that do not require water
IPX0 protection
- Degree of protection Components for which vertically falling drops
IPX1 must have no harmful effect
Page 69 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
Test Applicable to Required
specifications
K-18 Harmful gas test Components with switching contacts that are None
not leak-tight with respect to gas
C Chemical tests All components Chemicals
Operating mode
L-01 Life test - Components with mechanical/hydraulic Number of
mechanical/hydraulic endurance actuation/functional cycles, e.g. brake functional/actuation
test actuation, seat adjustment cycles, switch/tip cycles
switch actuations
L-02 Life test - high-temperature All components Test duration
endurance test
L-03 Life test - temperature All components Number of test
cycle test cycles
Page 70 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
13.1.2 Test
Table 50: Test parameters, M-01 Free fall
DUT operating mode Operating mode I.a
Drop height 1m
Impact surface Concrete floor
Test cycle For each of the 3 DUTs one drop in both directions
of a spatial axis (1st DUT:
2nd DUT: ±Y, 3rd DUT: ±Z)
Number of DUTs 3
13.1.3 Requirement
The DUT must be evaluated visually with the naked eye and tested for loose or
rattling parts by means of shaking.
- If the DUT is not damaged on the outside, it must be fully functional after the
test, and all parameters must meet the specifications. Verification takes place
by means of a parameter test (large) as per section 10.4. Hidden damages are
not permissible.
Page 71 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
13.2.2 Test
The test is performed on the basis of DIN EN ISO 20567-1, test method B, with the
following parameters:
Table 51: Test parameters, M-02 Stone impact test
DUT operating mode Operating mode I.b
Quantity of blasting medium 500 g
Test pressure 2 bar
Blasting material Hard-cast granular material as per
DIN EN ISO 11124-2, grain size 4 to 5 mm
Test surface on DUT All surfaces that are freely accessible on the vehicle
Impact angle 54° to blasting direction
Test equipment Multi-stone impact test device as per
DIN EN ISO 20567-1
Number of cycles 2
Number of DUTs 6
13.2.3 Requirement
The DUT must be fully functional before and after the test, and all parameters must
meet the specifications. Verification takes place by means of a parameter test (small)
as per section 10.4.
In addition, the DUT must be evaluated visually with the naked eye and tested for
loose or rattling parts by means of shaking.
Changes/damages must be documented in the test report and evaluated with the
purchaser.
An evaluation as per the characteristic values of DIN EN ISO 20567-1 is not required.
Page 72 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
13.3.2 Test
The test is carried out as per ISO 20653 with the following parameters:
Page 73 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
13.3.3 Requirement
The degree of protection specified in the Component Performance Specification as
oer ISO 20653 must be achieved.
The DUT must be fully functional before, during and after the test, and all parameters
must meet the specifications. Verification takes place by means of a parameter test
(small) as per section 10.4.
In addition, the DUT must be evaluated visually with the naked eye and tested for
loose or rattling parts by means of shaking.
Changes and damage must be documented in the test report and evaluated with the
purchaser.
Page 74 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
13.4.2 Test
The test is performed on the basis of ISO 16750, part 3.
The test is carried out as per DIN EN 60068-2-6 for sinusoidal vibration excitation
and DIN EN 60068-2-64 for wide-band vibration excitation with the following
parameters:
Table 53: Test parameters for general vibration
DUT operating mode If the component is not operated with operating
load during driving operation:
II.a during the entire test
Page 75 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
Components that are installed on an electric machine must be tested at least as per
vibration profile D. However, this test profile does not take into account the special
vibration loads coming from an electric machine. But in practice, these special
vibration loads can occur and can act on the component. Therefore, the special
vibration loads coming from an electric machine must be taken into account in the
test. For this purpose, measurements must be taken on the particular electric
machine.
The test must be performed without bracket or add-on parts. The Component
Performance Specification must define how connected lines (e.g., electric wiring,
coolant hoses, hydraulic lines) must be fastened in the test setup.
For components that are installed on the bracket or vehicle through damping
elements, it must be specified in the Component Performance Specification whether
must be tested.
The sampling rate must be selected so that interruptions or short circuits can be
unambiguously detected.
Additional tests to verify the strength of the whole system of component, holder, and
add-on parts in the assembly must be agreed upon with the purchaser.
Page 76 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
Table 54: Temperature curve for vibration
Time (min) Temperature (°C)
0 TRT
60 Tmin
150 Tmin
300 Tmax
410 Tmax
480 TRT
If there is a coolant circuit, the coolant temperature must track the respective test
temperature to the limits Tcool,min and Tcool,max. Only the ambient temperature is varied
outside of the coolant temperature limits.
Page 77 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
Page 78 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
Page 79 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
Table 56: Test parameters – vibration, wide-band random vibration for engine-mounted parts
Vibration excitation Wide-band random vibration
Test duration for each spatial axis 22 h
RMS value of acceleration 181 m/s²
Vibration profile Figure 26 Frequency in Hz Power density spectrum
in (m/s²)²/Hz
10 10
100 10
300 0,51
500 20
2 000 20
Figure 26: Vibration profile, wide-band random vibration for engine-mounted parts
Page 80 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
Page 81 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
Table 58: Test parameters – vibration, wide-band random vibration for gearbox-mounted
parts
Vibration excitation Wide-band random vibration
Test duration for each spatial axis 22 h
RMS value of acceleration 96,6 m/s²
Vibration profile Figure 28 Frequency in Hz Power density
spectrum (m/s²)²/Hz
10 10
100 10
300 0,51
500 5
2 000 5
Figure 28: Vibration profile, wide-band random vibration for gearbox-mounted parts
Page 82 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
Figure 29: Vibration profile, sinusoidal for components on the decoupled intake plenum
Page 83 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
Figure 30: Vibration profile, wide-band random vibration for sprung masses
Page 84 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
Figure 31: Vibration profile, wide-band random vibration for unsprung masses
13.4.3 Requirement
The DUT must be fully functional before, during and after the test, and all parameters
must meet the specifications. Verification takes place by means of continuous
parameter monitoring and a parameter test (small) as per section 10.4.
Page 85 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
13.5.2 Test
The test is carried out as per DIN EN 60068-2-27 with the following parameters:
13.5.3 Requirement
The DUT must be fully functional before, during and after the test, and all parameters
must meet the specifications. Verification takes place by means of continuous
parameter monitoring and a parameter test (small) as per section 10.4.
Page 86 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
13.6.2 Test
The test is carried out as per DIN EN 60068-2-29 with the following parameters:
13.6.3 Requirement
The DUT must be fully functional before, during and after the test, and all parameters
must meet the specifications. Verification takes place by means of continuous
parameter monitoring and a parameter test (small) as per section 10.4.
Page 87 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
14.1.2 Test
Table 64: Test parameters, K-01 High-/low-temperature storage
DUT operating mode Operating mode I.a
Test duration and test 2 cycles for 24 h each (consisting of 12 h storage
temperature at Tmin and 12 h storage at Tmax each)
Number of DUTs As specified in the test sequence plan in the
Component Performance Specification
14.1.3 Requirement
The DUT must be fully functional before and after the test, and all parameters must
meet the specifications. Verification takes place by means of a parameter test (large)
as per section 10.4.
Page 88 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
14.2.2 Test
Table 65: Test parameters, K-02 Incremental temperature test
DUT operating mode During the parameter test (functional test) operating mode II.c,
otherwise operating mode II.a
Test temperature A temperature profile as per Figure 32 must be applied to the
DUTs.
The temperature change per increment is 5 °C.
Test sequence The DUT must be held at every temperature increment until it
completely maintains the temperature (see section 10.4).
Then a parameter test (functional test) must be performed as
per section Parameter test (see section 10.4).
Number of DUTs 6
14.2.3 Requirement
All DUT parameters must meet the specifications during the parameter test
(functional test).
Page 89 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
14.3.2 Test
The test is carried out as per DIN EN 60068-2-1, test Ab, with the following
parameters:
Number of DUTs 6
For components dissipating heat, the test must also be carried out as per
DIN EN 60068-2-1, test Ab.
If there is a coolant circuit, the minimum coolant temperature Tcool,min must be set.
For components with high power loss, the test chamber temperature may increase
above Tmin due to the self-heating during the test in operating mode II.c in agreement
between the contractor and the purchaser.
14.3.3 Requirement
The DUT must be fully functional before, during and after the test, and all parameters
must meet the specifications. Verification takes place by means of continuous
parameter monitoring and a parameter test (small) as per section 10.4.
Page 90 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
14.4.2 Test
Table 67: Test parameters, K-04 Repainting temperature
DUT operating mode Operating mode II.a
Test duration and test temperature 15 min at 130 °C and 1 h at 110 °C
Number of DUTs 6
If there is a coolant circuit, the temperature of the stationary coolant must be defined
at TRT.
14.4.3 Requirement
The DUT must be fully functional before and after the test, and all parameters must
meet the specifications. Verification takes place by means of a parameter test (small)
as per section 10.4.
Page 91 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
14.5.2 Test
The test is carried out as per DIN EN 60068-2-14 with the following parameters:
14.5.3 Requirement
The DUT must be fully functional before and after the test, and all parameters must
meet the specifications. Verification takes place by means of a parameter test (large)
as per section 10.4.
Page 92 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
14.6.2 Test
The test is carried out as per DIN EN 60068-2-11 with the following parameters:
Table 69: Test parameters, K-06 Salt spray test with operation, exterior
DUT operating During the spray phase: 1 h of operating mode II.a and 1 h of
mode operating mode II.c intermittently
When performing the test, the as-installed position of the component in the vehicle
must be simulated.
If there is a coolant circuit, the coolant temperature must be set to the test
temperature.
Page 93 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
Figure 33: Salt spray test with operation, exterior – spray phases
14.6.3 Requirement
The DUT must be fully functional before, during and after the test, and all parameters
must meet the specifications. Verification takes place by means of continuous
parameter monitoring and a parameter test (small) as per section 10.4.
Page 94 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
14.7.2 Test
The test is carried out as per DIN EN 60068-2-11 Ka with the following parameters:
Table 70: Test parameters, K-07 Salt spray test with operation, interior
DUT operating mode During the spray phase: 55 min of operating mode II.a
and 5 min of operating mode II.c intermittently
When performing the test, the as-installed position of the component in the vehicle
must be simulated. The test setup (as-installed position, covers, trims, situation
during operation) must be recommended by the contractor, coordinated with the
purchaser and documented.
If there is a coolant circuit, the coolant temperature must be set to the test
temperature.
Page 95 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
Figure 34: Salt spray test with operation, interior – spray phases
14.7.3 Requirement
The DUT must be fully functional before, during and after the test, and all parameters
must meet the specifications. Verification takes place by means of continuous
parameter monitoring and a parameter test (small) as per section 10.4.
Page 96 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
14.8.2 Test
The test is carried out as per DIN EN 60068-2-30 with the following parameters:
If there is a coolant circuit, the coolant temperature must track the respective test
temperature to the limits Tcool,min and Tcool,max. Only the ambient temperature is varied
outside of the coolant temperature limits.
14.8.3 Requirement
The DUT must be fully functional before, during and after the test, and all parameters
must meet the specifications. Verification takes place by means of continuous
parameter monitoring and a parameter test (small) as per section 10.4.
In addition, a parameter test (functional test) must be carried out after the upper and
the lower test temperature have been reached.
Page 97 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
14.9.2 Test
The test is carried out as per DIN EN 60068-2-38 with the following parameters:
Table 72: Test parameters, K-09 Damp heat, cyclic (with frost)
DUT operating mode Intermitting 40 min operating mode II.a and 10 min.
operating mode II.c each
If there is a coolant circuit, the coolant temperature must track the respective test
temperature to the limits Tcool,min and Tcool,max. Only the ambient temperature is varied
outside of the coolant temperature limits.
14.9.3 Requirement
The DUT must be fully functional before, during and after the test, and all parameters
must meet the specifications. Verification takes place by means of continuous
parameter monitoring and a parameter test (small) as per section 10.4.
Page 98 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
14.10.2 Test
The test is carried out as per ISO 20653 with the following parameters:
Table 73: Test parameters, K-10 Water protection - IPX0 to IPX6K
DUT Intermitting 1 min operating mode II.a and 1 min operating mode II.c
operating each
mode
If several operating situations (see section 10) are relevant to the
component in operating mode II.c, the component must be operated
in all operating situations relevant to operating mode II.c with equal
time proportions in the time intervals in which operating mode II.c is
required in the test.
Required As specified in the Component Performance Specification
degree of
protection
Number of 6
DUTs
14.10.3 Requirement
The degree of protection specified in the Component Performance Specifications as
per ISO 20653 must be achieved.
The ingress of water is not permissible. The DUT must not be opened until after
completion of the complete test sequence.
The DUT must be fully functional before, during and after the test, and all parameters
must meet the specifications. Verification takes place by means of continuous
parameter monitoring and a parameter test (small) as per section 10.4.
Page 99 of 161
Version 2.2 LV 124 Creation date 2013-02-28
VW 80000: 2013-06
14.11.2 Test
The test is carried out as per ISO 20653 with the following parameters:
Table 74: Test parameters,
DUT operating mode Operating mode II.a
Required degree of IPX9K
protection
Water pressure The minimum pressure of the pressure washer is 10 000 kPa
(100 bar), measured directly at the nozzle.
Water temperature 80 °C
Procedure The DUT must be subjected to the water jet from any freely
accessible spatial direction of the vehicle.
Number of DUTs 6
14.11.3 Requirement
The degree of protection IP X9K as per ISO 20653 must be achieved.
The ingress of water is not permissible. The DUT must not be opened until after
completion of the complete test sequence (chapter12.2).
The DUT must be fully functional before, during and after the test, and all parameters
must meet the specifications. Verification takes place by means of continuous
parameter monitoring and a parameter test (small) as per section 10.4.
14.12.2 Test
Table 75: Test parameters, K-12 Temperature shock with splash water
DUT operating mode If the component is not operated with operating load during
driving operation:
II.a during the entire test
When performing the test, the as-installed position of the component in the vehicle
must be simulated.
The test setup (as-installed position, covers, trims, situation during operation) must
be recommended by the contractor, coordinated with the purchaser and documented.
If there is a coolant circuit, the coolant temperature must track the respective test
temperature up to the limit Tcool,max. Only the ambient temperature is varied above the
coolant temperature limit.
Dimensions (mm)
14.12.3 Requirement
The ingress of water is not permissible. The DUT must not be opened until after
completion of the complete test sequence.
The DUT must be fully functional before, during and after the test, and all parameters
must meet the specifications. Verification takes place by means of continuous
parameter monitoring and a parameter test (small) as per section 10.4.
14.13.2 Test
The test is carried out as per ISO 20653 with the following parameters:
If there is a coolant circuit, the coolant temperature must track the respective test
temperature up to the limit Tcool,max. Only the ambient temperature is varied above the
coolant temperature limit.
14.13.3 Requirement
The ingress of water is not permissible. The DUT must not be opened until after
completion of the complete test sequence (chapter12.2).
The DUT must be fully functional before, during and after the test, and all parameters
must meet the specifications. Verification takes place by means of continuous
parameter monitoring and a parameter test (small) as per section 10.4.
14.14.1.2 Test
The test is carried out as per DIN EN 60068-2-78 with the following parameters:
14.14.1.3 Requirement
The DUT must be fully functional before, during and after the test, and all parameters
must meet the specifications. Verification takes place by means of continuous
parameter monitoring and a parameter test (small) as per section 10.4.
In addition, a parameter test (functional test) must be carried out every 7 days.
14.14.2.1 Aim
This test simulates in compact form the load of the component through damp heat
during vehicle service life.
The test serves to verify the quality and reliability of the component with respect to
faults caused by damp heat, e.g. corrosion, migration/dendrites, swelling and
degradation of plastics, sealing and filling compounds.
14.14.2.2 Test
The test is carried out as per DIN EN 60068-2-78 with the following parameters:
If there is a coolant circuit, the coolant temperature must track the respective test
temperature up to the limit Tcool,max. Only the ambient temperature is varied above the
coolant temperature limit.
Before this life test is performed, it must be tested whether the test parameters 65 °C
and 93% relative humidity exceed the physical limits of the materials used (e.g.
hydrolysis of plastics) during the compact form of the test. If required, contractor and
purchaser must agree upon the adaptation of the test temperature and test humidity
while increasing the test duration as per the Lawson model (e.g., to 55 °C and 93%
relative humidity) so that the physical limits of the materials used are not exceeded
during the test. However, the test severity must be maintained. The test humidity
must not exceed a value of 93% relative humidity.
It must be ensured that no condensation takes place on the DUT during the test (also
no local condensation).
Table 79: Test parameters, K-14 Damp heat, constant, for components with reduced
performance at high temperatures
DUT operating
Intermitting operation as per Figure 38
mode
As specified in the Component Performance Specification as per
section E.1 (Lawson model).
Test duration
The respective ramp times between 65 °C and Top, max are not
included in the test duration.
As per Figure 38
Test temperature The temperature gradient must be selected so that no
condensation occurs on the DUT.
Test humidity 93% relative humidity
Interval time t1 47 h
Interval time t2 1h
Number of DUTs 6
If there is a coolant circuit, the coolant temperature must track the respective test
temperature up to the limit Tcool,max. Only the ambient temperature is varied above the
coolant temperature limit.
t1
65°C
Top,max
t2
Figure 38: Temperature profile for testing components with reduced performance at high
temperatures above Top,max
14.15.1.2 Test
The test is performed with assemblies without a housing with the following
parameters:
°C
%
100
90
1)
80
70
60
50
40
30 2)
20
∫
3)
10
0
30 30 30 150 30 30 75 15 Time (t) in
min
Condensation phase **) Drying phase
1 cycle
**) Recording of test chamber humidity and temperature, temperature difference < 15 °C
14.15.1.3 Requirement
The DUT must be fully functional before, during and after the test, and all parameters
must meet the specifications. Verification takes place by means of continuous
parameter monitoring and a parameter test (small) as per section 10.4.
In addition, the electr. assembly must be examined with respect to electrochemical
migration (e.g. traces of silver or tin migration) and dendrite increase.
The creation of electrochemical migration/dendrite increase is not permissible.
Other changes of the electr. assembly (e.g. corrosion, contamination) must be
documented in the test report and evaluated with the purchaser.
The following documents must be attached to the test report:
14.15.2.1 Aim
This test simulates in compact form the load on the component due to damp heat
during the vehicle service life, taking into account the protective effect of watertight
housings.
The test is used to verify the quality and reliability of the component with respect to
faults caused by damp heat, e.g., corrosion, migration/dendrites, and swelling and
degradation of plastics, sealing compounds, and filling compounds.
14.15.2.2 Test
The must be performed with complete components (device, electronic control unit,
mechatronics, etc. with housing).
The test must be performed as a sequence of five test blocks as per Figure 42:
Figure 42: Sequence, K-15 b Climate test for components with watertight housings
Table 81: Test parameters, K-15 b Climate test for components with watertight housings
Test blocks 1, 3, and 5
DUT operating Operating mode II.a
mode 12 hours after the start of the test block and subsequently after
every 24 hours, a parameter test (functional test) must be
performed.
If there is a coolant circuit, the coolant temperature must track the respective test
temperature up to the limit Tcool,max. Only the ambient temperature is varied above the
coolant temperature limit.
Table 82: Test parameters, K-15 b Climate test for components with watertight housings
Test blocks 2 and 4
DUT operating Operating mode II.a
mode 12 hours after the start of the test block and subsequently after
every 24 hours, a parameter test must be performed for
environmental tests (functional test).
Test duration 240 h
per test block
Number of 10
cycles
Test cycle The first five cycles must include a cold phase and the remaining
sequence cycles must be carried out without a cold phase.
Number of 6
DUTs
If there is a coolant circuit, the coolant temperature must track the respective test
temperature to the limits Tcool,min and Tcool,max. Only the ambient temperature is varied
outside of the coolant temperature limits.
The test is to be performed exclusively with the electr. assembly of the component
without housing and mechanical parts.
14.16.2 Test
The test is carried out as per DIN EN 60068-2-14 with the following parameters:
14.16.3 Requirement
The DUT must be fully functional before and after the test, and all parameters must
meet the specifications. Verification takes place by means of a parameter test (large)
as per section 10.4.
14.17.2 Test
The test is carried out as per DIN 75220 with the following parameters:
14.17.3 Requirement
The DUT must be fully functional before and after the test, and all parameters must
meet the specifications. Verification takes place by means of a parameter test (large)
as per section 10.4.
In addition, the DUT must be evaluated visually with the naked eye.
Changes or damage must be documented in the test report and evaluated with the
purchaser.
14.18.2 Test
The test is carried out as per DIN EN 60068-2-60, method 4, with the following
parameters:
Table 85: Test parameters, K-18 Harmful gas test
DUT operating mode Operating mode I.b
Temperature TRT
Humidity 75% relative humidity
Harmful gas concentration SO2 0,2 ppm
H2S 0,01 ppm
NO2 0,2 ppm
Cl2 0,01 ppm
Test duration 21 days
Number of DUTs 6
14.18.3 Requirement
The DUT must be fully functional before and after the test, and all parameters must
meet the specifications. Verification takes place by means of a parameter test (large)
as per section 10.4.
In addition, the contact resistances of switches and contacts must be measured. The
measured values must meet the specifications.
15.1.2 Test
Table 86: Test parameters, chemical tests
DUT operating mode As specified in the Component Performance
Specification
Chemicals As specified in the Component Performance
Specification
Typical chemicals for different installation locations
are indicated in Table 87.
Conditioning Unless otherwise specified, the DUTs and the
chemicals must be aged in standard climate.
Test procedure The test is performed on the basis of
ISO 16750, part 5:
1. The chemical must be applied to the DUT at
TRT. Unless otherwise defined in the
Component Performance Specification, an
appropriate type of application must be
selected for each chemical as per Table 88.
The selected type of application must be
documented in the test report. It must be
ensured that the DUT is sufficiently covered
with the chemical.
2. The DUT must then be aged at the
temperature indicated in Table 87 for the
specified exposure time.
Number of DUTs 1 DUT per chemical
Multiuse of a DUT for several chemicals is permitted
in coordination with the purchaser
15.1.2.1 Chemicals
Table 87: Overview of chemicals (see also ISO 16750-5)
ID Chemical agent
DUT temperature
Exposure time
Description/
reference
1 Diesel Tmax 22 h EN 590
2 FAME Tmax 22 h EN 14214
3 Gasoline, unleaded TRT 10 min EN 228
4 Kerosine TRT 10 min ASTM 1655
5 Methanol TRT 10 min CAS 67-56-1
6 Engine oil Tmax 22 h Multigrade oil SAE 0W40, API SL/CF
7 Differential oil Tmax 22 h Hypoid gear oil SAE 75W140, API GL-5
8 Gearbox oil Tmax 22 h ATF Dexron III
9 Hydraulic fluid Tmax 22 h DIN 51 524-3 (HVLP ISO VG 46)
10 Grease Tmax 22 h DIN 51 502 (KP2K-30)
11 Silicone oil Tmax 22 h CAS 63148-58-3 (AP 100)
12 Battery acid TRT 22 h 37% H2SO4
13 Brake fluid Tmax 22 h ISO 4926
14 Antifreeze agent Tmax 22 h Ethylene glycol (C2H6O2) - water (mixture ratio 1:1)
15 Urea Tmax 22 h ISO 22241-1
16 Cavity sealing medium TRT 22 h e.g., undercoating, by Teroson 1
17 Preservative TRT 22 h e.g., W550 (by Pfinder) 1
18 Preservative remover Tmax 22 h e.g., Friapol 750 (by Pfinder) 1
19 Windshield cleaner TRT 2h 5% anionic tensides, distilled water
20 Automotive washing chemicals TRT 2h CAS 25155-30-0
CAS 9004-82-4
21 Interior cleaner/cockpit spray TRT 2h e.g., Cockpit-spray (by Motip) 1
22 Glass cleaner TRT 2h CAS 111-76-2
23 Rim cleaner TRT 2h e.g. Xtreme (Sonax) 1
24 Cold-cleaning agent TRT 22 h e.g., P3-Solvclean AK (by Henkel) 1
25 Acetone TRT 10 min CAS 67-64-1
26 Cleaner's naphtha TRT 10 min DIN 51635
27 Cleaner containing ammonia TRT 22 h e.g., Ajax (by Henkel) 1
28 Methylated spirits TRT 10 min CAS 64-17-5 (ethanol)
29 Contact spray Tmax 22 h e.g. WD 40 1
30 Sweat TRT 22 h DIN 53 160
31 Cosmetic products, e.g. creams TRT 22 h e.g. Nivea, Kenzo 1
32 Refreshment containing caffeine and sugar TRT 22 h Cola
33 De-icer (aviation) TRT 2h SAE AMS 1435A
34 E85 fuel TRT 10 min DIN 51625
Other chemicals
1
) Sample manufacturer, exact chemicals must be coordinated with the responsible department
15.1.3 Requirement
The DUT must be fully functional before and after the test, and all parameters must
meet the specifications. Verification takes place by means of a parameter test (large)
as per section 10.4.
16 Service-life tests
16.1 L-01 Life test - mechanical/hydraulic endurance test
16.1.1 Aim
This test simulates the functioning/actuation cycles of the component during vehicle
service life.
The test serves to verify the quality and reliability of the component with respect to
functioning/actuation cycles, e.g. brake actuation, seat adjustment cycles, switch/tip
switch actuation.
16.1.2 Test
Test details must be defined in the Component Performance Specification as per the
functioning/actuation cycle.
Table 89: Test parameters, L-01 Life test - mechanical/hydraulic endurance test
DUT operating mode Operating mode II.c as per functioning/actuation cycle
Test temperature The functioning/actuation cycles must be performed at the
temperatures indicated in the temperature spectrum, the
duration depending on its percentage.
Number of
functional/actuation As specified in the Component Performance Specification
cycles
Number of DUTs 6
If there is a coolant circuit, the coolant temperature must track the respective test
temperature to the limits Tcool,min and Tcool,max. Only the ambient temperature is varied
outside of the coolant temperature limits.
16.1.3 Requirement
The DUT must be fully functional before, during and after the test, and all key
parameters must meet the specifications. This must be verified by means of
continuous parameter monitoring. Intermediate measurements at 25%, 50%, and
75% of the test duration and parameter tests as per the test sequence plan must only
be carried out if the functioning of the component cannot be sufficiently monitored
during the test.
The data of the continuous parameter monitoring must be examined with respect to
drifts, trends and irregularities.
16.2.2 Test
The test is carried out as per DIN EN 60068-2-2 with the following parameters:
t2
Tmax
Top,max
t1
1 hr 1 hr 1 hr
Figure 43: Temperature profile for testing components with reduced performance at high
temperatures
16.2.3 Requirement
The DUT must be fully functional before, during and after the test, and all key
parameters must meet the specifications. This must be verified by means of
continuous parameter monitoring. Intermediate measurements at 25%, 50%, and
75% of the test duration and parameter tests as per the test sequence plan must only
be carried out if the functioning of the component cannot be sufficiently monitored
during the test.
The data of the continuous parameter monitoring must be examined with respect to
drifts, trends and irregularities.
16.3.2 Test
The test is carried out as per DIN EN 60068-2-14 with the following parameters:
Table 93: Test parameters, L-03 Life test - temperature cycle test – Test for components
without a connection to the coolant circuit without reduced performance at low or high
temperatures
DUT operating Intermitting operating mode II.c and operating mode II.a as per
mode Figure 44.
Temperature
As per Figure 44
profile
Minimum test
Tmin
temperature
Maximum test
Tmax
temperature
4 °C/min
Temperature If the temperature gradient cannot be produced by the testing
gradient device, it can be reduced to values up to a minimum of 2 °C/min in
coordination with the purchaser.
Holding time at 15 min after the component has achieved the condition at which it
Tmin and Tmax maintains the temperature (see section 0)
The total number of test cycles must be calculated while taking into
Number of account all relevant operating situations (section 10.1) as per
cycles appendix D.1 (Coffin-Manson model) and specified in the
Component Performance Specification.
Number of
6
DUTs
Tmax
TRT
Tmin
5 min
Time
Operating mode Operating mode Operating mode
II.a II.c II.a
Figure 44: Temperature profile, L-03 Life test - temperature cycle test, for components
without reduced performance at low or high temperatures
Table 94: Test parameters, L-03 Life test - temperature cycle test – Test for components
without a connection to the coolant circuit with reduced performance at low or high
temperatures
DUT operating
Operating mode II.a and operating mode II.c as per Figure 45.
mode
Temperature profile As per Figure 45
Minimum test
Tmin
temperature
Maximum test
Tmax
temperature
Temperature
4 °C/min
gradient
Holding times at 15 min after the component has achieved the condition at
Tmin, Tmax, Top,min and which it maintains the temperature
Top,max (see section 0)
The total number of test cycles must be calculated while
taking into account all relevant operating situations
Number of cycles
(section 10.1) as per appendix D.1 (Coffin-Manson model) and
specified in the Component Performance Specification.
Number of DUTs 6
Figure 45: Temperature profile – test for components with reduced performance at low or
high temperatures
Table 95: Test parameters, L-03 Life test - temperature cycle test – Test for components on
the coolant circuit
DUT operating Operating mode II.a and operating mode II.c as per Figure 44 or
mode Figure 45
Temperature
As per Figure 44 or Figure 45
profile
Minimum test
Tmin and Tcool,min
temperature
Maximum test
Tmax and Tcool,max
temperature
Temperature
4 °C/min
gradient
Holding times at 15 min after the component has achieved the condition at which
Tmin, Tmax, Top,min it maintains the temperature
and Top,max (see section 0)
The total number of test cycles must be calculated while taking
into account all relevant operating situations (section 10.1) as
Number of cycles per appendix D.3 (Coffin-Manson model for use with
components on coolant circuits) and specified in the Component
Performance Specification.
Number of DUTs 6
16.3.3 Requirement
The DUT must be fully functional before, during and after the test, and all key
parameters must meet the specifications. This must be verified by means of
continuous parameter monitoring. Intermediate measurements at 25%, 50%, and
75% of the test duration and parameter tests as per the test sequence plan must only
be carried out if the functioning of the component cannot be sufficiently monitored
during the test.
The data of the continuous parameter monitoring must be examined with respect to
drifts, trends and irregularities.
Appendix A (normative)
Test sequence
A.1 Test sequence plan
The tests that are not required for a component as per the test selection table must
be deleted from the test sequence plan.
If the test "Damp heat, cyclic (with frost)" is carried out instead of the test "Damp
heat, cyclic" in the sequence test, the test "Damp heat, cyclic (with frost)" can be
omitted in the parallel tests.
All components must be tested with the original connector or adapter starting with the
test M-01 Free fall.
If the test "Damp heat, cyclic (with frost)" is carried out instead of the test "Damp
heat, cyclic" in the sequence test, the test "Damp heat, cyclic (with frost)" can be
omitted in the parallel tests.
All components must be tested with the original connector or adapter starting with the
test M-01 Free fall.
Appendix B (normative)
Table 96: Overview of installation locations, typical spectrums, and temperature rises
Installation location of the component Spectrum no. Temperature rise in K
Interior, without special requirement 1 36
Hang-on part, without special requirements 1 36
Interior exposed to sun radiation 2 46
Hang-on part, roof 2 46
Engine compartment, but not on the engine 3 60
On the radiator 3 60
Engine-mounted parts 4 75
Gearbox-mounted parts 4 75
Appendix C (normative)
For each temperature TFeld,1 … TFeld,n, an acceleration factor AT,1 … AT,n is calculated
on the basis of the following equation:
EA ⋅ 1 −
1
−
T
k Test + 273,15 T + 273,15
A T,i = e
Field,i
(1)
Where:
AT,i Acceleration factor of the Arrhenius model
EA Activation energy EA = 0,45 eV
k Boltzmann constant (k = 8,617 x 10-5 eV/K)
TTest Test temperature (°C), generally Tmax
TFeld,i Field temperature (°C) according to the temperature spectrum as per
use profile
- Absolute zero of the temperature
273,15 °C
The total test duration for the high-temperature endurance test results from the
acceleration factor as per
pi
t test = t oper. ⋅ ∑ (2)
i A T,i
Where:
ttest Test duration (hours) of the high-temperature endurance test life test
toper Operating time (hours) in the field
pi Percentage of the operating time for which the component is operated at the
temperature TFeld,i in the field
AT,i Acceleration factor for temperature TFeld,i
and an operating time of 8 000 h, the test duration for the high-temperature
endurance test is calculated as follows:
The acceleration factors AT,i for all five temperatures (see Table 102) of the
temperature spectrum indicated above are calculated by means of equation (1) and
TTest = Tmax = 105 °C.
AT,1 = 5 369
AT,2 = 45,8
AT,3 = 6,46
AT.4 = 1,20
AT,5 = 1,00
The total test duration of the "high-temperature endurance test" life test results from
equation (2) as:
C.3 Arrhenius model for the use for components with reduced performance at
high temperatures
To calculate the test duration for the high-temperature endurance test life test for
components with reduced performance at high temperatures starting with Top,max, the
temperature spectrum as per the use profile in the Component Performance
Specification is divided into the two temperature ranges T ≤ Top,max and T>Top,max.
Table 103: Temperature spectrum for T ≤ Top,max with test temperature Top,max
Temperature (°C) Distribution (%)
TField.1 p1
TField.2 p2
… … m<n
TField.m (≤ Top,max) pm
Table 104: Temperature spectrum for Top,max < T ≤ Tmax with test temperature Tmax
Temperature (°C) Distribution (%)
TField.m+1(> Top,max) pm+1
TField.m+2 pm+2
… … m<n
TField.n pn
For each temperature TFeld,1 … TFeld,m … TFeld,n, an acceleration factor AT,1 … AT,m …
AT,n is calculated by means of equation (12), where for temperature range T ≤ Top,max
a test temperature of TTest = Top, max and for temperature range T > Top,max a test
temperature of TTest = Tmax is assumed.
The required test duration top, max for test temperature Top, max results from the
equation (2) with i = 1 ...m.
The required test duration tmax for test temperature Tmax results from the equation (2)
with i=m+1 …n.
The total test duration tGes is the sum of top, max and tmax.
To ensure a test similar to the real conditions, the test is carried out intermittently at
the test temperatures Top,max and Tmax (see Figure 43).
The typical interval of 48 h is divided at the ratio of the part test durations top, max and
tmax.
C.4 Example of Arrhenius model for use with components with reduced
performance at high temperatures:
The temperature spectrum as per Table 105 and Table 106 applies to the electronic
control unit. For an operating time of 8 000 h, the test duration for the "high-
temperature endurance test" life test for components with reduced performance
above Top,max = 90 °C is calculated as follows:
The proportionate temperature distribution as per the use profile is divided into the
ranges T ≤ Top,max and T > Top,max.
By means of equation (1) and TTest = 90 °C, the acceleration factors AT,i for all
temperatures T ≤90 °C (see Table 105) of the first part of the temperature spectrum
are calculated:
AT,1 = 3060,78
AT,2 = 25,95
AT,3 = 3,65
By means of equation (1) and TTest = 105 °C, the acceleration factors AT,i for all
temperatures T >90 °C (see Table 106) of the second part of the temperature
spectrum are calculated:
AT.4 = 1,20
AT,5 = 1,00
0,08 0,01
t max (TTest = 105°C) = 8 000 hours ⋅ + = 612 hours
1,20 1,00
The total test duration for the "high-temperature endurance test" life test is the sum of
the two test durations:
t Ges = t op, max + t max = 1 485 hours + 612 hours = 2 097 hours
The test is performed as per Figure 43 intermittently at the test temperatures Top,max
and Tmax with the intervals
For components with a connection to the coolant circuit, all pertinent operating
situations i (see Figure 22; i corresponds to the consecutive number of the operating
situations) and the associated temperature distributions for the environment and the
coolant circuit must be taken into account.
For the "high-temperature endurance test" life test, the test durations and test
temperatures for the environment and the coolant circuit must be calculated for each
relevant operating situation i as described below; the total test duration is the sum of
the test durations for each relevant operating situation i.
For each relevant operating situation i, the test duration for the ambient temperature
and the coolant circuit must first be calculated separately according to the Arrhenius
model as per appendix C.1 or C.3 in order to calculate the test duration for operating
situation i.
Because the resulting test durations ttest,environment and ttest,CC (CC = coolant circuit)
generally differ but the component can only be tested for the respective operating
situation i with a uniform test duration, the test durations must be aligned between the
ambient temperature and the coolant circuit.
The shorter of the two test durations ttest, environment and ttest, CC must be adapted to the
longer test duration as per the following iteration method by dividing the test into at
least two partial tests and reducing the test temperatures for all but one partial test.
Test duration:
For ttest,environment < ttest,CC, the test duration for operating situation i is
ttest, situation i = ttest, CC.
3. Additional iterations (m = 2, 3, …)
A part of the test duration for operating situation i ttest,situation i is covered by the
first m partial tests, so a remaining test duration still to be covered by the
additional partial tests results from
m −1
t Re maining , m = tTest , Mode i − ∑ tTest , TField , n−k
k =0
In addition, the portions pn-k with
k = 0, 1, …, (m-1) of the temperature distribution of the ambient temperature
are covered by the first m partial tests. Therefore, these portions pn-k must be
set to
pn-k = 0 for the further calculation.
To specify the test temperature for the (m+1)th partial test, the test
temperature Tadapted must first be determined using the Arrhenius model as per
C.1 or C.3 in such a way that a test duration with the magnitude of the
remaining test duration tremaining, m results for the distribution (adapted with pn-k
= 0) of the ambient temperature.
Test duration:
For ttest, environment > ttest, CC, the test duration for operating situation i is
ttest, situation i = ttest, environment.
3. Additional iterations (m = 2, 3, …)
A part of the test duration for operating situation i ttest,situation i is covered by the
first m partial tests, so a remaining test duration still to be covered by the
additional partial tests results from
m −1
t Re. ,m
= t Test, Mode i − ∑ t Test, TField, n−k
k =0
C.6 Example of Arrhenius model for use with components on coolant circuits
For an electronic control unit connected to the coolant circuit, with the temperature
spectrum specified in the following tables for the ambient temperature and the
coolant temperature
Table 109: Sample spectrum for ambient temperature
Temperature (°C) Distribution (%)
-40 6
23 20
50 65
100 8
105 1
and an operating time of 8 000 h, the test duration for the high-temperature
endurance test is calculated as follows:
Test duration:
Calculation of the test durations for ambient temperature and coolant temperature
with the Arrhenius model:
ttest, environment = 1 143 h
ttest, CC = 2 009 h
Because ttest, environment is less than ttest, CC, the calculation is performed as per case A
described in appendix C.5. The test duration for the ambient temperature must be
adapted to ttest,situation i = ttest,CC = 2 009 h.
2. First iteration:
A part of the test duration for operating situation i ttest,situation i was already
covered by the first partial test. Therefore, the remaining test duration
must be recalculated: tremaining, 1 = ttest, situation i – ttest, T_Field, 5 = 2 009 h –
80 h = 1 929 h.
Table 111: Adapted temperature spectrum for environment after first partial test
Temperature (°C) Distribution (%)
-40 6
23 20
50 65
100 8
105 0
Second iteration
An additional part of the test duration for operating situation i ttest, situation i
was covered by the 2nd partial test, so the remaining test duration is
given by:
tremaining, 2 = ttest, situation i – (ttest, T_Field, 5 + ttest, T_Field, 4) = 2 009 h - 80 h -
640 h= 1 289 h.
The portions p5 and p4 of the temperature spectrum for the environment
were already covered by the first two partial tests. Therefore, the
portions must be set to p4 = p5 = 0 for the further iteration, as per the
following table.
Table 112: Adapted temperature spectrum for environment after 1st and 2nd partial test
Temperature (°C) Distribution (%)
-40 6
23 20
50 65
100 0
105 0
In total, testing must be performed for 80 h at 105 °C ambient temperature, for 640 h
at 100 °C ambient temperature, and for 1 289 h at 82 °C ambient temperature.
In this example, the coolant temperature is constant at 80 °C during the entire test
duration.
Appendix D (normative)
Depending on the average temperature change in the field, the acceleration factor of
the Coffin-Manson model is calculated as follows:
c
ΔTTest
A CM = (3)
ΔTField
Where:
ACM Acceleration factor of the Coffin-Manson model
∆TTest Temperature difference during a test cycle (∆TTest = Tmax - Tmin)
∆TFeld Average temperature difference during service life in the field
c Parameter of the Coffin-Manson model
In this standard a fixed value of 2,5 is used for c.
N TempCyclesField
N Test = (4)
A CM
Where:
NTest Required number of test cycles
NTempCyclesField Number of temperature cycles during service life in the field
ACM Acceleration factor of the Coffin-Manson model as per equation (3)
D.2 Example:
The number of test cycles (NTest) is calculated for an electronic control unit with Tmin = -
40 °C and Tmax = 105 °C, a service life of 15 years in the field and an average
temperature difference in the field of ∆TField = 40 °C as described below:
5. The holding time is the time until the component achieves the condition at which
it maintains the temperature plus 15 min. Assuming that the component
maintains the temperature after 20 min, we have a holding time of 35 min.
7. In the example:
8. For 438 cycles the total test duration is therefore 1 040 h.
For components with a connection to the coolant circuit, all relevant operating situations
i (see Figure 22; i corresponds to the consecutive number of the operating situations)
and the associated temperature rises for the environment and the coolant circuit must
be taken into account.
For the "temperature cycle test" life test, the key temperatures and the number of test
cycles must be calculated for each relevant operating situation i, as described below;
the total number of test cycles results from the sum of the partial numbers of test cycles
for each relevant operating situation i.
For each relevant operating situation i, the numbers of test cycles for the ambient
temperature and the coolant circuit must first be calculated separately according to the
Coffin-Manson model as per appendix C.7 in order to calculate the number of test
cycles for operating situation i.
Because the resulting numbers of test cycles Ntest, environment and Ntest, CC (CC = coolant
circuit) generally differ but the component can only be tested for the respective
operating situation i with a uniform number of test cycles, the numbers of test cycles
must be aligned between the ambient temperature and the coolant circuit.
The shorter of the two numbers of test cycles Ntest, environment and Ntest, CC must be
adapted to the longer number of test cycles as per the following calculation by dividing
the test into three partial tests. One partial test is performed with a full temperature rise
between Tmin and Tmax; the other two partial tests are performed with a reduced
temperature rise between Tmin and TRT or between TRT and Tmax.
The number of test cycles for the coolant Ntest, CC must be adapted to the larger number
of test cycles for the environment Ntest, environment. The test cycles must be performed in
the following three temperature ranges:
1. xCC test cycles must be performed between TCC, min and TCC, max.
The acceleration factor ACM, CC, 1 is calculated as per the Coffin-Manson model
with ∆TTest, 1 = TCC, max - TCC, min
2. ½ * (Ntest, situation i - xCC) test cycles must be performed between TCC, min and TRT.
The acceleration factor ACM, CC, 2 is calculated as per the Coffin-Manson model
with ∆TTest, 2 = TRT - TCC, min.
3. ½ * (Ntest,situation i - xCC) test cycles must be performed between TRT and TCC, max.
The acceleration factor ACM, CC, 3 is calculated as per the Coffin-Manson model
with ∆TTest, 3 = TCC, max – TRT.
The numbers of test cycles for the three partial tests are obtained by inserting xCC into
points 1. to 3. listed above.
If TCC, op, max < TC, max or TCC, op, min > TCC, min or Tenvironment, op, max < Tenvironment, max or
Tenvironment, op, min > Tenvironment, min, additional holding times at the corresponding
temperatures as per Figure 45 in section 16.3.2.1 must be taken into account.
The temperature cycles for the ambient temperature and for the coolant circuit proceed
synchronously during a test.
The number of test cycles for the environment Ntest, environment must be adapted to the
larger number of test cycles for the coolant Ntest, CC. The test cycles must be performed
in the following three temperature ranges:
1. xenvironment test cycles must be performed between Tenvironment, min and Tenvironment,
max. The acceleration factor ACM, environment, 1 is calculated as per the Coffin-
Manson model, with ∆TTest, 1 = Tenvironment, max – Tenvironment, min.
2. ½ * (Ntest,situation i – xenvironment) test cycles must be performed between Tenvironment,
min and TRT. The acceleration factor ACM, environment, 2 is calculated as per the
Coffin-Manson model, with ∆TTest, 2 = TRT – Tenvironment, min.
3. ½ * (Ntest,situation i – xenvironment) test cycles must be performed between TRT and
Tenvironment, max. The acceleration factor ACM, environment, 3 is calculated as per the
Coffin-Manson model, with ∆TTest, 3 = Tenvironment, max – TRT.
The numbers of test cycles for the three partial tests are obtained by inserting xenvironment
into points 1. to 3. listed above.
If Tenvironment, op, max < Tenvironment, max or Tenvironment, op,min > Tenvironment, min or TCC, op, max < TCC,
max or TCC, op,min > TCC, min, additional holding times at the corresponding temperatures as
per figure 45 in section 16.3.2.1 must be taken into account.
The temperature cycles for the ambient temperature and for the coolant circuit proceed
synchronously during a test.
For an electronic control unit connected to the coolant circuit, with the ambient
temperature range Tenvironment, min = -40 °C to Tenvironment, max = 120 °C and the coolant
temperature range TCC, min = -40 °C to TCC, max = 80 °C, a service life in the field of
15 years, an average temperature difference of the environment in the field of ∆Tfield,
environment = 60 K, and an average temperature difference of the coolant in the field of
∆Tfield, CC = 36 K, the number of test cycles for an operating situation i is calculated as
follows:
Because Ntest, environment > Ntest, CC, the number of test cycles for operating situation i
Ntest, situation i = Ntest, environment = 943 cycles. The number of test cycles for the coolant must
be adapted.
Therefore, the following numbers of test cycles calculated as per points 1. to 3. result for
the three temperature ranges:
1. Between TCC, min = -40 °C and TCC, max = 80 °C, 453 cycles must be performed.
2. Between TCC, min = -40 °C and TRT = 23 °C, 245 cycles must be performed.
3. Between TRT = 23 °C and TCC, max = 80 °C, 245 cycles must be performed.
Adding the partial test cycles results again in the total number of test cycles for
operating situation i Ntest, situation i = 943 cycles.
The temperature cycles for the ambient temperature and for the coolant circuit proceed
synchronously during a test.
Appendix E (normative)
Table 113: Average ambient humidity and temperature in the parked vehicle
Installation location Average ambient humidity in Average temperature in
the parked vehicle the parked vehicle
RHFieldParked TFieldParked
In the passenger
60% relative humidity 23 °C
compartment/trunk
Outside the passenger
65% relative humidity 23 °C
compartment/trunk
Depending on the average ambient humidity and temperature in the field, the
acceleration factor of the Lawson model is calculated as follows:
E A 1 1 2
+ b⋅ RH Prüf − RH FieldParked
2
− ⋅ −
T
k Test + 273,15 T + 273,15
A T/RH = e FieldParked
(5)
ini
Where:
AT/RH Acceleration factor of the Lawson model
b Constant (b = 5,57 x 10-4)
EA Activation energy (EA = 0,4 eV)
k Boltzmann constant (k = 8,617 x 10-5 eV/K)
TTest Test temperature in °C
TFieldParked Average temperature (°C) in the parked vehicle
RHTest Relative humidity (%) during the test
RHFieldParked Average relative humidity (%) in the parked vehicle
-273,15 °C Absolute zero of the temperature
The test duration for the constant damp heat test - severity 2 - is calculated by means
of:
t FieldParked
t Test = (6)
A T/RH
E.2 Example:
For an electronic control unit installed in the engine compartment, the test duration is
calculated as follows:
Appendix F (informative)
During the temperature increase, the temperature of the water bath is used as control
variable. When 80 °C are reached, the climatic chamber is switched over to temperature
control (standard operation).
Appendix G (informative)