MBN 10305-1 2008-06

Mercedes-Benz MBN 10 305-1
Engineering Standard Date Published: 2008-06-27

Category: 22 Total No. of Pages (Including Annex): 38
Person in Charge: Dr. Getto
Plant 96; Dept.: GR/EEH
Phone: +49-(0)7031/4389-413
E/E Environmental Testing

Part 1: Test Specifications
Foreword
This part of the standard defines environmental tests for the qualification of E/E components in
automotive applications.
This standard shall be used in combination with the document MBN 10 305-2 "E/E Environmental
Testing; Part 2: Test Selection Process” to develop component specific test requirements.
Changes
This standard is the completely reworked edition of the first edition of MBN 10 305 published in
2002.
Copyright Daimler AG 2008
Uncontrolled copy when printed (: Daniel Volkmann, 2008-10-10)

MBN 10 305-1, 2008-06-27, Page 2
Contents
1 Scope ......................................................................................................................................................3
2 Normative References.............................................................................................................................3
3 Terms and Definitions .............................................................................................................................3
4 Regulated Substances and Recyclability ................................................................................................5
5 Environmental Testing.............................................................................................................................5
5.1 Environmental Stress Categories ........................................................................................................5
5.1.1 Climatic Stresses ......................................................................................................................5
5.1.2 Mechanical Stresses.................................................................................................................5
5.1.3 Solids/ Fluids Stresses .............................................................................................................5
5.1.4 Chemical Stresses ....................................................................................................................5
5.2 Classification........................................................................................................................................5
5.2.1 Temperature Classification .......................................................................................................5
5.2.2 Vibration Classification .............................................................................................................5
5.2.3 IP Classification ........................................................................................................................6
5.3 Testing Requirements..........................................................................................................................6
5.4 Test documentation .............................................................................................................................7
5.5 Test Equipment and Fixture ................................................................................................................7
5.6 Parametric Measurements and Analysis .............................................................................................7
5.6.1 Parametric measurements before/after tests ...........................................................................7
5.6.2 Parametric measurements at defined intervals during tests ....................................................7
5.6.3 Parametric measurements - Continuous Monitoring ................................................................8
5.6.4 Data analysis using Parametric Trend or Drift (PTA): ..............................................................8
5.7 Accuracy of Measurement...................................................................................................................8
5.7.1 Default Tolerances....................................................................................................................8
5.7.2 Measurement Resolution..........................................................................................................8
6 Environment Test Specification...............................................................................................................8
6.1 Climatic Stresses .................................................................................................................................8
6.1.1 Shipping/Storage Temperature Exposure ................................................................................8
6.1.2 Low Temperature Operating Endurance ..................................................................................9
6.1.3 High Temperature Operating Endurance (HTOE) ..................................................................10
6.1.4 Powered Thermal Cycle Endurance (PTCE)..........................................................................11
6.1.5 Thermal Shock........................................................................................................................13
6.1.6 Thermal Shock Immersion......................................................................................................14
6.1.7 Thermal Humidity Cycle..........................................................................................................15
6.1.8 High Temperature and Humidity Endurance (HTHE) .............................................................16
6.1.9 Solar Radiation Soak ..............................................................................................................17
6.2 Mechanical Stresses..........................................................................................................................18
6.2.1 Vibration..................................................................................................................................18
6.2.2 Mechanical Shock...................................................................................................................25
6.2.3 Mechanical Shock Endurance ................................................................................................25
6.2.4 Package Drop .........................................................................................................................26
6.2.5 Handling Drop .........................................................................................................................26
6.2.6 Switch Mechanical Operation/ Abrasion Endurance ..............................................................27
6.3 Solids/ Fluids Compatibility................................................................................................................29
6.3.1 Dust (and other solid intrusion)...............................................................................................29
6.3.2 Water Intrusion........................................................................................................................30
6.3.3 High Pressure Steam Jet Exposure........................................................................................30
6.3.4 Salt Water Immersion .............................................................................................................31
6.4 Chemical Resistance .........................................................................................................................32
6.4.1 Mixed Flowing Gas .................................................................................................................32
6.4.2 Salt Fog...................................................................................................................................33
6.4.3 Chemical Exposure – Cabin Compartment ............................................................................34
6.4.4 Chemical Exposure - Outside Cabin Compartment................................................................36

MBN 10 305-1, 2008-06-27, Page 3
1 Scope
This part of the standard defines environmental tests for the qualification of E/E components in automotive
applications.
It shall be used in combination with the document MBN 10 305-2 "E/E Environmental Testing; Part 2: Test
Selection Process”. Releasing Engineers shall follow the procedures described in MBN 10 305-2 to select
applicable environmental tests from this standard for their components along with appropriate test
parameters.
The final decision to use or modify the tests contained within this standard for specific component
application rests with the component Releasing Engineer. Deviations from the requirements contained in
this standard shall be noted in the Component Specific Released Document.
Any questions concerning the content or the application of this standard should be directed to the
responsible team within GR/EEH.
2 Normative References
MBN 10 305-2 E/E Environmental Testing; Part 2: Test Selection Process
DIN 40 050-9 Degrees of Protection (IP-Code)
DIN 75 220 Solar Radiation effect on automotive components
IEC 60068-2-6 Environmental testing - Sinusoidal Vibration Test
IEC 60068-2-11 Environmental testing - Salt mist Test
IEC 60068-2-38 Environmental testing - Composite Temperature/Humidity Cyclic Test
IEC 60068-2-60 Environmental testing - Flowing mixed gas corrosion test
IEC 60068-2-64 Environmental testing - Broadband (Random) Vibration Test
IEC 60068-2-70 Environmental testing- Abrasion of marking and lettering due to rubbing of fingers/ hands
JIS D 0207 Japanese Industrial Standard - Dust Test for Automotive Parts
3 Terms and Definitions

Ambient Temperature: Temperature surrounding the component as tested in a test chamber or as
installed in the vehicle.
Component: Any electrical or electronic assembly used in the vehicle, such as engine control module,
instrument cluster, junction block, sensor, switch, etc. Also used interchangeably with terms such as ECU
(Electronic Control Unit), Module, Device, DUT (Device Under Test), etc.
Component Specific Released Document: Component specific Requirement Specifications (German:

"Lastenheft").
Crest Factor: It is defined as the peak over the Grms value in vibration testing. Some times also referred
as Sigma Value or Sigma Clipping.
E/E: Electrical and/or Electronic.
HTHE: High Temperature and Humidity Endurance test.
HTOE: High Temperature Operating Endurance test.
Intermittent Operation: When a component goes through pre-defined time cycles of “Operational” and
“Non-operational” (see definitions) conditions during the test, the component operational status shall be
considered as “Intermittent Operation”. Intermittent operation frequencies specified in some of the tests in
this standard are for guidelines only, and Releasing Engineer shall specify the most appropriate
operational intermittency for their component in the Component Specific Released Document.
IP Class: International Protection classification for solid and/or water intrusion for automotive applications
as described in DIN 40 050-9 (ISO 20653).
Nine Point Check: Parametric measurements of component’s functional parameters at 3 different

temperatures (Top.min, RT, Top.max) and 3 different test-voltage levels (UT.min, UT.typ, UT.max).

MBN 10 305-1, 2008-06-27, Page 4
Non-operational: A component shall be considered “Non-operational”, if it is connected to a power

source, but does not perform any normal operating functions during the test. The condition requires use of
mating connectors during the test. This condition is similar to the one experienced by an E/E component in
a parked vehicle.
Operational: A component shall be considered "Operational", if it performs functions as experienced
during vehicle operations. Power source may be from vehicle battery, ignition feed or an independent
power source, as in case of, RKE- Remote Keyless Entry, or TPM Sensor - Tire Pressure Monitor Sensor,
etc.
PCB: Printed Circuit Board.

2
Power Spectral Density (PSD): PSD describes the power of random vibration intensity in g /Hz or
2 2 2
[(m/s ) /Hz] where, 1 g equals 9.80665 m/s . Over a frequency bandwidth, random vibration is expressed
in units of root mean squared acceleration, GRMS.
Power-off: A component shall be considered "Power-off", when it is not electrically connected to a power
source, as in case of shipping or storage conditions. “Power-off” condition may require use of mating
connectors during some of the tests and shall be specified clearly in the “Test Parameters”.
PTA: Parametric Trend (Drift) Analysis. If a component is tested in operational or intermittent-operational

mode, a set of key functional parameters (such as, standby current , operating current, output voltages,
signal rise times, etc.) shall be continuously monitored during the test preferably by using a computerized
measurement data logger and the measured data shall be evaluated for drifts, trends and conspicuous
behavior afterwards. This analysis should lead to an improved understanding of aging mechanisms and
may therefore be helpful in defining the initial tolerances of lifetime-related parameters.
PTCE: Powered Thermal Cycle Endurance test.
RT: Room Temperature (23 + 5) °C.
Releasing Engineer: Engineer with design and/ or product releasing responsibility (also some times
referred as Development Engineer).
Soak Time (Tsoak): Time taken by component to reach chamber ambient temperature at high or low
temperature during thermal cycling tests from the time chamber temperature reaches corresponding high
or low temperature levels. MBN 10 305-2 includes a table with typical soak times versus the mass of a
component for components weighing up to 4.5 kg. The soak time must be verified by the supplier via
measurements and adapted in coordination with the client if necessary. For heavier components (more
than 4.5 kg), soak time studies are required to determine the component specific soak time.
Sub-component: Any electrical/ electronic parts or sub-assemblies (such as transistors, resistors, ASICs,
Microprocessors, LEDs, etc.) used in an E/E component.
Temperature class: Classification of maximum temperature a component will experience based on its
mounting location and specific packaging variations in the vehicle. Refer to section 5.2.1 for details.
Tmin: Lowest ambient temperature experienced by any component (Usually -40 0C).
Tmax: Highest ambient temperature experienced by any component. Value of Tmax depends on
temperature class of the component.
Top. min: Minimum value of the ambient temperature at which the component is still providing full
functionality. If technical constraints does not require Top. min to be higher than Tmin, Top. min shall be
equal to Tmin.
Top. max: Maximum value of the ambient temperature at which the component is still providing full
functionality. If technical constraints does not require Top. max to be lower than Tmax, Top. max shall be
equal to Tmax.
UT. min: Minimal test-voltage applied to the component.
UT. typ: Typical test-voltage applied to the component.
UT. max: Maximum test-voltage applied to the component.

MBN 10 305-1, 2008-06-27, Page 5
Vibration Class: Classification of vibration intensities a component will experience based on its mounting
location in the vehicle.
4 Regulated Substances and Recyclability

All materials, procedures, processes, components, or systems must conform to the current regulatory
(governmental) requirements regarding regulated substances and recyclability.
5 Environmental Testing
5.1 Environmental Stress Categories
This standard classifies environmental stresses into four categories typically experienced by E/E
component in vehicle. The environmental tests listed in section 6 are developed based on four categories
described below:
5.1.1 Climatic Stresses
This category includes tests to demonstrate compatibility with climatic stresses such as temperature,
humidity and solar radiation.
5.1.2 Mechanical Stresses
This category includes tests to withstand effects of mechanical stresses such as vibration, mechanical
shock, switch mechanical operations and handling drop.
5.1.3 Solids/ Fluids Stresses
This category includes tests to demonstrate component compatibility to solids and fluids such as dust,
water, rain, steam, etc.
5.1.4 Chemical Stresses
This category includes tests to demonstrate component resistance to corrosive effects of certain
environmentally pollutant gases, salt fog environment, and situations involving accidental fluid spills.
5.2 Classification
5.2.1 Temperature Classification
Five temperature classes are defined based on the maximum ambient temperature Tmax that may occur in
the mounting location of the component as given in Table 1:
Table 1: Temperature Classification and Tmax Values
Temperature Class I II III IV V

Empirically
Maximum Temperature (Tmax 0C) 85 105 125 155
Specified
It is possible to use a unique empirically specified Temperature Class (V) for a component, if Releasing
Engineer can provide location specific temperature data from test or field measurements. In any case,
Tmax shall be measured to confirm in-vehicle application for all temperature classes.
5.2.2 Vibration Classification
Depending upon their mounting location, components shall be classified in one of the four Vibration
Classes given in Table 2:

MBN 10 305-1, 2008-06-27, Page 6
Table 2: Vibration Classification based on Component Mounting Location
Component Mounting Location Vibration Class

Component mounted on Instrument Panel, Body sheet metal, Overhead console,
I
Doors, Lift gate, and Trunk
Component mounted on engine II
Component mounted on transmission III
Component mounted on suspension or wheel IV
5.2.3 IP Classification
IP (International Protection) codes identify safeguards against solid and/or liquid intrusion when exposed.
Table 3 lists different solid and liquid protection categories, for example, IP 5K7 requires a device to be
protected against dust and temporary water immersion. Refer to DIN 40 050-9 for further details.
Table 3: International Protection codes for Solid and Liquid (Intrusion) - based on DIN 40 050-9 for
automotive applications
Protection against intrusion of solid

IP Code Protection against intrusion of water IP Code
foreign objects (including dust)
No protection 0 No protection 0
With diameter > 50 mm 1 Vertical water drips 1
With diameter > 12.5 mm 2 Water drips (15 ° inclination) 2
With diameter > 2.5 mm 3 Water spray 3
With diameter > 1.0 mm 4 Water splash with pressure 4K
Dust protection 5K High-velocity water jet 5

High-velocity water jet with increased
Dust proof 6K 6K
pressure
Temporary immersion in water 7
Continuous submersion in water 8
High-pressure steam-jet cleaning 9K
5.3 Testing Requirements
It is mandatory for the supplier to demonstrate 100% success for all the tests listed in the Component
Specific Released Document. A test shall be considered successful if the component functional and
parametric checks conform to requirements stated in the component specific engineering standard.
If a component fails during any test, supplier shall conduct root cause analysis that may include
disassembly of failed components and/or some other diagnostic tests to determine cause(s) of failure(s).
Disassembled components shall be inspected for potting/ seal failures, liquid/solid intrusion, corrosion, etc.
as applicable.
Supplier shall provide a written report containing the following sections (8D-report):
- Team members,
- Problem description,
- Interim (short term) containment/actions,
- Root cause analysis/identification,
- Permanent corrective action,
- Verification (to determine effectiveness of permanent actions),
- Prevention of problem recurrence and
- Review

MBN 10 305-1, 2008-06-27, Page 7
Supplier shall demonstrate effectiveness of such corrective actions by either repeating the failed test or
completing a truncated test supported by parametric test results. Details shall be agreed upon with
Component Releasing Engineer. New test sample(s) shall be used to replace the failed component(s) to
continue remaining tests in a test sequence.
During all tests, components shall be supplied with the typical test voltage UT.typ, whenever the test
requires the component to be operational (either continuous or intermittent). If a different voltage level(s)
are required for a certain component, Releasing Engineer shall document this deviation in the Component
Specific Released Document.
Supplier shall be responsible for providing all the required resources such as test equipment and
measuring gages, hardware/software and required technical and management personnel to ensure timely
completion of component testing and analysis.
5.4 Test documentation
Supplier shall provide a written report on the complete qualification procedure as described in the
Component Specific Released Document. The testing procedures (equipment including test parameters,
test environment, test sequence etc.) and detailed test results (results of parametric measurements as
defined in section 5.6 of this standard, additional documentation such as photographs, diagrams etc.) shall
be documented according to the engineering state of the art (results measured as numerical values must
not be reduced to pass/fail information but should be documented as numerical values) and shall be
delivered on request.
Details on test documentation shall be agreed upon between supplier and Releasing Engineer.
5.5 Test Equipment and Fixture
A test fixture shall be required to mechanically and electrically simulate the intended vehicle system and
exercise all functions of the component. Test fixture shall simulate the in-vehicle mounting position
including the appropriate cable dressing and connectors. Loads should be equivalent to those seen in the
vehicle. Original production wiring harness and connectors shall be used for testing including properly
terminated wires of correct gauge size and crimping from production intent processes.
Test equipment must be able to withstand vibration and shock intensities specified in the Vibration and
Mechanical Shock test sections of this document. Production intent rigid fixture shall be used to simulate
the in-vehicle mounting orientation.
5.6 Parametric Measurements and Analysis
5.6.1 Parametric measurements before/after tests
Component Specific Released Document shall identify a set of key functional parameters such as standby
current, operating current, output voltages, contact resistance, signal rise times, bus communication, etc.
These key functional parameters shall be measured for conformance before the start and after completion
of every test. Unless specified otherwise, functional parameters shall be measured at 3 different
temperatures (Top. min, RT and Top. max) and 3 different test-voltage conditions UT.min (low test voltage),
UT.typ (nominal test voltage) and UT.max (maximum test voltage). This parametric check involves nine (9)
combinations of different temperatures and voltages and is generally referred to as “Nine Point Check“.
“Nine point checks” of key functional parameters are generally required for every test. However,
component releasing engineer may deviate from this general requirement for some tests e.g. by omitting
the measurements at Top.min and Top.max and performing only a "3 point check" at RT for the 3 different
test-voltage conditions. These deviations should be described and reasoned in the Component Specific
Released Document.
In a test sequence, the parametric measurements after one test shall be considered as the parametric
measurements before the subsequent test.
5.6.2 Parametric measurements at defined intervals during tests
The longer duration tests, such as, the High Temperature Operating Endurance test, the High
Temperature and Humidity Endurance test, and the Powered Thermal Cycle Endurance test, shall be

MBN 10 305-1, 2008-06-27, Page 8
temporarily interrupted at certain intervals to measure a set of functional parameters, which shall be
defined in the Component Specific Released Document. Unless otherwise specified in the Component
Specific Released Document, the tests shall be interrupted after 25%, 50% and after 75% of the test time
and the parametric measurements shall be performed as "Nine point Checks", i.e. at 3 different
temperatures and 3 different voltage levels.
5.6.3 Parametric measurements - Continuous Monitoring
For tests which require test samples to be “operational” or “intermittently operated”, a set of key functional
parameters (such as standby current, operating current, output voltages, signal rise time, etc.) shall be
defined in the Component Specific Released Document. These parameters shall be continuously
monitored preferably using a computerized data logger. The sampling rate and other measurement details
shall be described in the Component Specific Released Document.
5.6.4 Data analysis using Parametric Trend or Drift (PTA):
If the Component Specific Released Document requires Parametric Trend Analysis (PTA) for a certain
test, the data acquired during Continuous Monitoring (see sub-section 5.6.3) shall be evaluated for drifts,
trends and conspicuous behavior. This analysis should lead to an improved understanding of aging
mechanisms and may also be helpful for defining initial tolerances of some of the key functional
parameters. Details of the PTA shall be agreed upon between the supplier and the Component Releasing
Engineer.
5.7 Accuracy of Measurement
5.7.1 Default Tolerances
Unless otherwise specified, Room temperature shall be a default temperature for all tests. In the absence
of any tolerance specification, the following default tolerances shall apply:
- Frequency: (+1%, -1%) of stated frequency across component range

- Relative Humidity: (+5%, -5%)
- Temperature: (+2 0C, -2 0C)
- Time: (+5%, -0%)
- Vibration: (+3 dB, -3 dB) for PSD profile over the test range and (+5%, -5%) for specified GRMS level.
The vibration set-up shall be configured to provide "Crest Factor" of 3.0 (Sigma Value or Sigma
Clipping); +/- 3dB alarm limits on the control channel and +/- 6 dB abort limits on the control channel
shall be used.
- Test Voltages (UT.min, UT.typ, UT.max): (+2%, -2%)
0 0
- Room temperature: 23 C (+5 0C, -5 0C) or 73 F (+9 0F, -9 0F)
5.7.2 Measurement Resolution
Test equipment shall be capable of exercising the component with resolution/accuracy one order of
magnitude finer than the most significant digit of the quantity being measured. For example, even though
a 0.1 mA and 0.10 mA might be the same current, an ammeter capable of 0.01 mA may be used to
measure the first current but an ammeter with 0.001 mA resolution is required to measure the second
current.
6 Environment Test Specification
6.1 Climatic Stresses
6.1.1 Shipping/Storage Temperature Exposure
Purpose
Verify functional performance of the component after extended exposure to temperature extremes
experienced during shipping and warehouse storage. This test is also intended to cover high temperature
exposure experienced during re-painting process in the Assembly Plants. Test will simulate stresses,
which can cause extreme temperature related failures in the component, such as cracking of PCB or
ceramic substrates, plastic creep or distortion, changes in component parametric values, and so on.

MBN 10 305-1, 2008-06-27, Page 9
Scope
This test shall apply to all components.
Test Parameters and Requirements
Suppliers shall test to the following requirements:
Test duration (including chamber ramp

160 hours
times and component operation time)
0
Minimum temperature -50 C
0
Maximum temperature +95 C
0
Temperature ramp rate 0.6 C/ minute
Sample size 5
Component Operating status Power-off without mating connectors

Parametric Measurements before/after test (refer to section
Parametric measurement & analysis
5.6.1)
Test Procedure
0
A. Place component in a temperature chamber and ramp down the chamber temperature to -50 C within
0
2 hours. Keep component at -50 C for next 24 hours.
0 0
B. Ramp up the chamber temperature to +95 C within 4 hours. Keep component at +95 C for next 48
hours.
C. Ramp down the chamber temperature to RT over a period of 2 hours.
D. Repeat steps A through C one more time (total two cycles).
Acceptance Criteria
Functional performance shall be verified by parametric measurements before start and after completion of
the test to conform requirements stated in the Component Specific Released Document.
6.1.2 Low Temperature Operating Endurance
Purpose
Verify functional performance of the component after extended exposure to low operating temperature
extremes as experienced during vehicle operation in extreme low ambient temperatures. Test will simulate
stresses, which can cause low temperature related failures in the component, such as cracking of PCB or
ceramic substrates, freezing of capacitors with liquid electrolyte, and so on.
Scope
This test shall only apply to components having electronics (such as ICs, transistors, capacitors, resistors,
diodes, etc.).

MBN 10 305-1, 2008-06-27, Page 10
Test duration 120 hours
Test chamber temperature Top.min
Sample size 5
Intermittent operation with Continuous Monitoring (refer to
Operating status
section 5.6.3)
5.6.1)
PTA Analysis shall be required if specified in the Component
Test Procedure
A. Place component in a climatic chamber and ramp down the chamber temperature to Top.min.
B. Operate component at Top.min for 120 hours with continuous monitoring.
Acceptance Criteria
If PTA Analysis is required in the Component Specific Released Document, parametric results observed
during the test using shall be assessed for parametric drifts, trends and conspicuous behavior. Information
from such analysis shall be taken into consideration when establishing specification limits for end-of-line
checks in the final component assembly.
6.1.3 High Temperature Operating Endurance (HTOE)
Purpose
Verify functional performance of component after extended exposure to high operating temperature
extremes for specified time duration. Test will induce high temperature related failures in the component,
such as cracking of PCB or ceramic substrates, plastic creep or distortion, electro-migration, diffusion,
oxidation, corrosion, etc.
Scope
As defined in the Component Specific Released Document

Test duration
based on MBN 10 305-2
Test chamber temperature Top.max
Sample size 5
Operating status Operational with Continuous Monitoring (refer to section 5.6.3)

Parametric Measurements before/after and at defined intervals
Parametric measurement & analysis during test (refer to sections 5.6.1 and 5.6.2).
PTA Analysis shall be required.
Test Procedure
A. Place component in a temperature chamber and ramp up the chamber temperature to Top.max.

MBN 10 305-1, 2008-06-27, Page 11
B. Operate component at Top.max for the specified test duration with continuous monitoring.
Interrupt test after pre-defined intervals specified in the Component Specific Released Document to
perform parametric measurements according to section 5.6.2.
Acceptance Criteria
Functional performance shall be verified by parametric measurements before start, at pre-defined interval
during the test and after completion of the test to conform requirements stated in the Component Specific
Released Document.
Parametric results observed during the test using PTA shall be assessed for parametric drifts, trends and
conspicuous behavior. Information from such analysis shall be taken into consideration when establishing
specification limits for end-of-line checks in the final component assembly.
6.1.4 Powered Thermal Cycle Endurance (PTCE)
Purpose
Verify functional performance of component after exposing to thermal cycling from Tmin to Tmax for
specified thermal cycles to simulate accelerated test condition for temperature changes experienced
during the vehicle's service life. Test will simulate thermal fatigue related failures in the component to
uncover design/ process related issues, such as solder joint cracks, distortion or cracking of PCB,
changes in component parametric values, and so on.
Scope
As defined in the Component Specific Released Document based

Number of test cycles
on MBN 10 305-2
Minimum Chamber temperature Tmin
Maximum Chamber temperature Tmax
Note (1)
Temperature Change rate 4 °C/min
Component soak time on MBN 10 305-2
Suitability of defined soak-time shall be verified by measurements
Sample size 5
Intermittent operation with Continuous Monitoring (refer to section
Operating status Note (2)
5.6.3) as shown in Figure 1-A and 1-B
Note (1): If a supplier does not have climatic chamber that can meet temperature ramp up/down rate of 4
0
C/ min, Release Engineer shall use supplier chamber ramp rate capability to derive suitable test
parameters for PTCE test. However, lower values in temperature change rates will increase overall test
time.
Note (2): Two modes of Intermittent Operations (Intermittent Operation-1 and Intermittent Operation-2)
shall be defined in the Component Specific Released Document. Intermittent operations are used to verify
component operational status at different temperatures during the test. For example, a typical intermittent
operation can be 1 minute operational and 9 minutes non-operational for Intermittent Operation-1. This
operational status is designed to operate component with very small operational interval and large non-

MBN 10 305-1, 2008-06-27, Page 12
operational phase to prevent excessive heating during temperature downward ramp and at low
temperature, but operation is essential to assess the device functionality. Similarly, for Intermittent
Operation-2, a typical intermittent operation can be 9 minutes operational and 1 minute non-operational.
This operational status is designed to operate component with a large operational interval and very small
non-operational phase to simulate real-life conditions during high temperature zones.
Test Procedure
Refer to Figure 1A and 1B as applicable to the component.

Figure 1A profile applies if Top.max = Tmax and Top.min = Tmin.
Figure 1B profile applies if either Top.max is not = Tmax and/or Top.min is not = Tmin.
A. Place component in a temperature chamber, operate component (Intermittent Operation-1) with

continuous monitoring and ramp down the chamber temperature to Tmin with the specified
temperature change rate (t1 to t2 in Fig. 1-A and Fig.1-B).
B. Keep component at Tmin for the specified component soak time (t2 to t3 in Fig. 1-A or t2 to t3’ in Fig. 1-
B).
If Top.min is not = Tmin, ramp up chamber temperature to Top.min with the specified temperature change
rate (t2a to t2b in Fig 1-B) and keep component at Top.min for 5 minutes (t2b to t3 in Fig 1-B).
C. Change operating status to Intermittent Operation-2 with continuous monitoring. Ramp up chamber
temperature from Tmin or Top.min to Tmax with the specified temperature change rate (t3 to t4 or t3’ to t4).
D. Keep component at Tmax for the specified component soak time (t4 to t5 in Fig. 1-A or t4 to t5’ in Fig. 1-
B).
If Top.max is not = Tmax, ramp down chamber temperature to Top.max with the specified temperature
change rate (t4a to t4b in Fig 1-B) and keep component at Top.max for the specified component soak
time (t4b to t5 in Fig. 1-B).
E. Ramp-down the chamber temperature from Tmax or Top.max to RT with the specified temperature
change rate (t5 to t6 or t5’ to t6’).
F. Repeat powered thermal cycle (steps A through E) for the specified number of cycles.
Interrupt test after pre-defined intervals specified in the Component Specific Released Document to
perform parametric measurements according to section 5.6.2.
Acceptance Criteria
Released Document.

MBN 10 305-1, 2008-06-27, Page 13
Figure 1-A: Powered Thermal Cycle Endurance Profile (Without TOp. Extremes)
Figure 1-B: Powered Thermal Cycle Endurance Profile (With TOp. Extremes)
6.1.5 Thermal Shock
Purpose
Verify functional performance of component after exposing to sudden temperature changes from Tmin to
Tmax to simulate sudden temperature changes experienced during the vehicle's service life (air-to-air
thermal shift). This test is intended to prove thermal stress or fatigue failures of solder-joints, potting/ seal
failures, and failures of circuit components due to mechanical stresses caused by thermal expansion and
contraction.
Scope
This test shall apply to all components, which are not permanently operated in a liquid medium.

MBN 10 305-1, 2008-06-27, Page 14
Number of test cycles 100

Transfer time < 30 seconds
Sample size 5
Operating status Power-off with mating connectors
Parametric measurement & analysis Parametric Measurements before/after test (refer to section 5.6.1).
Test Procedure
A. Place component in a chamber with dual temperature zone capability and adjust the temperature
zones to Tmax and Tmin, respectively. If a chamber with dual temperature zone capability is not
available, use two chambers in close proximity and maintain one chamber at Tmax and another at
Tmin.
B. Maintain component at Tmin for specified component soak time.
C. Transfer component from Tmin zone to Tmax zone within 30 seconds.
D. Keep component at Tmax for the specified component specific soak time.
E. Transfer component from Tmax zone to Tmin zone within 30 seconds.
F. Repeat the thermal cycles (steps B through E) for the specified number of test cycles.
G. Allow the component to return to the room temperature within 2 hours before removing it from the test
chamber.
Acceptance Criteria
6.1.6 Thermal Shock Immersion
Purpose
Verify functional performance of component after exposing to sudden temperature changes from Tmin to
Tmax to simulate sudden temperature changes experienced during the vehicle's service life (liquid-to-liquid
thermal shift). This test is intended to prove thermal stress or fatigue failures of solder-joints, potting/ seal
failures, and failures of circuit components due to mechanical stresses caused by thermal expansion and
contraction.
This test provides protection rating equivalent of IP X8 and will be used for only those components which
operate in liquid medium. If any component operates in liquid medium, this test shall be mandatory and all
other solid/fluid compatibility tests shall not be required.

MBN 10 305-1, 2008-06-27, Page 15
Scope
This test shall apply to all components permanently operated in a liquid medium and therefore being
categorized into IP protection class IP X8 as in the case of Cam and Crank Sensor (oil medium).
Number of test cycles 100

Transfer time < 30 seconds
Use liquid in which the component normally operates. Ensure Tmax

Liquid used in the bath
and Tmin temperatures are possible in the liquid state.
Sample size 5
Parametric measurement & analysis Parametric Measurements before/after test (refer to section 5.6.1).
Test Procedure
A. Keep the component in a hot bath chamber maintained at Tmax for the specified component soak time.
B. Transfer component to cold bath chamber maintained at Tmin within 30 seconds.
C. Keep this component in cold bath chamber for the specified component soak time.
D. Transfer component to hot bath chamber maintained at Tmax within 30 seconds.
E. Repeat the thermal cycles (steps A through D) for the specified number of test cycles.
F. Allow the component to return to the room temperature within 2 hours before removing it from the test
chamber.
Acceptance Criteria
6.1.7 Thermal Humidity Cycle
Purpose
Verify functional performance of component in situations that can cause humidity condensation (every day
driving conditions) or frost conditions (cold climates). This test can cause swelling of material due to
moisture absorption, potting and seal failures, conformal coating compound failure, electrical shorts due to
condensation, oxidation and/or galvanic corrosion of metals, dendrite growth, etc.

MBN 10 305-1, 2008-06-27, Page 16
Scope
This test will be applicable to all components.
Suppliers shall test to the following requirements. This test is based on IEC 60068-2-38 “Composite
temperature / humidity cyclic test”.
Test duration 240 hours

According to IEC 60068-2-38.
The first five temperature cycles shall be performed with cold
Temperature and humidity profile
phase and the following temperature cycles shall be performed
without cold phase. (refer to IEC 60068-2-38 for details).
0
Minimum chamber temperature -10 C
0
Maximum chamber temperature +65 C
93% (uncontrolled during the intervals defined in IEC 60068-2-
Relative humidity
38)
Sample size 5
Operating status Note
section 5.6.3)
5.6.1)
PTA Analysis shall be required if specified in the Component
Note: Intermittent operation shall be kept at a level that does not generate excessive internal heat which
may interfere with chamber conditions. Intermittent operation shall be used to verify component
operational status at different temperatures, humidity and condensation levels during the test. A typical
intermittent operation can be 50-minutes operational and 50-minutes non-operational during the test.
Component Specific Released Document shall provide intermittent operational details for this test.
Test Procedure
A. Place component in a climatic chamber.
B. Operate component with continuous monitoring while running a temperature and humidity profile
according to IEC 60068-2-38.
Acceptance Criteria
during the test shall be assessed for parametric drifts, trends and conspicuous behavior. Information from
such analysis shall be taken into consideration when establishing specification limits for end-of-line checks
in the final component assembly.
6.1.8 High Temperature and Humidity Endurance (HTHE)
Purpose
Verify functional performance of component after exposing to high temperature and high humidity (85 0C
and 85% RH) for a specified time to simulate accelerated test condition for temperature and humidity
experienced during the vehicle's service life. This test can cause swelling of material due to moisture

MBN 10 305-1, 2008-06-27, Page 17
absorption, potting and seal failures, conformal coating compound failure, electrical shorts due to
condensation, oxidation and/or galvanic corrosion of metals, etc.
Scope

Test duration
on MBN 10 305-2
0
Test chamber temperature 85 C
Test chamber relative humidity 85% RH
Sample size 5
Intermittent operation with Continuous Monitoring (refer to section
5.6.3) - Components shall be non-operational for 47 hours and
Operating status
operational for 1 hour. This cycle shall be repeated till the end of
the test.
Test Procedure
0
A. Place component in a test chamber and maintain chamber temperature at 85 C for 1 hour.
B. Introduce humidity to the chamber and maintain the relative humidity inside the chamber at 85% RH.
C. Operate component (1 hour operational after 47 hours of non-operational by turns) with continuous
monitoring for the specified test duration. Interrupt test after pre-defined intervals specified in the
Component Specific Released Document to perform parametric measurements according to section
5.6.2. Condensation shall be prevented when replacing the (cold) component into the climatic
chamber by heating the component to 85 °C first without humidity and introducing humidity only after
component has reached 85°C.
Acceptance Criteria
Released Document.
6.1.9 Solar Radiation Soak
Purpose
Verify aging effect of solar radiation on component surface exposed to direct solar soak (Solar constant
2
1.374 kW/ m ) for a specified time. This test can cause discoloration, peeling, and cracking of material due
to solar radiation. This test should be conducted only for production approved material. The test is not
required to be repeated, if the prior phase test was completed successfully with no changes in design and
material.

MBN 10 305-1, 2008-06-27, Page 18
Scope
This test will be applicable to any component exposed to direct sunlight and has first appearance surface
visible from outside.
Test Parameters and Requirements (Follow DIN 75 220)
According to DIN 75 220 (Solar Radiation effect on automotive

Test Procedure
components)
Follow outdoor cycle test in DIN 75 220 (Z-OUT) – Section
For Components outside passenger
7.2.1.1 and 7.2.1.2 in DIN 75 220 with Tables 2 & 5 for dry and
cabin or trunk
humid cycles
Follow indoor cycle test in DIN 75 220 (Z-IN 1) – Section 7.2.1.1
For Components inside passenger
and 7.2.1.2 in DIN 75 220 with Tables 3 & 5 for dry and humid
cabin
cycles
Test time 25 days (15 days - dry cycle and 10 days – wet cycle)
Sample size 5

5.6.1)
Acceptance Criteria
Inspect component for any signs of damage or degradation, such as possible overheating,
hardening/brittleness in plastics, fissure formation, discoloration, cracking, peeling, etc. Compare test
sample condition with the acceptance criteria defined in the Component Specific Released Document.
6.2 Mechanical Stresses
6.2.1 Vibration
Purpose
Verify functional performance of component after exposing to the vibration profile based on component
location. The vibration profiles described in this section are accelerated test stresses to simulate vibrations
experienced by component due to road conditions while driving and/ or engine cranking. This test can
cause fatigue related failures in the component.
Scope
This test shall apply to all components according to their Vibration Classes as defined in section 5.2.2.
6.2.1.1 Vibration Class I (For component mounted on Instrument Panel, Body sheet metal, Overhead
console, Doors, Lift-gate, Trunk, etc.)
Test Parameters and Requirements (Vibration Class I)

MBN 10 305-1, 2008-06-27, Page 19
Table 4: Vibration Class I (Component mounted on Instrument Panel, Body sheet metal, Overhead
console, Doors, Lift gate, and Trunk)
Vibration class I
As defined in the Component Specific Released Document based on
MBN 10 305-2
Test duration per axis During the first 8 hours, test samples are subjected to low and high
thermal profile and for the remaining test duration, test shall be
performed at RT as shown in Figure 2.
Ramp rate of temperature
1 - 1.5 °C/min
profile
Minimum temperature of
Top.min
temperature profile
Maximum temperature of
Top.max
temperature profile
Power spectral
Power spectral density
Frequency [Hz] density (PSD) 2
2 2 (PSD) [G /Hz]
[(m/s ) /Hz]
5 0.884 0.0092
10 20.00 0.2080
Vibration profile 55 6.50 0.0676
Random vibration 180 0.25 0.0026
300 0.25 0.0026
360 0.14 0.0015
1000 0.14 0.0015
2000 0.14 0.0015
2
RMS* acceleration 30.8 m/s 3.14 GRMS
Sample size 5
Operational with Continuous Monitoring (refer to section 5.6.3) during
Operating status
the interval shown in figure 2 and non-operational otherwise
Parametric Measurements before/after test (refer to section 5.6.1).
Parametric measurement &
PTA Analysis shall be required, if specified in the Component Specific
analysis
Released Document.
* RMS – Root Mean Squared.
Test Procedure (Vibration Class I)
A. Program vibration shaker for the random vibration profile given in Table 4.
B. Program temperature chamber for the temperatures, ramp rates and duration shown in the Figure 2
and given in Table 4.
C. Place component on the vibration shaker inside the temperature chamber. Mount the component in
one of the axes using a released bracket or mounting hardware, connector and wiring harness.
D. Start vibration and temperature sequence and operate component with continuous monitoring for the
specified test duration per axis.
E. At the end of the test cycle for one axis, repeat steps C and D for the remaining two axes.

MBN 10 305-1, 2008-06-27, Page 20
Figure 2: Temperature Profile for Vibration Class I and IV
6.2.1.2 Vibration Class II (For component mounted directly on the engine)
Test Parameters and Requirements (Vibration Class II)
Table 5: Vibration Class II (Component mounted on Engine):
Vibration class II
Test duration for random vibration MBN 10 305-2.
per axis During the entire test, samples shall be subjected to a temperature
profile as shown in figure 3.
Test duration for sinusoidal MBN 10 305-2.
vibration per axis During the entire test, samples shall be subjected to a temperature
Ramp rate of temperature profile 1 – 1.5 °C/min
Top.min
temperature profile
Top.max
temperature profile

MBN 10 305-1, 2008-06-27, Page 21
Vibration class II
Power spectral
Power spectral density
Frequency [Hz] density (PSD) 2
2 2 (PSD) [G /Hz]
[(m/s ) /Hz]
10 10.0 0.104
Vibration profile
100 10.0 0.104
Random vibration
300 0.51 0.005
500 20.0 0.208
2000 20.0 0.208
2
RMS acceleration 181 m/s 18.41 GRMS
Amplitude of Amplitude of
Frequency [Hz] 2
acceleration [m/s ] acceleration [G]
100 100 10.2
Vibration profile 150 150 15.3
Sinusoidal vibration 200 200 20.4
240 200 20.4
255 150 15.3
440 150 15.3
Sample size 5
Operational with Continuous Monitoring (refer to section 5.6.3) during
Operating status
the interval shown in figure 3 and non-operational otherwise
PTA Analysis shall be required, if specified in the Component Specific
analysis
Released Document.
Since, engine related vibration depend on size and type of engine, it is recommended to determine
vibration test profile for a vehicle with the help from Stress Lab after the vehicle is built.
Test Procedure (vibration class II)
A. Program vibration shaker for the random and sinusoidal vibration profiles given in Table 5.
B. Program temperature chamber for the temperatures, ramp rates and duration shown in Figure 3 and
given in table 5.
D. Start sinusoidal vibration and temperature sequence and operate component with continuous
monitoring.
E. Repeat temperature cycles while maintaining the vibration sequence through the specified test
duration for sinusoidal vibration given in table 5.
F. Start program to run random vibration and temperature sequence and operate component with
continuous monitoring.
G. Repeat temperature cycles while maintaining the vibration sequence through the specified test
duration for random vibration given in table 5.
H. Repeat steps C through G two more times for the remaining two axes.

MBN 10 305-1, 2008-06-27, Page 22
Figure 3: Temperature Profile for Vibration Class II and III
6.2.1.3 Vibration Class III (For component mounted directly on the transmission)
Test Parameters and Requirements (Vibration Class III)
Table 6: Vibration Class III (Component mounted on Transmission)
Vibration class III

Test duration for random on MBN 10 305-2.
Test duration for sinusoidal on MBN 10 305-2.
1 – 1.5 °C/min
profile
Top.min
temperature profile
Top.max
temperature profile

MBN 10 305-1, 2008-06-27, Page 23
Power spectral Power spectral

Frequency [Hz] density (PSD) density (PSD)
2 2 2
[(m/s ) /Hz] [G /Hz]
10 10.0 0.104
Vibration profile
100 10.0 0.104
Random vibration
300 0.51 0.0053
500 5.0 0.052
2000 5.0 0.052
2
RMS acceleration 96.6 m/s 9.85 GRMS
Amplitude of
Amplitude of
Frequency [Hz] 2 acceleration
acceleration [m/s ]
Vibration profile [G]
Sinusoidal vibration 100 30.0 3.06
200 60.0 6.12
440 60.0 6.12
Sample size 5
Operational with Continuous Monitoring (refer to section 5.6.3)
Operating status
during the interval shown in figure 3 and non-operational otherwise
PTA Analysis shall be required, if specified in the Component
analysis
Test Procedure (vibration class III)
A. Program vibration shaker for the random and sinusoidal vibration profiles given in Table 6.
given in Table 6
D. Start sinusoidal vibration and temperature sequence and operate component with continuous
monitoring.
E. Repeat temperature cycles while maintaining vibration sequence through the specified test duration
for sinusoidal vibration given in table 6.
F. Start program to run random vibration and temperature sequence and operate component with
continuous monitoring.
G. Repeat temperature cycles while maintaining vibration sequence through the specified test duration
for random vibration given in table 6.
H. Repeat steps C through G two more times for the remaining two axes.
6.2.1.4 Vibration Class IV (For component mounted on suspension/ wheel)
Test Parameters and Requirements (Vibration Class IV)

MBN 10 305-1, 2008-06-27, Page 24
Table 7: Vibration Class IV (Components mounted on suspension or wheel)
Vibration Class IV

on MBN 10 305-2.
Test duration per axis During the first 8 hours, test samples are subjected to low and high
thermal profile and for the remaining test duration, test shall be
performed at RT as shown in Figure 2.

1 – 1.5 °C/min
profile
Top.min
temperature profile
Top.max
temperature profile
Power spectral Power spectral
Frequency [Hz] density (PSD) density (PSD)
2 2 2
[(m/s ) /Hz] [G /Hz]
20 200.00 2.08
Vibration profile 40 200.00 2.08
Random vibration 300 0.50 0.005
800 0.50 0.005
1000 3.00 0.031
2000 3.00 0.031
2
RMS acceleration 107 m/s 10.94 GRMS
Sample size 5
Operational with Continuous Monitoring (refer to section 5.6.3)
Operating status
during the interval shown in figure 2 and non-operational otherwise
analysis
Vibration of suspension/ wheel mounted components is random and induced by rough-road-driving. Loads
with frequencies lower than 20 Hz are not covered by the test profile specified here. In practice high
amplitude can occur below 20 Hz; therefore, loads acting on the component under test in this frequency
range shall be considered separately in the component Released Document.
Test Procedure (Vibration Class IV)
A. Program vibration shaker for the random vibration profile given in Table 7.
given in table 7.
C. Place component on a vibration shaker inside a temperature chamber. Mount the component in one of
the axes using a released bracket or mounting hardware, connector and wiring harness.
D. Start vibration and temperature sequence for the component.
E. At the end of the test cycle for one axis, repeat steps C and D for the remaining two axes.
Acceptance Criteria

MBN 10 305-1, 2008-06-27, Page 25
6.2.2 Mechanical Shock
Purpose
Verify functional performance of component and its capability to withstand shock stresses induced during
scenarios, such as vehicle deceleration in sudden braking situation, handling shocks during shipping, and
driving over road bumps at high speed.
Scope
Number of Shocks per each direction

10
(+/- X, Y, and Z)
2
Peak Acceleration 500 m/s
Shock Duration 11 ms
Test Temperature RT
Sample size 5
Operating Status Power-off with mating connectors

5.6.1).
Test Procedure
A. Define component in-vehicle mounting coordinates relative to the vehicle coordinates X (longitudinal),
Y (transverse), and Z (vertical). Mount the component on the shock test equipment to simulate in-
vehicle coordinates.
B. Apply half-sine pulse 10 times per each direction of +/- X, Y, and Z at room temperature. Total number
of shocks shall be 60.
Acceptance Criteria
6.2.3 Mechanical Shock Endurance
Purpose
Verify functional performance of component and its capability to withstand continuous shock stresses
induced during closing of doors, trunk, or hood.
Scope
This test shall apply to all components mounted directly on doors, trunk, or hood as well as component
mounted adjacent to these specific areas, that are likely to receive such repeated induced shocks.

MBN 10 305-1, 2008-06-27, Page 26
Suppliers shall test to the following requirements

based on MBN 10 305-2.
Typical numbers are given below for 10 & 15 year design life:
Location For 10 year life For 15 year life
Driver Door 72 000 100 000
Number of Shocks
Passenger Doors
36 000 50 000
(Front/Rear)
Trunk, Lift gate 18 000 30 000
Hood 2 000 3 000
2
Peak Acceleration 400 m/s
Shock Duration 6 ms
Test Temperature RT
Sample size 5

5.6.1).
Test Procedure
A. Define component in-vehicle mounting coordinates relative to the vehicle coordinates X (longitudinal),
Y (transverse), and Z (vertical). Mount the component on the shock test equipment to simulate in-
vehicle coordinates.
B. Apply half-sine shocks to the amount as specified in the above table.
Acceptance Criteria
6.2.4 Package Drop
Canceled
6.2.5 Handling Drop
Purpose
Verify component capability to withstanding drops in manufacturing and/or assembly facilities or during
part replacement/ servicing situations at dealership locations.
Scope

MBN 10 305-1, 2008-06-27, Page 27
1 - For each of the six samples, a different surface to fall on (+/-

Number of Drops per component
X, Y, Z) shall be chosen.
Drop Height 1m
Test Temperature RT
Sample size 6
Operating status Power-off without mating connectors

5.6.1)
Test Procedure
A. Drop the component from 1-m height to a concrete surface. The component shall be oriented prior to
the release so that each component is released only once in one of the positive and negative direction
of its primary +/- X, Y, and Z-axes.
Acceptance Criteria
Component shall be visually inspected for any obvious damage with the naked eye.
If the component shows no obvious damage (e.g. breakage of indicator lamps, vacuum fluorescent display
(VFD), liquid crystal display (LCD) or similar), functional performance shall be verified by parametric
measurements before start and after completion of the test to conform requirements stated in the
Component Specific Released Document.
If the component shows obvious damage, this damage shall be documented e. g. by photographs and
reviewed with the Component Releasing Engineer.
6.2.6 Switch Mechanical Operation/ Abrasion Endurance
Purpose
Evaluate abrasion resistance of labels and inscription on switch surfaces to human interface along with
switch mechanical functions through the useful life. This test is based on IEC 60068-2-70 “Abrasion of
markings and letterings caused by rubbing of fingers and hands”.
Scope
This test shall apply to all switches and components with integrated switches having human interaction
during vehicle use.
Number of switching cycles As defined in the Component Specific Released Document

including switch functions/positions covered, types of travel,
Type of switch activation
travel time (from one position to another), dwell time (time in
each position), off time in each position, etc.
(10 +/- 2) N unless otherwise defined in the Component
Actuation force
Actuation force direction As defined in the Component Specific Released Document
2 strokes per minute unless otherwise defined in the
Switch cycle rate/cycle frequency
Component Specific Released Document
If any test liquid shall be used, the type of liquid (e. g. artificial
Test liquid sweat) shall be defined in the Component Specific Released
Document.

MBN 10 305-1, 2008-06-27, Page 28
In deviation from IEC 60068-2-70, a temperature profile

Test chamber temperatures
according to figure 4 shall be used (Top.min, RT and Top.max)
Sample size 5
Operating status Operational with Continuous Monitoring (refer to section 5.6.3)

5.6.1).
Test Procedure
A. Place component/switch in the temperature chamber. Cycle the chamber through the temperature
profile shown in Figure 4.
B. Operate switch functions with continuous monitoring for the specified number of switching cycles
using mechanical test finger (size 2 according to IEC 60068-2-70) while applying test liquid if specified
in the Component Specific Released Document. Refer to IEC 60068-2-70 "Environmental testing-
Abrasion of marking and lettering due to rubbing of fingers/ hands" for additional information and test
procedure details.
In deviation from IEC 60068-2-70, 50% of the switching cycles shall be performed at RT, 25% of the
switching cycles shall be performed at Top.min °C (including transition time) and 25% of the switching
cycles shall be performed at Top.max °C (including transition time).
Figure 4: Switch Mechanical Operation/ Abrasion Endurance Cycle Profile

MBN 10 305-1, 2008-06-27, Page 29
Acceptance Criteria
the test to conform requirements stated in the Component Specific Released Document. This shall include
measurements of displacement (travel) versus force (load) and of the contact resistance.
6.3 Solids/ Fluids Compatibility
6.3.1 Dust (and other solid intrusion)
Purpose
Evaluate component functionality and protection level when exposed to dust or some other solid objects.
Dust intrusion in the E/E component can cause higher friction between moving parts and can also form
conductive bridge in the presence of humidity causing short circuit situation. Intrusion due to solid objects
(other than dust) can impair performance of component and may cause safety issues in some situations.
Scope
This test shall apply to all components categorized in IP protection classes IP 1X to IP 6KX. This test shall
not apply if no solid protection is required for the component (IP 0X) as in the case of components
permanently operating in the oil medium (examples: Power-train sensors or ECUs packaged/ operated in
the transmission chambers).
IP (International Protection) IP 1X to IP 6KX as defined in the Component Specific Released

category Document
According to DIN 40 050-9 (An English translation of this standard
shall be available on request).
Test procedure
Alternatively, a test procedure according to JIS D 0207 may be
used for testing protection classes IP 5KX and IP 6KX.
Dust type (for IP 5KX and IP 6KX) As specified in DIN 40 050-9 or JIS D 0207
3 3
Dust concentration/ Amount (for IP Approximately 2 kg per m of test chamber volume or (5 + 2) g/m
5KX and IP 6KX) air/dust mixture
Dust agitation method (for IP 5KX Continuous circulation of air & dust mixture or Floating dust
and IP 6KX) method using blower or some other
Sample size 5
Intermittent operation with Continuous Monitoring or power-off with
Operating status mating connectors as defined in the Component Specific Released
Document.
PTA Analysis shall be required for operating status "Intermittent
operation", if specified in the Component Specific Released
Document.
Test Procedure
Follow DIN 40050-9 for testing protection classes IP 1X to IP 6KX.

Alternatively follow JIS D 0207 for testing protection classes IP 5KX or IP 6KX.

MBN 10 305-1, 2008-06-27, Page 30
Acceptance Criteria
6.3.2 Water Intrusion
Purpose
Evaluate component functionality when exposed to different levels of water intrusion situations ranging
from water drip (experienced during light rain exposure) to high-velocity water jet with increased pressure
(experienced by exterior components when vehicle is washed by high pressure water jets).
Scope
This test shall apply to all components categorized in IP protection classes IP X1 to IP X6K as defined in
Table 3.
Supplier shall test to the following requirements:
IP X1 (Vertical water drip) to IP X6K (High velocity-pressure water

IP (International Protection) category
jet) as specified in the Component Specific Released Document.
Test Procedure According to DIN 40 050-9
Sample size 5
Operational or Intermittent operation with Continuous Monitoring
Operating status (refer to section 5.6.3) as defined in the Component specific
Released Document
Parametric measurement & analysis PTA Analysis shall be required, if specified in the Component
Test Procedure
Follow DIN 40050-9 for testing protection classes IP X1 to IP X6K.
Acceptance Criteria
6.3.3 High Pressure Steam Jet Exposure
Purpose
Evaluate component functionality when exposed to high-pressure steam jet cleaning conditions. This test
can cause seal failures causing electrical shorts, corrosion due to galvanic and electrolytic action, plastic
distortion, and failure of conformal coating, etc.

MBN 10 305-1, 2008-06-27, Page 31
Scope
This test shall apply to all components, which are sometimes exposed to high-pressure and/or steam jet
cleaning during car wash, engine wash or maintenance service and are therefore categorized in IP
protection class IP X9K.
IP Category IP X9K (High pressure steam jet exposure)
Test Procedure According to DIN 40 050-9
Sample size 5
Operating status Non-operational with mating connectors

5.6.1).
Test Procedure
Follow DIN 40050-9 for IP protection class IP X9K.
Acceptance Criteria
6.3.4 Salt Water Immersion
Purpose
Evaluate component functionality when exposed to periodic or temporary water immersion experienced
when a vehicle passes over a water puddle or when a car stops in water puddle. The test described in this
section is considered to be sufficient to prove compliance with protection class IP X7 according to DIN 40
050 for components in automobile use. The test failure can cause water intrusion, seal failures causing
electrical shorts, corrosion due to galvanic and electrolytic action, plastic distortion, and failure of
conformal coating, etc.
Scope
This test shall apply to all components categorized in IP protection class IP X7. Generally, under-hood or
under-body components that are located within 50 cm from the ground and are likely to be exposed to
water splash/immersion while driving through water puddle belong into protection class IP X7. However, in
some cases components located above the stated criteria may also require IP X7 protection based on
decision of Releasing Engineer.
Number of immersion cycles 20
0
Minimum test temperatures 0 C
0
Maximum test temperature Tmax, if Tmax is less than 110 °C, otherwise 110 C

MBN 10 305-1, 2008-06-27, Page 32

Component soak time at maximum based on MBN 10 305-2.
test temperature Suitability of defined soak time shall be verified by
measurements.
Immersion time 5 minutes
Sample size 5
Power-off during pre-heating and operational with Continuous
Operating status
Monitoring during immersion
5.6.1).
Test Procedure
A. Place component with connector and wiring harness in a temperature chamber and pre-heat
components to applicable maximum test temperature.
B. Keep the component at maximum test temperature for the specified component soak time.
C. Submerge the component within 30 seconds after removing from temperature chamber in salt water
0
(5% by weight) tank and operate component at 0 C for about 5 minutes with continuous monitoring.
Component shall be at least 25 mm below the surface of the water.
D. Repeat steps A through C for 20 times.
Acceptance Criteria
6.4 Chemical Resistance
6.4.1 Mixed Flowing Gas
Purpose
Determine influence of corrosive gases on the operating and storage conditions of electrical components,
and especially on switch and connector terminals/ contacts. This test can cause corrosion of contact
surfaces causing increase in the circuit resistance or even open circuit situation.
Scope
This test shall apply to all components which are not permanently operated in a liquid medium (e. g:
Power-train sensors or ECUs packaged/ operated in the transmission chambers).
Test duration 14 days
Test procedure According to IEC 60068-2-60 Method 4

MBN 10 305-1, 2008-06-27, Page 33
Hydrogen sulfide (H2S) 10 ppb

Note
Composition of test gases Sulfur dioxide (SO2) 200 ppb
Chlorine (Cl2) 10 ppb
Nitrogen dioxide (NO2) 200 ppb
Relative Humidity 75%
Test chamber temperature RT
Sample size 5

5.6.1).
9
Note: Gas concentration in ppb = parts per billion (1 in 10 ) volume per volume (vol/vol) in air.
Test Procedure
Follow all the necessary safety procedures!
A. Place component with mating connector in a test chamber and subject it to mixed flowing gas
environment according to IEC 60068-2-60.
B. Terminate testing after specified test duration.
Acceptance Criteria
the test to conform requirements stated in the Component Specific Released Document. This shall include
the measurement of contact resistances.
6.4.2 Salt Fog
Purpose
Evaluate component functionality after exposure to salt fog environment as experienced in coastal regions
and or from road salt exposure in the snow-belt region during winter season. This test can cause corrosion
of contact surfaces causing increase in the circuit resistance or even open circuit situation.
Scope
24 hours for components located inside passenger cabin,

Test duration trunk or door and 96 hours for all other locations (under-hood,
underbody and exterior)
Test procedure According to IEC 60068-2-11
0
Test chamber temperature 35 C

MBN 10 305-1, 2008-06-27, Page 34
Sample size 5
Salt water solution 5% (+1, -1) by weight

Note
Operating status section 5.6.3) as defined in the Component Specific
Released Document
5.6.1).
Note: Intermittent ECU operation depends on component location and type of connectors used.
Component Specific Released Document shall specify intermittent operation cycle. Typically, ECUs
located in Under-hood and underbody shall have sealed connectors. Such ECUs shall have more
operational interval and less non-operational interval, whereas, ECUs located inside passenger cabin/
trunk use unsealed connectors and are usually non-operational for longer duration.
Test Procedure
A. Place component with mating connectors in the test chamber.
B. Subject component to salt fog atmosphere according to IEC 60068-2-11while operating the
component with continuous monitoring for the specified test duration.
Acceptance Criteria
6.4.3 Chemical Exposure – Cabin Compartment
Purpose
Evaluate component performance due to accidental spills from commonly used fluid/ chemicals in the
passenger cabin compartment. This test can cause failure of sealing mechanism causing corrosion or
shorts, loss of switch actuation due to sticking or binding.
Scope
This test shall apply to all components mounted in the passenger cabin and are likely to be exposed to
commonly used fluids in the passenger cabin such as coffee, cola, glass or leather cleaners, etc.
The following fluids/ chemicals are likely to be exposed to a component during vehicle’s useful life and
shall therefore be tested to qualify component located in the passenger cabin.
The liquids to be used for a certain component shall be specified in the Component Specific Released
Document.

MBN 10 305-1, 2008-06-27, Page 35
Name of Fluid/
Specific Grade/ type
Chemical
Interior cleaning fluid -
MB no. A 000 986 47 74
Cockpit spray
Solvent - Stain remover MB no. A 001 986 28 71
Leather care foam MB no. A 001 986 59 71
Plastic and vinyl cleaner MB no. A 000 986 51 71
Glass cleaner MB no. A 001 986 38 71

5% soap concentration
Soapy water
by weight
100 ml Coffee with
Hot beverages cream (6 ml.) and sugar
(6 ml)
Cold beverages Regular (non-diet) cola
Saline solution 10% salt by weight
Note: MB specific fluids/ chemicals can be purchased from Mercedes-Benz dealership. The fluid selection
in the above table is for reference only. The liquids to be used for an individual component shall be
specified in the Component Specific Released Document. Additional fluids may be added if necessary.
Test duration 24 hours per fluid application
Fluids/Chemicals As defined in the Component Specific Released Document

Amount of test fluid/chemical 100 ml - Cleaning fluids shall be applied by spaying while bulk
liquids shall be applied by pouring/spilling.
0
Storage temperature 70 C
Dwell time at storage temperature 4 hours + 12 hours = 16 hours per cycle (refer to figure 5)
Sample size 5 (up to 3 fluids per test sample)

Non-operational with mating connectors and power supplied to
Operating status
simulate parking situation
5.6.1)
Test Procedure (Refer to Figure - 5)
A. Place component in a temperature chamber maintained at 40 °C on a test fixture representative of in-

vehicle position with any protective surrounding structures.
B. Keep the component at 40 °C for one hour (a to b in Fig. 5). Remove component from the chamber
and apply 100 ml of test fluid/chemical by either spraying or pouring to cover all faces of component.
Store component at outside ambient temperature (RT) for 1 hour (b to c in Fig. 5).
0
C. Replace the component in the chamber and keep it at 40 C for one hour (c to d in Fig. 5). Then ramp
0
up the chamber temperature to 70 C within 30 min (d to e in Fig. 5) and keep the component at 70 °C
0
for 4 hours (dwell time - e to f in Fig. 5). Ramp down the chamber temperature to 40 C within 30 min
(f to g in Fig. 5).

MBN 10 305-1, 2008-06-27, Page 36
D. Repeat steps B and C for the same fluid, but prolong dwell time from 4 hours to 12 hours at high
temperature (k to l in Fig. 5).
E. Repeat step B, C and D for the next fluid in the set. Continue the process up to a maximum of three
fluids per component.
Acceptance Criteria
Figure - 5 Temperature Profile (Fluid Exposure Tests)
6.4.4 Chemical Exposure - Outside Cabin Compartment
Purpose
Evaluate component performance due to accidental spills from commonly used fluid/ chemicals in the
under-hood, under-body, suspension or wheel mounted locations. This test can cause failure of potting or
sealing mechanism causing corrosion or shorts, plastic distortion of materials, cracking of PC boards or
ceramic substrates, and loss of integrity of component housing material.
Scope
This test shall apply to all components mounted outside the passenger compartment.
The following fluids/ chemicals are likely to be exposed to component during vehicle’s useful life and shall
therefore be tested to qualify components located in the under-hood, chassis or under-body.
The liquids to be used for an individual component shall be specified in the Component Specific Released
Document.
Components exposed to "Battery Acid" shall not be exposed to any other fluid for safety reasons.

MBN 10 305-1, 2008-06-27, Page 37
Test Sample
Name of Fluid/ chemical Specific Grade Numbers
1 2 3 4 5
Automatic transmission fluid A 001 989 21 03 X
Hypoid lubricant A 001 989 26 03 X
Hydraulic fluid A 001 989 24 03 / X
Power steering fluid A 000 989 88 03 X
Differential lubricant A 001 989 17 03 X
Central hydraulic fluid A 001 989 20 03 X
Engine oil A 000 989 78 01 X
Engine Wax Protective A 000 986 33 70 X
Engine Coolant/ Ethylene Glycol A 000 989 08 25 X
Gasoline DIN EN 228 X
Diesel fuel DIN EN 590 X
Bio-diesel/ Methanol based fuel DIN V51 606 X
Brake fluid A 000 989 08 07 X
Windshield washer A 001 986 75 71 X
Car Wash Cleaner/ Soap solution A 001 986 41 71 X

3
Battery acid - dilute sulfuric acid Density: 1.285 g/cm X
Note: MB specific fluids/ chemicals can be purchased from Mercedes-Benz dealership.

The fluid selection in the above table is for reference only. The liquids to be used for an individual
component shall be specified in the Component Specific Released Document. Additional fluids may be
added if necessary.
Test duration 24 hours per fluid application
Fluids/Chemicals As defined in the Component Specific Released Document

Amount of test fluid/chemical 100 ml - Cleaning fluids shall be applied by spaying while bulk liquids
shall be applied by pouring/spilling.
0 0
Storage temperature 70 C; 60 C (for battery acid)
Dwell time at storage
4 hours + 12 hours = 16 hours per cycle (refer to figure 5)
temperature
Sample size 5 (up to 4 fluids per test sample)
Non-operational with mating connectors and power supplied to
Operating status
simulate parking condition
analysis

MBN 10 305-1, 2008-06-27, Page 38
Test Procedure (Refer to Figure - 5)
A. Place component in a temperature chamber maintained at 40 °C on a test fixture representative of in-

vehicle position with any protective surrounding structures.
0
B. Keep component at 40 C for one hour (a to b in Fig. 5). Remove component from the chamber and
apply 100 ml of test chemical by either spraying or pouring to cover all faces of component. Store
component at outside ambient temperature (RT) for 1 (b to c in Fig. 5).
0
C. Replace the component in the chamber and keep it at 40 C for one hour (c to d in Fig. 5). Then ramp
0 0
up the chamber temperature to 70 C (60 C for battery acid) within 30 min (d to e in Fig. 5) and keep
the component at that temperature for 4 hours (dwell time - e to f in Fig. 5). Ramp down the chamber
0
temperature to 40 C within 30 min (f to g in Fig. 5).
D. Repeat steps B and C for the same fluid but prolong dwell time from 4 hours to 12 hours at high
temperature (from k to l in Fig. 5).
E. Repeat step B, C and D for the next fluid in the set. Continue the process up to a maximum of four
fluids per component.
Acceptance Criteria
End of Main Document

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Mercedes-Benz MBN 10 305-1

Engineering Standard Date Published: 2008-06-27

E/E Environmental Testing

Copyright Daimler AG 2008

Uncontrolled copy when printed (: Daniel Volkmann, 2008-10-10)

Copyright Daimler AG 2008

Uncontrolled copy when printed (: Daniel Volkmann, 2008-10-10)

3 Terms and Definitions

Component Specific Released Document: Component specific Requirement Specifications (German:

E/E: Electrical and/or Electronic.

HTHE: High Temperature and Humidity Endurance test.

HTOE: High Temperature Operating Endurance test.

Nine Point Check: Parametric measurements of component’s functional parameters at 3 different

Copyright Daimler AG 2008

Uncontrolled copy when printed (: Daniel Volkmann, 2008-10-10)

Non-operational: A component shall be considered “Non-operational”, if it is connected to a power

PCB: Printed Circuit Board.

PTA: Parametric Trend (Drift) Analysis. If a component is tested in operational or intermittent-operational

PTCE: Powered Thermal Cycle Endurance test.

RT: Room Temperature (23 + 5) °C.

UT. min: Minimal test-voltage applied to the component.

UT. typ: Typical test-voltage applied to the component.

UT. max: Maximum test-voltage applied to the component.

Copyright Daimler AG 2008

Uncontrolled copy when printed (: Daniel Volkmann, 2008-10-10)

4 Regulated Substances and Recyclability

5.1 Environmental Stress Categories

5.1.1 Climatic Stresses

5.1.2 Mechanical Stresses

5.1.3 Solids/ Fluids Stresses

5.1.4 Chemical Stresses

5.2.1 Temperature Classification

Table 1: Temperature Classification and Tmax Values

Temperature Class I II III IV V

5.2.2 Vibration Classification

Copyright Daimler AG 2008

Uncontrolled copy when printed (: Daniel Volkmann, 2008-10-10)

Table 2: Vibration Classification based on Component Mounting Location

Component Mounting Location Vibration Class

Component mounted on transmission III

Component mounted on suspension or wheel IV

Protection against intrusion of solid

With diameter > 50 mm 1 Vertical water drips 1

With diameter > 12.5 mm 2 Water drips (15 ° inclination) 2

With diameter > 2.5 mm 3 Water spray 3

With diameter > 1.0 mm 4 Water splash with pressure 4K

Dust protection 5K High-velocity water jet 5

Continuous submersion in water 8

High-pressure steam-jet cleaning 9K

5.3 Testing Requirements

Copyright Daimler AG 2008

Uncontrolled copy when printed (: Daniel Volkmann, 2008-10-10)

5.4 Test documentation

5.5 Test Equipment and Fixture

5.6 Parametric Measurements and Analysis

5.6.1 Parametric measurements before/after tests

5.6.2 Parametric measurements at defined intervals during tests