VW80000 en PDF

Group standard VW 80000
Issue 2013-06
Class. No.: 8MA00
Descriptors: component, electric component, electronic component, electr. assembly, test condition, LV 124
Electric and Electronic Components in Motor Vehicles up to 3,5 t

General Requirements, Test Conditions and Tests
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
– Transfer of supply specification LV 124 to VW 80000
Page 1 of 1. Continued on 161 pages of LV 124.

Always use the latest version of this standard.
This electronically generated standard is authentic and valid without signature.
The English translation is believed to be accurate. In case of discrepancies, the German version is alone authoritative and controlling.
Numerical notation acc. to ISO/IEC Directives, Part 2.
Technical responsibility The Standards department

EEIP/1 Dr. Torsten Polte Tel.: +49 5361 9 36035
I/EE-61 Uwe Girgsdies Tel.: +49 841 89 90836 EKDV/4 Dirk Beinker EKDV
EEH4 Achim Henne Tel.: +49 711 911 88782 Tel.: +49 5361 9 32438 Manfred Terlinden
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
Electric and Electronic Components in Motor Vehicles

up to 3,5 t - General Component Requirements,
Test Conditions and Tests
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Change history
Date of issue
2013-02 Editorial changes incorporated.
Part I – Electrical requirements and tests of the 12 V electric

system:
Thoroughly revised – each test was adapted to current requirements.
Part II – Environmental requirements and tests:

Expanded to components that are described in several operating
situations and components that are connected to coolant circuits; the
service life tests were revised.
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Contents
Part I – Electrical requirements and tests of the 12 V electric system ..................... 6

1 Scope ................................................................................................................... 6
2 Referenced standards ........................................................................................ 6
3 Terms and definitions ......................................................................................... 7
3.1 Terms and abbreviations....................................................................................... 7
3.2 Voltages and currents ........................................................................................... 7
3.3 Temperatures........................................................................................................ 8
3.4 Times/durations .................................................................................................... 8
3.5 Internal resistance, terminal designation, frequency ............................................. 8
4 General requirements ......................................................................................... 9
4.1 Voltages and currents ........................................................................................... 9
4.2 Temperature specifications ................................................................................... 9
4.3 Standard tolerances .............................................................................................. 9
4.4 Standard values .................................................................................................. 10
4.5 Sampling rate and measured value resolution .................................................... 10
4.6 Test voltages ....................................................................................................... 10
4.7 Operating voltage ranges and encoding ............................................................. 10
4.8 Functional statuses ............................................................................................. 11
4.9 Operating modes ................................................................................................ 12
4.10 Interface description ............................................................................................ 13
4.11 Procedural limitations .......................................................................................... 13
4.12 Electrical tests ..................................................................................................... 14
5 Test selection table ........................................................................................... 16
6 Electrical requirements and tests .................................................................... 18
6.1 E-01 Long-term overvoltage................................................................................ 18
6.2 E-02 Transient overvoltage ................................................................................. 19
6.3 E-03 Transient undervoltage ............................................................................... 21
6.4 E-04 jump start .................................................................................................... 22
6.5 E-05 Load dump ................................................................................................. 23
6.6 E-06 Superimposed alternating voltage .............................................................. 24
6.7 E-07 Slow decrease and increase of the supply voltage ..................................... 26
6.8 E-08 Slow decrease, quick increase of the supply voltage ................................. 28
6.9 E-09 Reset behavior ........................................................................................... 30
6.10 E-10 Short interruptions ...................................................................................... 32
6.11 E-11 Start pulses ................................................................................................ 35
6.12 E-12 Voltage curve with electric system control .................................................. 39
6.13 E-13 Pin interruption ........................................................................................... 40
6.14 E-14 Connector interruption ................................................................................ 42
6.15 E-15 Reverse polarity.......................................................................................... 43
6.16 E-16 Ground offset .............................................................................................. 46
6.17 E-17 Short circuit in signal circuit and load circuits ............................................. 47
6.18 E-18 Insulation resistance ................................................................................... 49
6.19 E-19 Closed-circuit current.................................................................................. 50
6.20 E-20 Dielectric strength ....................................................................................... 51
6.21 E-21 Backfeeds................................................................................................... 52
6.22 E-22 Overcurrents ............................................................................................... 54
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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
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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
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
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Part I – Electrical requirements and tests of the 12 V

electric system
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
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3 Terms and definitions

3.1 Terms and abbreviations
Table 2: Abbreviations for electrical requirements and tests
Term/abbreviation Definition
Parts Electric, electronic or mechatronic component
(e.g. resistor, capacitor, transistor, IC, relay)
DUT Device under test – see "Device under test"
Functions Includes system-specific and diagnostic functions
ICT In-circuit test
Component Complete device, electronic control unit or mechatronics (with
housing)
Short circuit A short circuit of a load output is defined by a lower impedance
load case than with specified load up to the limit case 0 Ω.
Creeping short circuits (current just below short circuit detection)
are included.
A short circuit may be permanently present (component in
operation/not in operation).
On-grid parking Operating situation of a vehicle having an alternative drive train
that is parked and is connected to a charging station/socket but is
not being charged. In general, the vehicle can communicate with
the charging station.
Off-grid parking Operating situation of a vehicle having an alternative drive train
that is parked and is not connected to a charging station/socket.
Power user Real use case with maximum conceivable use
Device under test The system or component to be tested.
PTB Physikalisch-Technische Bundesanstalt (German national
metrology institute providing scientific and technical services)
Relevant to starting Components that are needed directly or indirectly for an engine
starting process
System Functionally linked components, e.g.,
brake control system (electronic control unit, hydraulic, sensors)
3.2 Voltages and currents

Table 3: Abbreviations for voltages and currents
VN Nominal voltage
VBmin Lower operating voltage limit
VB Operating voltage
VBmax Upper operating voltage limit
Vmax Maximum voltage that may occur during a test
Vmin Minimum voltage that may occur during a test
VPP Peak-peak voltage
Veff RMS value of a voltage
Vtest Test voltage
IN Nominal current
GND Device ground
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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)
3.5 Internal resistance, terminal designation, frequency

Table 6: Abbreviations for resistances, terminals, and frequencies
Ri Internal resistance of the source including the supply wiring
harness (see Figure 1: Internal resistance)
Terminal designations As per DIN 72552-2
f Frequency
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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
Figure 1: Internal resistance
All edge descriptions refer to the 10% or 90% voltage values.
4.2 Temperature specifications

Unless otherwise specified, all temperature specifications refer to the ambient air of the
DUT.
4.3 Standard tolerances

Unless otherwise indicated, the tolerances as per Table 7 apply.
The tolerances refer to the required measured value.
Table 7: Standard tolerances
Frequencies ±1%
Temperatures ±2 °C
Humidity ±5%
Times/durations +5%; 0%
Voltages ±2%
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Currents ±2%
4.4 Standard values

Unless otherwise indicated, the standard values as per Table 8 apply.
Table 8: Standard values
Room temperature TRT = 23 °C ± 5 °C
Humidity Hrel = 25% to 75% relative humidity
Test temperature Ttest = TRT
Operating voltage VB = 14 V
(for test)
4.5 Sampling rate and measured value resolution

The sampling rate and bandwidth of the measuring system must be adapted to the
respective test. All measured values with all maximum values (peaks) must be
recorded.
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.
4.6 Test voltages

Test voltages, especially for over- and undervoltage tests, can deviate significantly from
the operating voltage ranges in section 4.7 and will be specified individually.
Functional status A (see section 4.8) must always be fulfilled within the voltage range
applicable to the component.
4.7 Operating voltage ranges and encoding

Table 9: Operating voltage ranges
Encoding VBmin VBmax Description
a 6 V 16 V For functions that must retain their performance during
starting of the engine
b 8 V 16 V For functions that do not have to retain their performance
during starting of the engine
This encoding must only be used if the component cannot

be classified in the encoding a, c or d.
c 9V 16 V For functions that must retain their performance
when the engine is not running
d 9,8 V 16 V For functions that must retain their performance
when the engine is running
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4.8 Functional statuses

4.8.1 General
This section describes the functional status of the DUT during and after the test. The
functional status of the DUT is to be specified for each test.
The purchaser must define the functional behavior (including derating, e.g., with regard
to temperature and voltage) of the component in the functional statuses and the
customer perception (e.g., visual, acoustic, haptic, thermal) in the drawing or in the
Component Performance Specification.
Memory functions must always remain in functional status A. The integrity of the non-
volatile memories must be ensured at all times. The time sequences of the functional
statuses must be specified in the Component Performance Specification. Permissible
event memory entries must be coordinated with the purchaser and must be stipulated.
Damage to the DUT is not permissible in functional statuses A to D. The permissible
limits (e.g., electrical, thermal, mechanical) of the electrical/electronic parts installed in
the DUT, as specified in the data sheets, must not be exceeded. This is verified at least
by means of the parameter test (small) as per section 4.12.2.
4.8.2 Functional status A

The DUT must fulfill all functions during and after exposure to the test parameters.
4.8.3 Functional status B

The DUT must fulfill all functions during exposure to the test parameters; however, one
or more functions can lie outside the specified tolerance. After exposure to the test
parameters, the DUT must automatically achieve functional status A again.
4.8.4 Functional status C

The DUT does not fulfill one or more functions during exposure to the test parameters.
After exposure to the test parameters, the DUT must automatically achieve functional
status A again. Undefined functions are not permissible at any time.
4.8.5 Functional status D

The DUT does not fulfill one or more functions during exposure to the test parameters.
After exposure to the test parameters, the DUT must achieve functional status A again
by means of a terminal changeover, a reset, or a simple intervention (e.g., replacement
of a defective fuse). Undefined functions are not permissible at any time.
4.8.6 Functional status E

The DUT does not fulfill one or more functions during exposure to the test parameters
and must be repaired or replaced after exposure to the test parameters.
The device under test (DUT) must comply with the requirements for nonflammability as
per UL94-v0.
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4.9 Operating modes

4.9.1 General
The electric, electronic and mechatronic components and systems are operated in
different operating modes during service life, which must be simulated correspondingly
during the tests. Details concerning the operating modes, operating loads (e.g.,
activation, bus activity, bus messages, original sensors, original actuators, or
replacement circuitry), and the required boundary conditions must be agreed upon
between the contractor and the purchaser and must be documented.
4.9.2 Operating mode I - DUT not electrically connected

4.9.2.1 Operating mode I.a
The DUT is not electrically connected, without plug and harness.
Any present coolant circuit is not filled, and the connections are sealed.
4.9.2.2 Operating mode I.b

The DUT is not electrically connected, but with connected plugs and harness.
Any present coolant circuit is filled, and the coolant hoses are connected.
4.9.3 Operating mode II - DUT electrically connected
4.9.3.1 Operating mode II.a

The DUT must be operated without operating load.
Any present coolant circuit must be filled, and the coolant hoses must be
connected. If necessary, the flow rate and temperature of the cooling medium
must be set – as specified in the Component Performance Specification.
4.9.3.2 Operating mode II.b

The DUT must be operated with minimal operating load.
The DUT must be operated in a way that minimal self-heating occurs (e.g., by
reducing a continuous output power or by infrequent activation of external loads).
4.9.3.3 Operating mode II.c

The DUT must be operated at maximum load (power user, but no misuse).
The DUT must be operated in a way that maximum self-heating occurs (e.g., by
means of a realistic maximization of a continuous output performance or frequent
activation of external loads).
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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)
4.10 Interface description

All interfaces must be described completely in their statuses and electrical properties.
This description serves as a basis for the evaluation of the test results and must be
appropriately detailed.
4.11 Procedural limitations

The test laboratory must be organized and operated as per DIN EN ISO/IEC 17025. All
test equipment used for measuring must be calibrated as per DIN EN ISO/IEC 17025
(or as specified or recommended by the manufacturer). and it must be possible to trace
the equipment back to the PTB or an equivalent national standards laboratory. The
testing devices, equipment, set-ups, and test methods must not limit or influence the
behavior of the DUT (e.g., current draw). They must be documented in the test report
together with the accuracies and the expiration date of the calibration.
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4.12 Electrical tests

4.12.1 Test sequence
An electrical test begins when the DUT is completely started up and is in functional
status A.
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.
A set of sensitive parameters, so-called key parameters, e.g. closed-circuit current

consumption, operating currents, output voltages, contact resistances, input
impedances, signal rates (rise/fall times), and bus specifications, must be defined in the
Component Performance Specification or in agreement with the purchaser. Prior to
testing and after each test, it must be checked whether these parameters meet the
specifications.
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.
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4.12.2 Parameter test (small)

The key parameters must be measured and the functional behavior of the components
must be examined at TRT and VB. For components with event memories, the content of
the event memory must be read out. The components must be examined for external
damage/changes, e.g., cracks, chipping, bursting, discolorations, and deformation, in a
visual inspection as per DIN EN 13018 without opening the DUT.
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.
All results must be documented in the test report.
4.12.3 Parameter test (large)

The key parameters must be measured and the functional behavior of the components
must be measured at temperatures Tmax, TRT, and Tmin, in each case at voltages VBmin,
VB, and VBmax.
For components with event memories, the content of the event memory must be read
out. The components must be examined for external damage/changes, e.g., cracks,
chipping, bursting, discolorations, and deformation, in a visual inspection as per
DIN EN 13018 without opening the DUT.
memory entries and irregularities in the visual inspection must be evaluated regarding
the preceding test loads in comparison with the unused condition.
4.12.4 Physical analysis

For the physical analysis, the DUT must be opened and a visual inspection must be
conducted as per DIN EN 13018.
Additional analyses must be agreed upon between the purchaser and the contractor.
Examples of examinations are specified in Appendix G.
A change in the component in comparison with the unused condition must be evaluated.
If a DUT exhibits irregularities, the further analysis, possibly with additional DUTs, or the
use of additional analysis methods must be agreed upon with the purchaser.
The results must be documented and evaluated in the test report.
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5 Test selection table

Table 11: Test selection table
Test Applicable to To be additionally
defined by the
purchaser
E-01 Long-term overvoltage Components supplied via the 12 V Component
electric system necessary for
driving operation
E-02 Transient overvoltage Components supplied via the 12 V None
electric system
E-03 Transient undervoltage Components supplied via the 12 V None
electric system
E-04 Jump start Components supplied via the 12 V Component
electric system relevant/not
relevant to starting
E-05 Load dump Components supplied via the 12 V Safety-relevant
electric system component
E-06 Superimposed alternating Components supplied via the 12 V Test cases based
voltage electric system on connection in
the electric
system
E-07 Slow decrease and All components Relevant terminal
increase of the supply voltage status
E-08 Slow decrease, quick All components Relevant terminal
increase of the supply voltage status
E-09 Reset behavior All components Relevant terminal
status, test
boundary
conditions
E-10 Short interruptions All components None
E-11 Start pulses Components supplied via the 12 V Component
electric system relevant/not
relevant to starting
E-12 Voltage curve with electric Components supplied via the 12 V None
system control electric system
E-13 Pin interruption All components Relevant terminal
status
E-14 Connector interruption All components None
E-15 Reverse polarity Components that can be Severity, switch-
subjected to reverse polarity in the off of the
vehicle component in the
event of reverse
polarity
E-16 Ground offset All components None
E-17 Short circuit in signal All components None
circuit and load circuits
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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
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6 Electrical requirements and tests

6.1 E-01 Long-term overvoltage
6.1.1 Aim
The component's resistance to long-term overvoltage is tested. A generator control fault
during driving operation is simulated.
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
Figure 2: Test pulse E-01 Long-term overvoltage
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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.
b) For all other components:

Functional status C
6.2 E-02 Transient overvoltage

6.2.1 Aim
Transient overvoltages may occur in the electric system due to the switching off of loads
and due to short accelerator tip-ins. These overvoltages are simulated by means of this
test.
6.2.2 Test
Table 13: Test parameters, E-02 Transient overvoltage
Vmin 16 V
U1 17 V
Vmax 18 V (+4%, 0%)
tr 1 ms
tf 1 ms
t1 400 ms
t2 600 ms
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
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Figure 3: Test pulse E-02 Transient overvoltage
6.2.3 Requirement
Functional status A
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6.3 E-03 Transient undervoltage

6.3.1 Aim
Transient undervoltages in the electric system may occur due to switching on of loads.
These undervoltages are simulated by means of this test.
6.3.2 Test
Table 14: Test parameters, E-03 Transient undervoltage
Vmax 10,8 V (+4%, 0%)
Vmin 9 V (0%, -4%)
tr 1,8 ms
tf 1,8 ms
t1 500 ms
t2 1s
Test case 1
Ttest Tmax
Number of cycles 3
Test case 2
Ttest Tmin
Number of cycles 3
Figure 4: Test pulse E-03 Transient undervoltage
6.3.3 Requirement
Functional status A
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6.4 E-04 jump start

6.4.1 Aim
Jump starting of the vehicle is simulated. The maximum test voltage results from
commercial vehicle systems and their elevated electric system voltages.
6.4.2 Test
Table 15: Test parameters, E-04 jump start
Vmin 10,8 V
Vmax 26 V (+4%, 0%)
t1 60 s
tr <10 ms
tf <10 ms
Number of cycles 1
Figure 5: Test pulse E-04 jump start
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).
b) All other components:

Functional status C
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6.5 E-05 Load dump

6.5.1 Aim
Dumping of an electric load, in combination with a battery with reduced buffering ability,
results in an energy-rich overvoltage pulse due to the generator characteristics. This
pulse is simulated by means of this test.
6.5.2 Test
Table 16: Test parameters, E-05 Load dump
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
Figure 6: Test pulse E-05 Load dump
6.5.3 Requirement
a) Safety-relevant components:
Functional status B
b) All other components:

Functional status C
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6.6 E-06 Superimposed alternating voltage

6.6.1 Aim
Voltages may be superimposed to the electric system. The superimposed alternating
voltage may be applied during the entire running time of the engine. This situation is
simulated by means of these tests.
6.6.2 Test
Table 17: Test parameters, E-06 Superimposed alternating voltage
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
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
Figure 7: Test pulse E-06 Superimposed alternating voltage
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6.6.2.1 Test setup

The electric system conditions must be agreed upon with the appropriate departments.
The test setup must be documented in detail, including line inductance values, line
capacitance values, and line resistance values.
6.6.3 Requirement
Test case 1: Functional status A

Test case 2: Functional status A
Test case 3:
a) Components necessary for driving operation:
Functional status A
b) For all other components:

Functional status B
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6.7 E-07 Slow decrease and increase of the supply voltage

6.7.1 Aim
The slow decrease and increase of the supply voltage is simulated as it occurs during
the slow decharging and charging procedure of the vehicle battery.
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
Must be performed for all relevant statuses of

the voltage supply terminals (e.g., T.15, T.30,
T.87) and their combinations.
Start voltage VBmax (+4%, 0%)
Voltage change speed 0,5 V/min (+10%, -10%)
U1 VBmin
Holding time at V1 until event memory has been
t1
completely read out
Minimum voltage 0V
U2 VBmin
t2
completely read out
Final voltage VBmax (+4%, 0%)
Per relevant terminal status and their
combinations:
Number of cycles
1 cycle with operating mode II.a
1 cycle with operating mode II.c
Figure 8: Test pulse E-07 Slow decrease and increase of the supply voltage
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6.7.3 Requirement
The evaluation of the test results depends on the voltage range that is applied to the
component during the test.

a) Within the defined operating voltage of the component:
Functional status A
b) Outside of the defined operating voltage of the component:

Functional status C
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6.8 E-08 Slow decrease, quick increase of the supply voltage

6.8.1 Aim
This test simulates the slow decrease of the battery voltage to 0 V and the sudden
reapplication of the battery voltage, e.g., by applying a jump start source.
6.8.2 Test
Table 19: Test parameters, E-08 Slow decrease, quick increase of the supply voltage
Must be performed for all relevant statuses of the voltage

supply terminals (e.g., T.15, T.30, T.87) and their
combinations.
Start voltage VBmax (+4%, 0%)
Voltage drop 0,5 V/min (+10%, -10%)
V1 VBmin
t1
completely read out
Holding time at VBmin Until the event memory is completely read out.
Minimum voltage 0V
At least 1 min; however, as long as internal capacity is
t2
completely discharged
Final voltage VBmax (+4%, 0%)
tr ≤0,5 s
Number of cycles Per relevant terminal status and their combinations:
1 cycle with operating mode II.c
Figure 9: Test pulse E-08 Slow decrease, quick increase of the supply voltage
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6.8.3 Requirement
The evaluation of the test results depends on the voltage range that is applied to the
component during the test.
A distinction is made between the ranges:

a) Within the defined operating voltage of the component:
Functional status A
b) Outside of the defined operating voltage of the component:

Functional status C
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6.9 E-09 Reset behavior

6.9.1 Aim
The reset behavior of a component in its environment is simulated and tested. Test
boundary conditions (e.g., assembly, terminal, system) must be described in detail.
During operation, an arbitrary sequence of repeated switching-on/off procedures occurs;
this must not lead to an undefined behavior of the component.
The reset behavior is represented by a voltage variance and a time variance. Two
different test sequences are required to simulate different switch-off times. A component
must always undergo both sequences.
6.9.2 Test
Table 20: Test parameters, E-09 Reset behavior
Must be performed for all relevant statuses of the

voltage supply terminals (e.g., T.15, T.30, T.87) and
their combinations.
Vmax VBmin (0%, -4%)
Vth 6V
∆V1 (range from Vmax to Vth) 0,5 V
∆V2 (range from Vth to 0 V) 0,2 V
t2 At least ≥10 s and until the DUT has returned to 100%
operability (all systems rebooted without error).
tr ≤10 ms
tf ≤10 ms
For each test sequence, per relevant terminal status
and their combinations:
Number of cycles 1 cycle with operating mode II.c
Test case 1
t1 5s
Test case 2
t1 100 ms
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Figure 10: Test pulse, E-09 Reset behavior
6.9.3 Requirement
Functional status A when Vmax is reached again.
Undefined operating statuses must not occur under any circumstances.
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.
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6.10 E-10 Short interruptions

6.10.1 Aim
The component's behavior at short interruptions of different durations is simulated.
Test case 1 represents interruption of the supply voltage on the component.
Test case 2 represents interruption of the supply voltage in the electric system.
Such interruptions can occur due to events such as contact and line errors or bouncing
relays.
6.10.2 Test
Table 21: Test parameters, E-10 Short interruptions
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
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).
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S1 t2
tr
t1 t1
tf
Z1
Z2
t
Figure 11: State change of switch S1, E-10 Short interruptions
6.10.2.1 Test setup
Figure 12: Schematic circuit, E-10 Short interruptions
The closed switch S2 including the necessary lines must have a series resistance
<100 mΩ.
6.10.2.2 Test sequence

One reference measurement each with 100 Ω (±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.
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Then the tests as per Table 21 must be performed.
6.10.3 Requirement
For t1 <100 µs: Functional status A

For t1 ≥100 µs: Functional status C
It must be documented as of which time value t1 the DUT leaves functional status A for
the first time.
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6.11 E-11 Start pulses

6.11.1 Aim
When starting the engine, the battery voltage drops to a low value for a short period and
then slightly rises again. Most components are activated directly before starting for a
short period, then deactivated during starting, and activated again after starting when
the engine is running. In this test, the behavior of the component in the event of voltage
dips caused by starting is examined.
The starting process may be performed under different vehicle starting conditions: cold
start and hot start (automatic restart for start-stop). In order to cover both cases, two
different test cases are required. A component must always undergo both sequences.
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
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6.11.2.1 Test case 1 – Cold start

Table 23: Test parameters, E-11 Start pulses
Parameter "Normal" test pulse "Severe" test pulse
VB 11,0 V 11,0 V
VT 4,5 V (0%, -4%) 3,2 V +0,2 V
VS 4,5 V (0%, -4%) 5,0 V (0%, -4%)
VA 6,5 V (0%, -4%) 6,0 V (0%, -4%)
VR 2V 2V
tf ≤1 ms ≤1 ms
t4 0 ms 19 ms
t5 0 ms ≤1 ms
t6 19 ms 329 ms
t7 50 ms 50 ms
t8 10 s 10 s
tr 100 ms 100 ms
f 2 Hz 2 Hz
Break between two 2s 2s
cycles
Test cycles 10 10
Legend
a T.50 off
b T.50 on
c T.50 off
ttest Cycle
Figure 13: Cold start test pulse
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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.
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6.11.3.1 Components relevant for starting:
Test case 1 – Cold start:

"Normal" test pulse: functional status A
"Severe" test pulse: functional status B
Test case 2 – Hot start:

"Long" test sequence: functional status A
"Short" test sequence: functional status A
6.11.3.2 Components not relevant to starting:

Test case 1 – Cold start:
"Normal" test pulse: functional status C
"Severe" test pulse: functional status C
Test case 2 – Hot start:

"Long" test sequence: functional status A
"Short" test sequence: functional status A
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6.12 E-12 Voltage curve with electric system control

6.12.1 Aim
The behavior of the electric system with voltage controls, e.g., with the use of intelligent
generator controls or DC-DC converter controls, is simulated. By means of the control,
voltage curves can be set in the range from constant voltage to permanent voltage
fluctuations according to the test cases as per Table 25.
This is relevant to all load cases that the component can assume with the engine
running or the vehicle ready for operation.
6.12.2 Test
Table 25: Test parameters, E-12 Voltage curve with electric system control
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
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
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6.13 E-13 Pin interruption

6.13.1 Aim
The supply line interruption of individual pins is simulated. The test must be performed
in two different operating states. Different pulse forms must be used, because the
possible interruptions may differ greatly regarding their duration (from loose contacts to
permanent interruption).
6.13.2 Test
Table 26: Test parameters, E-13 Pin interruption
Must be performed for all relevant statuses of the voltage

supply terminals (e.g., T.15, T.30, T.87) and their
combinations.
Z1 Condition 1: pin connected
Z2 Condition 2: pin interrupted
tr ≤(0,1 * t1)
tf ≤(0,1 * t1)
Number of cycles The following applies to the two test cases and the
relevant terminal status:
3 cycles with operating mode II.a
3 cycles with operating mode II.c
Each test must be evaluated separately.

Test case 1
Each pin must be removed for t = 10 s and then replaced
(slow interval).
Test case 2
Burst on each pin in order to simulate a loose contact
(Figure 16)
Number of pulses t2 in the 4 000
burst
a Burst
t1 0,1 ms
t2 1 ms
t3 10 s
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Pin a
t2 t3
tf
t1
tr
Z1
Z2
t
Figure 16: Test pulse, E-13 Pin interruption, test case 2
The component is connected to the voltage supply.

The test must not be performed on the supply pins (e.g., T.15, T.30, T.87). The test
must also be performed on ground pins (T.31).
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.
Then the tests as per Table 26 must be performed.
6.13.3 Requirement
Functional status C for all test cases.
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6.14 E-14 Connector interruption

6.14.1 Aim
The line interruption of connectors is simulated.
6.14.2 Test
Table 27: Test parameters, E-14 Connector interruption
Number of cycles Each connector must be removed once in both
operating modes.

Each connector must be removed from the DUT for 10 s and then replaced. If the DUT
has several connectors, each connector must be tested individually. The test sequence
must be variable. If there are several connectors, their combinations must also be
tested.
6.14.3 Requirement
Functional status C
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6.15 E-15 Reverse polarity

6.15.1 Aim
The resistance of the DUT against reverse-polarity battery connection during jump
starting is simulated. Reverse polarity can occur several times and must not cause
damage to the component. Reverse polarity protection must be ensured for any
voltages down to the minimum test voltage. The vehicle fuse is not part of the reverse
polarity protection concept.
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.
The current draw during the test must be documented.

Table 28: Test parameters, E-15 Reverse polarity
DUT operating mode Operating mode II.a
Test case 1 Static reverse polarity as per Table 29
Test case 2 Dynamic reverse polarity as per Table 30
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6.15.2.1 Test case 1 – Static reverse polarity

This test case checks the robustness of the component at various reverse polarity
voltages that can arise depending on the vehicle state.
Table 29: Test parameters, E-15 Reverse polarity, static

Vmax 0V
Vmin -14,0 V
∆V1 -1 V
Severity 1 Ri <100 mΩ
t1 60 s
For a component for which the operating voltage is switched off

by a relay in the event of reverse polarity, the following deviating
value applies:
8 ms
t2 ≥60 s, but at least until the component has reached the same
thermal state as at the beginning of the test
tr ≤10 ms
tf ≤10 ms
Number of cycles 1
Figure 17: Test pulse, E-15 Reverse polarity – Static
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6.15.2.2 Test case 2 – Dynamic reverse polarity

This test case checks the reverse polarity of the component during operation in a
vehicle that is no longer capable of starting.
Table 30: Test parameters, E-15 Reverse polarity, dynamic

Vmax 10,8 V
Vmin -4,0 V
t1 60 s
For a component for which the operating voltage is switched off

by a relay in the event of reverse polarity, the following deviating
value applies:
8 ms
t2 ≤5 min
tr ≤10 ms
tf ≤10 ms
Number of cycles 3
Figure 18: Test case, E-15 Reverse polarity - Dynamic
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
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6.16 E-16 Ground offset

6.16.1 Aim
Potential differences between various ground connection locations can cause signal
distortions between components at these connection locations. It must be ensured that
potential differences between ground points up to a magnitude of ±1 V (static) in the
electrical assembly do not affect component functions.
6.16.2 Test
If the DUT has several voltage and ground connections, the test must be performed
individually for each connection point.
The component is connected as described in Figure 19.

Table 31: Test parameters, E-16 Ground offset
V 1V
Number of cycles Both switching positions
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
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6.17 E-17 Short circuit in signal circuit and load circuits

6.17.1 Aim
Short circuits on all device inputs and outputs and in the load circuit are simulated.
All inputs and outputs must be short-circuit-proof to +VB and GND (for activated and
non-activated outputs with and without voltage supply and with and without ground
connection).
The component must able to withstand a permanent short circuit.
6.17.2 Test
Table 32: Test parameters, E-17 Short circuit in signal circuit and load circuits
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
If the voltage supply/ground supply is provided via several pins, combinations must also
be taken into account.
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6.17.2.1 Test setup

The power supply unit used for the test must be able to supply the short-circuit currents
to be expected by the component. If this is not possible, buffering of the power supply
unit by means of a car battery is permissible (VBmax is the maximum
charging voltage in this case).
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

For inputs and outputs: record and evaluate the curve of the short-circuit current over
time.
The functional effects of the short circuits must be documented.
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
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6.18 E-18 Insulation resistance

6.18.1 Aim
The insulation resistance between parts without galvanic connection is determined.
Only the galvanically isolated pins that are connected in the vehicle and that required
isolation properties for their function are examined.
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.

For preparation, the DUTs must undergo the "damp heat, cyclic" test, which must be
agreed upon with the purchaser. Before the measurement, the DUTs must be allowed
to dry for 30 minutes.
6.18.3 Requirement
The insulation resistance must be at least 10 MΩ.
After the test, functional status A must be verified.
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6.19 E-19 Closed-circuit current

6.19.1 Aim
The closed-circuit current consumption must be determined.
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.
Table 34: Test parameters, E-19 Closed-circuit current

Test voltage 12,5 V (+4%, 0%)
Test case 1
T Tmin
Test case 2
T TRT
Test case 3
T Tmax
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.
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6.20 E-20 Dielectric strength

6.20.1 Aim
The dielectric strength between parts of the DUT that are galvanically isolated from
each other, e.g., connector pins, relays, windings, or lines, is simulated. The test must
be performed on components that contain or control inductive parts.
6.20.2 Test
Table 35: Test parameters, E-20 Dielectric strength
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.

For preparation, the DUTs must undergo the "damp heat, cyclic" test. Before the
measurement, the DUTs must be allowed to dry for 30 minutes.
6.20.3 Requirement
Functional status C
Dielectric breakdowns and electric arcs are not permissible.
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6.21 E-21 Backfeeds

6.21.1 Aim
The behavior of the DUT on T.15 and all other lines that can be used as wake-up lines
in the electric system is simulated. This test must be performed for all components
connected to T.15 and/or other "wakeable" lines.
6.21.2 Test
Table 36: Test parameters, E-21 Backfeeds
Vtest VBmax – 0,2 V
Test temperatures TBmax, TRT and TBmin

The DUT must be connected according to the circuitry in the vehicle (including sensors,
actuators, etc.) and operated in normal operation. The voltage curve at the terminal to
be tested must be measured during switch-off of the terminal. The terminal must be
switched off, e.g., by means of a relay or a switch (Ropen_switch→∞). Other possible
voltage sources such as T.30 must not be interrupted or switched off during the test (in
accordance with the behavior in the vehicle). Other resistors on the terminal to be tested
are not permitted for this test.
The voltage curve at the terminal to be tested must be examined with an external
resistance of ≥10 MΩ (e.g., oscilloscope) to T.31.
Legend
T Scanner head
Os Oscilloscope
K Terminal to be tested
Figure 21: Schematic circuit, test E-21 Backfeeds
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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.
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6.22 E-22 Overcurrents

6.22.1 Aim
The overcurrent protection of mechanical switches, electronic outputs and contacts is
tested. Higher currents than in the normal load case (e.g., maximum blocking current
Iblock of a motor) must also be considered.
6.22.2 Test
Table 37: Test parameters, E-22 Overcurrents
Temperature Tmax
Test conditions for electronic The output must withstand at least the triple value
outputs of the nominal load without damage.
Load duration 30 min

Test conditions for switched For components with IN ≤10 A:
outputs Itest = 3 x IN
For components with IN >10 A:
Itest = 2 x IN, but at least 30 A and at most
150 A
For components with Iblock >3 x IN:
Itest = Iblock
Under load, switch "OFF," "ON," and "OFF" again
once.
Load duration 10 min
Each contact must be tested individually in the case

of multiple-contact relays and multiple-contact
switches.
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).
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Part II – Environmental requirements and tests
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.
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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
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
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
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9 Terms and definitions

9.1 Terms and abbreviations
Table 39: Abbreviations for environmental requirements and tests
Electr. assembly PCB with circuit parts (without housing)
Parts Electric, electronic or mechatronic component
(e.g. resistor, capacitor, transistor, IC, relay)
DUT Device under test – see "Device under test"
Functions Includes system-specific and diagnostic functions
Hardware freeze The point during development as of which a modification of the
hardware is not possible anymore
ICT In-circuit test
Climatic chamber This is a specifically controlled water bath in the climatic
with condensation chamber by means of which the required water quantity is
option converted into water vapor.
The intensity of the condensation film on the circuit carrier
depends on the thermal mass, the relative humidity, and the
temperature gradient of the water bath.
The climate control of the climatic chamber is switched off
during the condensation phase. The test room temperature is
controlled by means of the temperature-controlled water bath.
Component Complete device, electronic control unit or mechatronic (with
housing)
DUT The system or component to be tested (device under test)
PTB Physikalisch-Technische Bundesanstalt
PSD Power Spectral Density
Circuit carrier Substrate without mounted parts for general electronics
(unpopulated PCB, ceramic, leadframe, flexband, etc. without
mounted parts)
System Functionally linked components, e.g.,
brake control system (electronic control unit, hydraulic,
sensors)
9.2 Voltages
Table 40: Abbreviations for voltage definitions
VBmin Lower operating voltage limit
VB Operating voltage
VBmax Upper operating voltage limit
9.2.1 Voltages for components with expanded requirements
VBmin,HV Lower HV operating voltage limit – lower DC operating voltage

VB,HV Operating voltage – HV DC operating voltage
VBmax,HV Upper HV operating voltage limit – upper DC operating voltage
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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
9.3.1 Temperatures for components on a coolant circuit

Tcool,nom Nominal coolant temperature in the coolant circuit
Tcool,min Minimum coolant temperature of the coolant circuit
Tcool,max Maximum coolant temperature of the coolant circuit
9.4 Times/durations
Table 42: Time definitions
ttest Test duration
toper. Operating hours over service life
9.5 Standard tolerances

Unless otherwise indicated, the tolerances as per Table 43 apply.
The tolerances refer to the required measured value.
Table 43: Standard tolerances
Frequencies ±1%
Temperatures ±2 °C
Humidity ±5%
Times/durations +5%; 0%
Voltages ±2%
Currents ±2%
Vibrations ±3 dB
Vibration PSD ±5%
9.6 Standard values

Unless otherwise indicated, the standard values as per Table 44 apply.
Table 44: Standard values
Room temperature TRT = 23 °C ± 5 °C
Humidity Hrel = 25% to 75% relative humidity
Test temperature Ttest = TRT
Operating voltage VB = 14 V
(for test)
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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.
Table 45: Description General part

Operating situations
Power line
High-voltage
Operating Vehicle Charging communication
battery pack
situation parked cable inserted active
charging
(if available)
Driving operation no no yes/no no
Charging
yes yes yes yes
operation
Preconditioning yes yes/no yes/no yes/no
On-grid parking yes yes no yes
Off-grid parking or
yes no no no
parking
All operating situations relevant to the component as per Figure 22 must be taken
into account when deriving the test requirements.
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Figure 22: Division of the load spectrum according to Operating situations
10.2 Operating modes

10.2.1 General
The electric, electronic and mechatronic components and systems are operated in
different operating modes during service life, which must be simulated
correspondingly during the tests. Details concerning the operating modes, operating
loads (e.g., activation, bus activity, bus messages, original sensors, original
actuators, or replacement circuitry), and the required boundary conditions must be
agreed upon between the contractor and the purchaser and must be documented.
10.2.2 Operating mode I – DUT not electrically connected
10.2.2.1 Operating mode I.a

The DUT is not electrically connected, without plug and harness.
Any present coolant circuit is not filled, and the connections are sealed.
10.2.2.2 Operating mode I.b

The DUT is not electrically connected, but with connected plugs and harness.
Any present coolant circuit is filled, and the coolant hoses are connected.
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10.2.3 Operating mode II – DUT electrically connected
10.2.3.1 Operating mode II.a

The DUT must be operated without operating load.
10.2.3.2 Operating mode II.b

The DUT must be operated with minimal operating load.
The DUT must be operated in a way that minimal self-heating occurs (e.g., by
reducing a continuous output power or by infrequent activation of external
loads).
10.2.3.3 Operating mode II.c

The DUT must be operated at maximum load (power user, but no misuse).
The DUT must be operated in a way that maximum self-heating occurs (e.g.,
by means of a realistic maximization of a continuous output performance or
frequent activation of external loads).
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10.2.3.4 Sample operating modes

Table 46: Sample operating modes
Sample component Operating Operating mode II.b Operating mode II.c
mode II.a
Car radio with Component Component in Component in running
navigation system as in parked running vehicle. vehicle. Component
vehicle Component switched on (CD,
(sleep). Post- switched off by navigation system, final
run current driver, BUS/µC's stage), BUS/navigation
stopped active, 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 Component Driving without Driving with frequent
system as in parked brake actuation. brake cycles (no
vehicle. Post- misuse, such as
run current uninterrupted brake
stopped. control operation).
On-board charger Off-grid On-grid parking Charging operation
parking (only power line
or communication, no
driving charging operation),
operation vehicle conditioning
High-voltage battery Off-grid On-grid parking with Driving operation,
pack (battery parking power line charging operation
energy communication
management
system)
10.3 Maintaining temperature

The temperature of a component exposed to a constant ambient temperature under
defined operating conditions is said to be maintained from the point in time as of
which the temperature will not change by more than ±3 °C at any point of the
component over the further course of time.
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.
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10.4 Parameter test

A set of sensitive parameters, so-called key parameters, e.g. closed-circuit current
consumption, operating currents, output voltages, contact resistances, input
impedances, signal rates (rise/fall time) and bus specifications, must be defined in
the Component Performance Specification. Prior to testing and after each test, it
must be checked whether these parameters meet the specifications.
For components connected to the coolant circuit, the parameter tests must be
performed at TRT with Tcool,nom, at Tmax with Tcool,max, and at Tmin with Tcool,min.
Unless otherwise specified in the Component Performance Specification, the
parameter tests must be performed at VBmin with VBmin,HV, at VB with VB,HV, and at
VBmax with VBmax,HV for components with HV supply.
10.4.1 Parameter test (small)

The key parameters must be measured and the functional behavior of the
components must be examined at TRT and VB. For components with event
memories, the content of the event memory must be read out. The components must
be examined for external damage/changes, e.g., cracks, chipping, bursting,
discolorations, and deformation, in a visual inspection as per DIN EN 13018 without
opening the DUT.
memory entries and irregularities in the visual inspection must be evaluated
regarding the preceding test loads in comparison with the unused condition.
10.4.2 Parameter test (large)

The key parameters must be measured and the functional behavior of the
components must be measured at temperatures Tmax, TRT, and Tmin, in each case at
voltages VBmin, VB, and VBmax.
out. The components must be examined for external damage/changes, e.g., cracks,
chipping, bursting, discolorations, and deformation, in a visual inspection as per
DIN EN 13018 without opening the DUT.
memory entries and irregularities in the visual inspection must be evaluated
regarding the preceding test loads in comparison with the unused condition.
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10.4.3 Parameter test (functional test)

The key parameters must be measured at a specified temperature at each of the
following voltages: VBmin, VB, and VBmax.
The basic functionalities of the components must be measured.
out.
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.
10.4.4 Physical analysis

For the physical analysis, the DUT must be opened and a visual inspection must be
conducted as per DIN EN 13018.
Additional analyses must be agreed upon between the purchaser and the contractor.
Examples of examinations are specified in Appendix G.
A change in the component in comparison with the unused condition must be
evaluated.
If a DUT exhibits irregularities, the further analysis, possibly with additional DUTs, or
the use of additional analysis methods must be agreed upon with the purchaser.
The results must be documented and evaluated in the test report.
10.5 Continuous parameter monitoring with drift analysis

The key parameters to be monitored must be recorded during the whole test.
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.
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10.6 Leak tightness test

For components through which a coolant flows, the leak tightness must be verified by
means of suitable tests. In these test, the specific design of the component and the
specification of the coolant circuit must be taken into account.
Unless otherwise specified in the Component Performance Specification, at least the
following tests must be performed to verify the leak tightness:
• 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).
10.7 Sampling rate and measured value resolution

The sampling rate and bandwidth of the measuring system must be adapted to the
respective test.
It must be ensured that function-relevant peaks (brief positive/negative deviation) are

detected and recorded.
The resolution of the measured values must be adapted to the respective test.
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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
11.2 Temperature spectrum

In order to completely describe the temperature load to which a component is
subjected at its installation location in the vehicle, in addition to the specification of
the minimum operating temperature Tmin and the maximum operating temperature
Tmax the distribution is required, which indicates for how long a component is
subjected to the different temperatures between Tmin and Tmax.
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).
In principle, this temperature distribution is a continuous distribution, as the ambient

temperature of the component may adopt any value between Tmin and Tmax.
For the design of the component and for a simple calculation of the test times by
means of the accelerated life-stress model by Arrhenius (see Appendix C), this
continuous distribution can be described sufficiently by means of several discrete
temperature sampling points TFeld, i. For each temperature sampling point, the
percentage pi of the operating time for which the component is exposed to the
sampling-point temperature must be indicated.
The respective temperature spectrum therefore has the following general form:
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Table 48: Temperature spectrum

Temperature (°C) Distribution
TField.1 = Tmin p1
TField.2 p2
… …
TField.n = Tmax pn
It is based mainly on field measurements and technical experiences.
Typical temperature spectrums for driving operation with regard to different

installation locations are indicated in Appendix B.
The usability of these typical temperature spectrums for a specific component must
be verified e.g. by means of vehicle measurement, simulation or experience. In case
of deviations, the temperature spectrum must be adapted to the relevant component.
For special installation locations and installation situations (e.g. a location near a heat
source), a component-specific temperature spectrum must always be defined.
The valid temperature spectrum must be documented in the Component
Performance Specification.
In addition to the typical temperature spectrums, typical values for an average
temperature rise of a component in the vehicle during driving operation are indicated
in Appendix B.
For temperature spectrums defined or adopted on a component-specific basis, this
value must also be documented on a component-specific basis and in the
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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
M-04 Vibration test All components None
-as per vibration profile Components installed on the engine

A
- as per vibration profile Components installed on the gearbox
B
- as per vibration profile Components installed on the decoupled intake
C plenum
- as per vibration profile Components installed on sprung masses
D (body)
- as per vibration profile Components installed on unsprung masses
E (wheel, suspension)
M-05 Mechanical shock All components None
M-06 Endurance shock test Components installed in r on doors and hoods Number of shocks
K-01 High-/low-temperature All components None

storage
K-02 Incremental temperature All components None
test
K-03 Low-temperature operation All components None
K-04 Repainting temperature Components installed on the vehicle exterior, None
which could be subjected to increased
temperatures during re-painting
K-05 Temperature shock All components Test method
(component) (Na or Nc),
as per Components that are not permanently if Nc:
DIN EN 60068-2-14 Na operated in a liquid test medium
(air-air)
as per Components that are permanently operated in
DIN EN 60068-2-14 Nc a liquid (IP X8)
(medium-medium)
K-06 Salt spray test with Components installed on the vehicle exterior, None
operation, exterior underbody or in the engine compartment
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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
- Degree of protection Components with an inclination of up to 15° in

IPX2 the installation position for which vertically
falling drops must have no harmful effect
- Degree of protection Components for which spray water must have

IPX3 no harmful effect
- Degree of protection Components for which spray water with
IPX4K increased pressure must have no harmful
effect
- Degree of protection Components for which water jets must have no
IPX5 harmful effect
- Degree of protection Components for which powerful water jets with
IPX6K increased pressure must have no harmful
effect
K-11 High-pressure cleaning Components that may be directly subjected to None
a high-pressure cleaning or underbody
cleaning
K-12 Temperature shock with Components installed on the vehicle exterior None
splash water which are expected to be subjected to splash
water (e.g. when driving through puddles)
K-13 Temperature shock - Components installed below the fording line for None
immersion which the temporary immersion into (salt)
water is to be expected (e.g. when driving
through waters) (IPX7)
K-14 Damp heat, constant All components Severity
K-15 Condensation and climate The necessity of the test must be evaluated for None
test each component. If required, the necessity of
the test must be specified in the Performance
Specification.
If the test is used in the Performance

Specification, the test can be performed as
test K-15 a Condensation test with assemblies
or as test K-15 b Climate test for components
with watertight housings for components with
watertight housings; the test must be
performed as test K-15 a Condensation test
with assemblies for components without a
watertight housing.
K-16 Temperature shock Electr. assemblies of all components None
(without housing)
K-17 Sun radiation Components exposed to direct solar radiation None
in the installation position
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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
12.2 Test sequence plan

A component-specific test sequence plan must be defined in the Component
A test sequence plan is contained in Appendix A as a basis for discussions for

cooperation projects between several OEMs (e.g., industrial assembly (IBK –
German abbreviation)).
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13 Mechanical requirements and tests

13.1 M-01 Free fall
13.1.1 Aim
This test simulates the free fall of a component to the floor, as it may occur during the
complete process chain until the intended installation of the component.
The test is used to ensure that a component that does not show any outwardly visible
damage and therefore is installed in the vehicle does not have any hidden damage or
pre-damage, e.g., internal part detachments or cracks.
13.1.2 Test
Table 50: Test parameters, M-01 Free fall
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 damaged on the outside, this damages must be documented in

the test report.
- 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.
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13.2 M-02 Stone impact test

13.2.1 Aim
This test simulates the mechanical load of the component imposed through stone
impact.
The test serves to verify the resistance of the component to faults, such as
deformation or cracks.
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.
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13.3 M-03 Dust test

13.3.1 Aim
This test simulates the dust load of the component during vehicle operation.
The test serves to verify the resistance of the component to electrical and mechanical
faults.
13.3.2 Test
The test is carried out as per ISO 20653 with the following parameters:
Table 52: Test parameters, M-03 Dust test

DUT For electrical/electronic components: operating mode II.a
operating
mode For mechatronic components
(e.g., for components with fans):
Operating mode II.c and operating mode II.a intermittently as per
Figure 23.
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.
Test setup Vertical flow direction as per ISO 20653:2006, figure 1
Degree of As specified in the Component Performance Specification
protection to
be achieved
Test duration 20 cycles of 20 minutes each
Number of 6
DUTs
Figure 23: Test sequence, M-03 Dust 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.
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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.
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13.4 M-04 Vibration test

13.4.1 Aim
These tests simulate the vibrational load of the component during driving operation.
The test serves to verify the resistance of the part to faults, such as component
displacement or material fatigue.
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
If the component is operated with operating load

during driving operation:
II.a and II.c intermittently in the "driving operation"
operating situation (see Figure 24)
Superimposed temperature Repeating as per Figure 24: Temperature curve
curve for vibration and Table 54: Temperature curve for
vibration
Frequency sweep time for 1 octave/min, logarithmic
sinusoidal excitation
Vibration profile A Vibration excitation, sinusoidal as per Figure 25
(for engine-mounted parts) and Table 55
Vibration excitation, wide-band random vibration

as per Figure 26 and Table 56
vibration profile B Vibration excitation, sinusoidal as per Figure 27
(for gearbox-mounted parts) and Table 57
Vibration excitation, wide-band random vibration

as per Figure 28 and Table 58
Vibration profile C Vibration excitation, sinusoidal as per Figure 29
(for components installed on the and Table 59
decoupled intake plenum)
Vibration profile D Vibration excitation, wide-band random vibration
(hang-on parts for components as per Figure 30 and Table 60
installed on sprung masses)
Vibration profile E Vibration excitation, wide-band random vibration
for unsprung masses (chassis) as per Figure 31 and Table 61
Number of DUTs 6
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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
- all DUTs with damping elements,

- all DUTs without damping elements or
- three DUTs with damping elements and three DUTs without damping
elements
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.
Figure 24: Temperature curve for vibration
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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.
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13.4.2.1 Vibration profile A (for engine-mounted parts)

Table 55: Test parameters – vibration, sinusoidal for engine-mounted parts
Vibration excitation Sinusoidal
Test duration for each 22 h
spatial axis
Vibration profile Characteristic 1 applies to components mounted on
engines with maximum 5 cylinders.
Characteristic 2 applies to components mounted on
engines with 6 or more cylinders.
The characteristics must be combined for components that

can be used in both cases.
Characteristic 1 in Frequency in Hz Amplitude of the
Figure 25 acceleration in m/s²
100 100
200 200
240 200
270 100
440 100
Characteristic 2 in Frequency in Hz Amplitude of the
Figure 25 acceleration in m/s²
100 100
150 150
440 150
Combination Frequency in Hz Amplitude of the
acceleration in m/s²
100 100
150 150
200 200
240 200
255 150
440 150
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Figure 25: Vibration profile, sinusoidal for engine-mounted parts
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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
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13.4.2.2 Vibration profile B (for gearbox-mounted parts)

Table 57: Test parameters – vibration, sinusoidal for gearbox-mounted parts
Vibration profile Figure 27 Frequency in Hz Amplitude of the
100 30
200 60
440 60
Figure 27: Vibration profile, sinusoidal for gearbox-mounted parts
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Table 58: Test parameters – vibration, wide-band random vibration for gearbox-mounted
parts
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
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13.4.2.3 Vibration profile C (for components installed on the decoupled

intake plenum)
Table 59: Test parameters, sinusoidal for components on the decoupled intake plenum
Vibration profile Figure 29 Frequency in Hz Amplitude of the
100 90
200 180
325 180
500 80
1 500 80
Figure 29: Vibration profile, sinusoidal for components on the decoupled intake plenum
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13.4.2.4 Vibration profile D (hang-on parts (for components installed on

sprung masses))
Table 60: Test parameters, wide-band random vibration for sprung masses
Test duration for each spatial axis 8h
Vibration profile Figure 30 Frequency in Hz Power density spectrum
in (m/s²)²/Hz
5 0,884
10 20
55 6,5
180 0,25
300 0,25
360 0,14
1 000 0,14
2 000 0,14
Figure 30: Vibration profile, wide-band random vibration for sprung masses
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13.4.2.5 Vibration profile E for unsprung masses (chassis)

Table 61: Test parameters, wide-band random vibration for unsprung masses
Test duration for each spatial axis 8h
Vibration profile Figure 31 Frequency Power density spectrum
in Hz in (m/s²)²/Hz
20 200
40 200
300 0,5
800 0,5
1 000 3
2 000 3
Figure 31: Vibration profile, wide-band random vibration for unsprung masses
13.4.3 Requirement
must meet the specifications. Verification takes place by means of continuous
parameter monitoring and a parameter test (small) as per section 10.4.
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13.5 M-05 Mechanical shock

13.5.1 Aim
This test simulates the mechanical load of components, e.g. when driving over curbs
or in accidents.
The test serves to verify the resistance of the component to faults, such as cracks or
component displacements.
13.5.2 Test
The test is carried out as per DIN EN 60068-2-27 with the following parameters:
Table 62: Test parameters, M-05 Mechanical shock

If the component is operated with
operating load during driving
operation:
II.c in the "driving operation"
operating situation
DUT operating mode
If the component is not operated
with operating load during driving
operation:
II.a
Peak acceleration 500 m/s2
Shock duration 6 ms
Shock form Half-sine
Number of shocks per direction (±X, ±Y, ±Z) 10
Number of DUTs 6
13.5.3 Requirement
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13.6 M-06 Endurance shock test

13.6.1 Aim
This test simulates the acceleration forces of components that are installed in doors,
hoods or liftgates and are subjected to high accelerations during opening and
closing.
The test serves to verify the resistance of the part to faults, such as component
displacement or material fatigue.
13.6.2 Test
Table 63: Test parameters, M-06 Endurance shock test

If several operating situations (see section 10) are

relevant to the component in operating mode II.c,
the mechanical shocks must be performed in the
various operating situations in equal proportions in
operating mode II.c.
Peak acceleration 300 m/s²
Shock duration 6 ms
Shock form Half-sine
Number of shocks
Installation area Number of shocks
Driver's door 100 000
Front passenger's 50 000
door/rear doors
Liftgats/rear gates 30 000
Engine hood 3 000
If the component is installed in several installation
areas, the highest number of shocks must be
applied.
Installation position The DUT must be mounted in the test device as
per the installation conditions in the vehicle.
Number of DUTs 6
13.6.3 Requirement
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14 Climatic requirements and tests

14.1 K-01 High-/low-temperature storage
14.1.1 Aim
This test simulates the thermal load of the component during storage and transport.
The test serves to verify the resistance to storage at high or low temperatures, e.g.
during the transport of the component (plane, ship container).
If the test is carried out at the beginning of a test sequence, it also serves to adjust all
components to the same initial conditions.
14.1.2 Test
Table 64: Test parameters, K-01 High-/low-temperature storage
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
meet the specifications. Verification takes place by means of a parameter test (large)
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14.2 K-02 Incremental temperature test

14.2.1 Aim
This test simulates the operation of the component at different ambient temperatures.
The test serves to verify the resistance of the component to malfunctions that may
occur within a small interval of the operating temperature range.
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
Figure 32: Temperature profile for incremental temperature test

14.2.3 Requirement
All DUT parameters must meet the specifications during the parameter test
(functional test).
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14.3 K-03 Low-temperature operation

14.3.1 Aim
This test simulates the load of the component at low temperatures.
The test is used to verify the function of the component after a long parking time or
driving time at extremely low temperatures.
14.3.2 Test
The test is carried out as per DIN EN 60068-2-1, test Ab, with the following
parameters:
Table 66: Test parameters, K-03 Low-temperature operation

DUT operating mode 12 h of operating mode II.a
12 h of operating mode II.c at VBmin
12 h of operating mode II.a
12 h of operating mode II.c at VB

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
Test duration 48 h
Test temperature Tmin
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
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14.4 K-04 Repainting temperature

14.4.1 Aim
This test simulates the load of the component during repainting.
The test serves to verify the resistance of the component to faults that occur due to
thermal load, e.g. cracking in soldered joints, adhesive joints and welded joints, in
bond connections as well as in seals or housings.
14.4.2 Test
Table 67: Test parameters, K-04 Repainting temperature
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
meet the specifications. Verification takes place by means of a parameter test (small)
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14.5 K-05 Temperature shock (component)

14.5.1 Aim
This test simulates the thermal load of a component imposed through shock-type
temperature changes during vehicle operation.
The test serves to verify the resistance of the component to faults that occur due to
thermal load, e.g. cracking in soldered joints, adhesive joints and welded joints, in
bond connections as well as in seals or housings.
14.5.2 Test
Table 68: Test parameters, K-05 Temperature shock (component)

Lower temperature/ Tmin
temperature of the cold
test bath
Upper temperature/ Tmax
temperature of the warm
test bath
Dwell time at 15 min after the component has achieved the condition at
upper/lower temperature which it maintains the temperature (see section 0)
Transfer duration ≤30 s
(air - air, medium -
medium)
Test fluid for test Nc Fluid in which the component is operated in the vehicle
Test As per DIN EN 60068-2-14 NA for components that are
not permanently operated in a fluid
As per DIN EN 60068-2-14 Nc for components that are

permanently operated in a liquid
(IP X8).
The DUT must be immersed so that all sides of the DUT
are covered by at least 25 mm of the test fluid.
Number of DUTs 6
14.5.3 Requirement
For medium - medium test additionally:

The fluid must not enter the DUT. The DUT must not be opened until after completion
of the complete test sequence (section 12.2).
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14.6 K-06 Salt spray test with operation, exterior

14.6.1 Aim
This test simulates the load of the component imposed by air and water containing
salt, a situation that may occur in certain areas of the world or at winterly road
conditions.
The test serves to verify the resistance of the component to malfunction under salt
load, e.g. due to short circuits and leakage currents caused by the ingress of salt into
the component.
14.6.2 Test
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
During the rest period: operating mode II.a

Test temperature 35 °C
Test cycle Each test cycle consists of a spray phase of 8 h and a rest phase
of 4 h as per Figure 33
Number of test For components on the underbody/in the engine compartment:
cycles 12 cycles
For other components: 8 cycles
Number of DUTs 6
must be simulated.
If there is a coolant circuit, the coolant temperature must be set to the test
temperature.
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Figure 33: Salt spray test with operation, exterior – spray phases
14.6.3 Requirement
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14.7 K-07 Salt spray test with operation, interior

14.7.1 Aim
This test simulates the load of the component imposed by air containing salt, as it
may occur in certain areas of the world.
The test serves to verify the resistance of the component to malfunction under salt
load, e.g. due to short circuits and leakage currents caused by the ingress of salt into
the components.
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

During rest phase: operating mode II.a

Test cycle Each test cycle consists of a spray phase of 8 h and a rest
period of 4 h as per Figure 34
Number of test cycles 2
Number of DUTs 6
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.
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Figure 34: Salt spray test with operation, interior – spray phases
14.7.3 Requirement
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14.8 K-08 Damp heat, cyclic

14.8.1 Aim
This test simulates the thermal load of the component imposed through cyclic
temperature changes at high humidities during vehicle operation.
The test serves to verify the resistance of the component to damp heat.
14.8.2 Test
Table 71: Test parameters, K-08 Damp heat, cyclic

Total test duration 144 h
Test variant Variant 1
Upper test temperature 55 °C
Number of cycles 6
Number of DUTs 6
14.8.3 Requirement
In addition, a parameter test (functional test) must be carried out after the upper and
the lower test temperature have been reached.
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14.9 K-09 Damp heat, cyclic (with frost)

14.9.1 Aim
This test simulates the thermal load (including frost) of the component imposed
through cyclic temperature changes at high humidities during vehicle operation.
The test serves to verify the resistance of the components to damp heat.
14.9.2 Test
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

Total test duration 240 h
Number of cycles 10
Test cycle sequence The first five cycles must include a cold phase and the
remaining cycles must be carried out without a cold
phase.
Number of DUTs 6
14.9.3 Requirement
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14.10 K-10 Water protection - IPX0 to IPX6K

14.10.1 Aim
This test simulates the load of the component when subjected to water.
The test serves to verify functioning of the component, e.g. when exposed to
condensed water, rain or spray water.
14.10.2 Test
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 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.
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14.11 K-11 High-pressure cleaning

14.11.1 Aim
This test simulates the load of the component when subjected to water during vehicle
cleaning.
The test serves to verify functioning of the component when exposed to high-
pressure cleaning.
14.11.2 Test
Table 74: Test parameters,
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.
completion of the complete test sequence (chapter12.2).
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14.12 K-12 Temperature shock with splash water

14.12.1 Aim
This test simulates the load of the component when exposed to splash water as it
occurs when driving through puddles.
The test serves to verify functioning of the component when subjected to shock-type
cooling by means of water.
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
If the component is operated with operating load during

driving operation:
II.a and II.c intermittently in the "driving operation" operating
situation (see Figure 35)
Test procedure Heating of the DUT to test temperature.
Then cyclical exposure of the DUT with splash water as per
Figure 35. The complete width of the DUT must be subjected
to splash water.
Cycle duration 30 min
Test temperature Tmax
Test medium for Tap water containing Arizona dust in a weight percentage of
splashing 3%, fine as per ISO 12103-1. Permanent mixing must be
ensured.
Splash water 0 to +4 °C
temperature
Splash nozzle See Figure 36
Splashing time 3s
Water flow 3 to 4 liters per splash/nozzle
Distance between 300 to 350 mm
nozzle and DUT
Number of DUTs 6
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.
temperature up to the limit Tcool,max. Only the ambient temperature is varied above the
coolant temperature limit.
Test setup as per Figure 37.
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Figure 35: Splash water test splashing times
Dimensions (mm)
Figure 36: Splash water test – splash nozzle
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Figure 37: Splash water test setup
14.12.3 Requirement
completion of the complete test sequence.
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14.13 K-13 Temperature shock – immersion

14.13.1 Aim
This test simulates the load of the component when immersed into water.
The test is to verify functioning of the component when subjected to immediate
cooling by means of immersion of the heated component.
14.13.2 Test
Table 76: Test parameters, K-13 Temperature shock – immersion

DUT operating If the component is operated with operating load during driving
mode operation:
II.c in the "driving operation" operating situation
If the component is not operated with operating load during

driving operation:
II.a
Required degree IP X7
of protection
Test procedure Heat the DUT to Top,max
Hold at Top,max until the DUT completely maintains its temperature
(see section 10.3) plus 15 min.
Completely immerse the DUT into the test medium within five
seconds so that all sides of the DUT are covered by at least
25 mm of the test medium.
Test medium 0 °C cold water with a salt content of 5%
Immersion time 5 min
Number of cycles 20
Number of DUTs 6
14.13.3 Requirement
completion of the complete test sequence (chapter12.2).
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14.14 K-14 Damp heat, constant

14.14.1 Constant damp heat - severity 1
14.14.1.1 Aim
This test simulates the load of the component through damp heat.
The test serves to verify the resistance 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.
14.14.1.2 Test
Table 77: Test parameters, K-14 Damp heat, constant– severity 1

Humidity 93% relative humidity
Test duration 21 days
Number of DUTs 6
14.14.1.3 Requirement
In addition, a parameter test (functional test) must be carried out every 7 days.
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14.14.2 Constant damp heat - severity 2
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
Table 78: Test parameters, K-14 Damp heat, constant– severity 2

DUT operating mode Intermitting operation, 47 h operating mode II.a and
1 h operating mode II.c each
Repeating until end of test duration

As specified in the Component Performance Specification
Test duration
as per section E.1 (Lawson model)
Test humidity 93% relative humidity
Number of DUTs 6
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).
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14.14.2.3 Deviating test for components with reduced performance at high
temperatures
For components with reduced performance (e.g., reduction of background lighting of
LCDs) at high temperatures from Top,max (Top,max <65 °C), the test must not be
performed at a constant temperature of 65 °C, but deviating from Table 78 with the
following parameters (see Table 79).
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.
Interval time t1 47 h
Interval time t2 1h
Number of DUTs 6
t1
65°C
Top,max
t2
II.a II.c II.a II.c II.a
Figure 38: Temperature profile for testing components with reduced performance at high
temperatures above Top,max
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14.15 K-15 Condensation and climate test

14.15.1 K-15 a Condensation test with assemblies
14.15.1.1 Aim
This test simulates the condensation on electronic assemblies in motor vehicles.
It is used to evaluate the resistance of electronic assemblies to condensation.
14.15.1.2 Test
The test is performed with assemblies without a housing with the following
parameters:
Table 80: Test parameters, K-15 a Condensation test with assemblies

DUT operating Operating mode II.a
mode In addition, parameter tests (functional tests) as described in the
"Test procedure" line must be carried out.
Test equipment Climatic chamber with condensation option (specifically controlled
water bath by means of which the required water amount is
converted into water vapor).
The climate control is switched off during the condensation phase.
The test room temperature is controlled by means of the
temperature-controlled water bath.
Test procedure 1. The climatic chamber keeps the initial temperature for
60 min to ensure that the DUT maintains the temperature.
Then the condensation phase begins.
2. A parameter test (functional test) is carried out at each
water bath temperature increase by 10 K starting 30 min
after beginning of the condensation phase (as per
Figure 41) until 30 min before the end of this phase,
however only at the voltage VB.
The parameter test (functional test) must be performed for a
maximum of 2 min with a power loss as low as possible;
otherwise the DUT is too strongly heated so that
condensation is prevented.
Test See Figure 41
temperature
Relative test See Figure 41
room humidity The relative humidity of the test room must be 100% (0%, -5%)
during the condensation phase.
Test duration 32,5 h (5 cycles à 6,5 h)
Test medium Distilled water with a maximum conductivity of 5 µS/cm
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DUT position As-installed position as in the vehicle.
Plastic brackets must be used to ensure that the electr.
assemblies remain in their as-installed position.
If the electr. assembly is used in different as-installed positions,
the DUTs must also be positioned in different as-installed
positions in the test room.
Test setup See Figure 39
During the test, a plastic cover as per Figure 40 must be used to
eliminate undesired effects in the case of different air speeds. The
cover must be aligned so that the bevel points to the test room
door.
The dimensions of the plastic cover must be adapted to the test
room size.
The distance between the plastic cover and the test room wall
must be 10% of the test room width/depth, however, at least 8 cm.
An angle of α ≥12° is to be used as roof slope of the plastic cover
as per DIN EN ISO 6270-2.
Test condition For the first time, the condensation test must be performed prior to
the final specification of the circuit layout (hardware freeze), but
already with assemblies manufactured under conditions similar to
production, to optimize detected condensation sensitivities, e.g.,
by means of layout and circuit modifications.
If the manufacturing process of the assembly is changed (e.g.,
circuit carrier, solder, flux, soldering process, layout, location, or
parts), the test must be repeated.
Number of 5
cycles
Number of 6 assemblies
DUTs
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Figure 39: Test setup, K-15 a Condensation test with assemblies
Figure 40: Plastic cover
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°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
1) Start of drying phase after reaching

75 °C air temperature Parameter test (function test) at UB Test chamber humidity
2) DUT must be dry Frel < 50 %
Water bath temperature ± 1 K Water bath temperature < 20°C

3) Transition from climate chamber control to
water bath control
Test chamber temperature ± 3 K Humidity curve not defined
**) Recording of test chamber humidity and temperature, temperature difference < 15 °C
Figure 41: Sequence, K-15 a Condensation test with assemblies
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:
1. Programming of the test chamber

2. Parameters (desired/actual) of a cycle
3. Parameters (desired/actual) of all five cycles
Examples see Appendix F.
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14.15.2 K-15 b Climate test for components with watertight housings
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
Test blocks 1, 3, and 5:

Table 81: Test parameters, K-15 b Climate test for components with watertight housings
Test blocks 1, 3, and 5
mode 12 hours after the start of the test block and subsequently after
every 24 hours, a parameter test (functional test) must be
performed.
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Test duration per As specified in the Component Performance Specification
test block Note:
The total test duration of test K-15 b (test blocks 1 to 5)
corresponds to the test duration of test K-14, Constant damp heat
– severity 2.
Of this, a test duration of 240 hours each is allotted to test blocks 2
and 4.
The remaining test time is allotted in thirds to test blocks 1, 3, and
5:
test durationtest block 1 = test durationtest block 3 = test durationtest block 5
= 1/3 (total test duration -2 * 240 hours).
Number of DUTs 6
Test blocks 2 and 4:

Table 82: Test parameters, K-15 b Climate test for components with watertight housings
Test blocks 2 and 4
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
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parameter monitoring and a parameter test (small) as per section 10.4.2.
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14.16 K-16 Temperature shock (without housing)

14.16.1 Aim
This technology test does not simulate any real load.
The test rather serves to detect weak spots in the field of mechanical joints on electr.
assemblies, such as solder points.
The test is to be performed exclusively with the electr. assembly of the component
without housing and mechanical parts.
14.16.2 Test
Table 83: Test parameters, K-16 Temperature shock (without housing)

Lower temperature Tmin
Upper temperature Tmax
Dwell time at 15 min after the component has achieved the condition at
upper/lower temperature which it maintains the temperature (see section 0)
Transfer duration ≤10 s
Number of DUTs 6 electr. assemblies
14.16.3 Requirement
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14.17 K-17 Solar radiation

14.17.1 Aim
This test simulates the influence of sun radiation and UV light onto the component.
The test serves to verify the resistance of the component to damages caused by
material fatigue, such as cracks or discolorations.
14.17.2 Test
The test is carried out as per DIN 75220 with the following parameters:
Table 84: Test parameters, K-17 Solar radiation

DUT operating Operating mode I.a
mode
Used test profiles The test profiles as per DIN 75220 must be used depending
on the installation location of the component.
Components in the Use of the Z-OUT profile as per Table 2 and Table 5 of
exterior DIN 75220
Components in the Use of the Z-IN1 profile as per DIN 75220
interior
Test duration 25 days (15 days dry, 10 days humid)
Number of cycles 1
Number of DUTs 6
14.17.3 Requirement
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.
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14.18 K-18 Harmful gas test

14.18.1 Aim
This test simulates the influence of harmful gases onto the component, particularly
onto its plug contacts and switches.
The test serves to verify the resistance of the part to faults, such as corrosion and
component damages.
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
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
In addition, the contact resistances of switches and contacts must be measured. The
measured values must meet the specifications.
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15 Chemical requirements and tests

15.1 C-01 Chemical tests
15.1.1 Aim
This test simulates the load of the component when subjected to different chemicals.
The test serves to verify the resistance of the component to chemical changes on the
housing and impairment of functioning due to chemical reactions.
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
Safety instructions and warnings for the chemicals must be observed.
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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
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Table 88: Types of application
Code number Application method
I Spraying
II Painting
III Wiping (e.g. with cotton cloth)
IV Dousing
V Short immersion
VI Immersion
15.1.3 Requirement
Changes to letterings or markings must be documented in the test report and

coordinated with the purchaser.
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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.
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
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 intermediate measurements must be carried out as parameter test (large).
The data of the continuous parameter monitoring must be examined with respect to
drifts, trends and irregularities.
For components on coolant circuits:

For components with coated copper parts in the coolant path, these copper parts
must be examined with a stereo microscope at 20x magnification after the test. Flaws
and copper corrosion that can be detected in the examination are not permissible.
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16.2 L-02 Life test – high-temperature endurance test

16.2.1 Aim
This test simulates in compact form the thermal load of the component during vehicle
service life.
faults that occur due to thermal load, e.g diffusion, migration and oxidation.
16.2.2 Test
16.2.2.1 Test for components without a connection to the coolant circuit

without reduced performance at high temperatures
Table 90: Test parameters, L-02 Life test – high-temperature endurance test – Test for
components without a connection to the coolant circuit without reduced performance at high
temperatures
DUT operating Intermitting, 47 h operating mode II.c an 1 h
mode Operating mode II.a
For each relevant operating situation as per section 10.1, the
partial test duration must be calculated as per appendix C.1
(Arrhenius model); the "parking" and "off-grid parking"
Test duration
operating situations generally must not be taken into account.
The total test duration is the sum of all partial test durations
and is specified in the Component Performance Specification.
Test temperature Tmax
Number of DUTs 6

with reduced performance at high temperatures
LCDs) at high temperatures from Top,max, the test must not be performed at a
constant test temperature of Tmax as per Table 91, but rather with a temperature
profile with the following parameters:
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components without a connection to the coolant circuit with reduced performance at high
temperatures
DUT operating
As per Figure 43
mode
(Arrhenius model for use with components with reduced
performance at high temperatures); the "parking" and "off-grid
parking" operating situations generally must not be taken into
Test duration
account.
The respective ramp times between Tmax and Top, max are not
included in the test duration.
Test temperature As per Figure 43
Must be calculated as per appendix C.3 and specified in the
Interval time t1
Must be calculated as per appendix C.3 and specified in the
Interval time t2
Number of DUTs 6
t2
Tmax
Top,max
t1
1 hr 1 hr 1 hr
II.c II.c* II.c II.a II.c II.c* II.c
*) A performance decrease is permissible for T > Top,max
Figure 43: Temperature profile for testing components with reduced performance at high
temperatures
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16.2.2.3 Test for components with a connection to a coolant circuit
components with a connection to a coolant circuit
DUT operating Intermittently 47 h operating mode II.c and 1 h
mode operating mode II.a
(Arrhenius model for use with components on coolant circuits);
Test duration the "parking" and "off-grid parking" operating situations
generally must not be taken into account.
Test temperature As per appendix C.5 (Arrhenius model for use with
Environment components on coolant circuits)
Test temperature for As per appendix C.5 (Arrhenius model for use with
coolant components on coolant circuits)
Number of DUTs 6
16.2.3 Requirement
during the test.

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16.3 L-03 Life test - temperature cycle test

16.3.1 Aim
This test simulates in compact form the thermal load of the component during
temperature changes that occur during vehicle service life.
faults that occur due to thermomechanical load, e.g. aging and cracking in soldered
joints, adhesive joints and welded joints, in bond connections as well as in seals or
housings.
16.3.2 Test

without reduced performance at low or high temperatures
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
Number of
6
DUTs
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Temp.
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

with reduced performance at low or high temperatures
LCDs) at low or high temperatures below Top,min and above Top,max, the test must be
performed with the following parameters:
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
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Figure 45: Temperature profile – test for components with reduced performance at low or
high temperatures
16.3.2.3 Test for components on the coolant circuit

For components on coolant circuits, the test must be performed with the following
parameters:
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
Number of DUTs 6
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16.3.3 Requirement
during the test.

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Appendix A (normative)
Test sequence
A.1 Test sequence plan
A component-specific test sequence plan must be defined in the Component

The tests that are not required for a component as per the test selection table must
be deleted from the test sequence plan.
If a component-specific adaptation of the test sequence is required, the test

sequence plan may be adapted.
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.
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A.2 Sequence tests
The numbers on the arrows indicate the number of DUTs to be used.
Figure 46: Test sequence plan – sequential
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If the DUTs have not been damaged in the test M-01 Free fall, two DUTs must be
used for the further sequence test. Otherwise, the spare DUTs must be used.
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.
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A.3 Tests outside the sequence (parallel tests)
Figure 47: Test sequence plan – parallel tests
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A.4 Life tests

Figure 48: Test sequence plan – service life
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Appendix B (normative)
Typical temperature spectrums for different installation areas
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
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B.1 Temperature spectrum 1

Table 97: Temperature spectrum 1
Temperature
Distribution (%)
(°C)
-40 °C 6%
23 °C 20%
40 °C 65%
75 °C 8%
80 °C 1%
Temperature (°C) Distribution (%)
-40 °C 6%
23 °C 20%
50 °C 65%
100 °C 8%
105 °C 1%

-40 °C 6%
23 °C 20%
65 °C 65%
115 °C 8%
120 °C 1%

-40 °C 6%
23 °C 20%
85 °C 65%
135 °C 8%
140 °C 1%
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Appendix C (normative)
Computation models for the life test "High-temperature endurance

test"
C.1 Arrhenius model
The calculation of the test duration of the high-temperature endurance test life test is
based on the temperature spectrum percentage as per the use profile in the
Component Performance Specification
Table 101: Temperature spectrum
TField.1 p1
TField.2 p2
… …
TField.n pn
and the operating hours tBetrieb of the vehicle in the field.
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
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C.2 Example of Arrhenius model:

For an electronic control unit with the temperature spectrum indicated in the following
table
Table 102: Sample spectrum
-40 6
23 20
60 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:
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 operating time of the component is toper = 8 000 h.
The total test duration of the "high-temperature endurance test" life test results from
equation (2) as:
 0,06 0,20 0,65 0,08 0,01 

t test = 8 000 hours ⋅  + + + +  = 1 452 hours .
 5369 45,8 6,46 1,20 1,00 
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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
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
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.
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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.
Table 105: Sample spectrum for T ≤90 °C

-40 6
23 20
60 65
Table 106: Sample spectrum for T >90 °C

100 8
105 1
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
This results in a test duration top, max at a test temperature of Top,max = 90 °C of
 0,06 0,2 0,65 

t op,max (TTest = 90°C) = 8 000 hours ⋅  + +  = 1 485 hours
 3060,78 25,95 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
This results in a test duration tmax at a test temperature of Tmax = 105 °C of
 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:
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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
t1 = 48 h * top,max / tGes = 48 h * 1485/2097 = 34 h

t2 = 48 h * tmax / tGes = 48 h * 612/2 097 = 14 h.
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C.5 Arrhenius model for use with components on coolant circuits
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.
Case A: ttest, environment < ttest, CC
Test duration:
For ttest,environment < ttest,CC, the test duration for operating situation i is
ttest, situation i = ttest, CC.
Test temperature for coolant:

The test temperature must be selected according to the Arrhenius model as per
appendix C.1 (generally Tcool,max).
Test temperatures for ambient temperature:

The test temperatures must be calculated iteratively as per the following algorithm on
the basis of the temperature spectrum of the ambient temperature of the operating
situation i under examination (Table 107).
Table 107: Temperature spectrum for environment

TField.1 p1
TField.2 p2
… …
TField.n pn
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1. Iteration start (m = 0):
The first partial test must be performed at the test temperature TFeld, n for the
partial test duration ttest, T_Field, n = toper * pn (where toper corresponds to the
operating time in the field of the operating situation i under examination in
hours).
2. First iteration (m = 1):

Part of the test duration for operating situation i ttest, situation i is covered by the
1st partial test, so a remaining test duration still to be covered by the additional
partial tests results from
tremaining, 1 = ttest, situation i – ttest, T_Field, n.
In addition, the portion pn of the temperature distribution of the ambient

temperature is covered by the first partial test. Therefore, this portion pn must
be set to pn = 0 for the further calculation.
To specify the test temperature for the 2nd partial test (m = 1), 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, 1 results for the distribution (adapted with pn =
0) of the ambient temperature.
If the adapted test temperature Tadapted determined in such a way is less than
TFeld, n-1, the 2nd partial test must be performed at the test temperature TFeld, n-1
for the test duration
ttest, T_Field, n-1 = tBetrieb * pn-1
and at least one additional iteration step must be performed.
If, however, the determined adapted test temperature Tadapted is greater than
TField, n-1, the 2nd partial test must be performed at the test temperature Tadapted
ttest, T_Field, n-1 = tremaining, 1
and an additional iteration step does not have to be performed (iteration end).
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
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.
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TField, n-m, the (m+1)th partial test must be performed at the test temperature
TField, n-m for the test duration
ttest, T_Field, n-m = toper * pn-m
Tadapted for the test duration
ttest, T_Field, n-m = tremaining, m
Case B: ttest,environment > ttest, CC
Test duration:
For ttest, environment > ttest, CC, the test duration for operating situation i is
ttest, situation i = ttest, environment.
Test temperature for environment:

The test temperature must be selected according to the Arrhenius model as per
appendix C.1 or C.3 (generally Tmax or Tmax and Top, max).
Test temperatures for coolant:

The test temperatures must be calculated iteratively as per the following algorithm on
the basis of the temperature spectrum for the coolant temperature of the operating
situation i under examination (Table 108).
Table 108: Temperature spectrum for coolant temperature

TFeld.1 p1
TFeld.2 p2
… …
TFeld.n pn
1. Iteration start (m = 0):

The first partial test must be performed at the test temperature TFeld, n for the
partial test duration ttest, T_Field, n = tOper * pn (where tOper corresponds to the
operating time in the field of the operating situation i under examination in
hours).
2. First iteration (m = 1):

Part of the test duration for operating situation i ttest, situation i is covered by the
first partial test, so a remaining test duration still to be covered by the
tremaining, 1 = ttest, situation i – ttest, T_Field, n.
In addition, the portion pn of the temperature distribution of the coolant

temperature is covered by the first partial test. Therefore, this portion pn must
be set to pn = 0 for the further calculation.
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To specify the test temperature for the second partial test (m = 1), the test
C.1 in such a way that a test duration with the magnitude of the remaining test
duration tremaining, 1 results for the distribution (adapted with pn = 0) of the
coolant temperature.
TFeld, n-1, the second partial test must be performed at the test temperature
TFeld, n-1 for the test duration
ttest, T_Field, n-1 = tOper * pn-1
TFeld, n-1, the 2nd partial test must be performed at the test temperature Tadapted
ttest, T_Feld, n-1 = tremaining, 1
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
m −1
t Re. ,m
= t Test, Mode i − ∑ t Test, TField, n−k
k =0
In addition, the portions pn-k with

k = 0, 1, …, (m-1) of the temperature distribution of the coolant 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
C.1 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
coolant temperature.
TField, n-m for the test duration
ttest, T_Fild, n-m = tOper * pn-m
TFeld, n-m, the (m+1)th partial test must be performed at the test temperature
Tadapted for the test duration
ttest, T_Field, n-m = tremaining, m
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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
-40 6
23 20
50 65
100 8
105 1
Table 110: Sample spectrum for coolant temperature

-40 6
23 20
40 65
75 8
80 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.
Test temperature for coolant:

The test temperature for the coolant is TCC, max = TField, 5 = 80 °C as per the
temperature spectrum.
Iterative calculation of test temperatures for ambient temperature:

1. Iteration start:
The first partial test occurs at TFeld, 5 = 105 °C. The test duration is ttest,
T_Field, 5 = tOper * p5 = 8 000 h * 1% = 80 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.
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Because the portion p5 of the temperature distribution is covered by the
first partial test, p5 is set to p5 = 0 in the temperature distribution for the
further calculation by the Arrhenius model, as per the following table.
Table 111: Adapted temperature spectrum for environment after first partial test
-40 6
23 20
50 65
100 8
105 0
In order to subsequently be able to determine the test temperature for

the 2nd partial test, the test temperature Tadapted must be calculated
using the Arrhenius model as per appendix C.1 in such a way that a test
duration with the magnitude of the remaining test duration tremaining, 1 =
1 929 h results. Taking into account the adapted temperature
distribution of the ambient temperature, the required test duration of
1 929 h results for a temperature of Tadapted = 89,5 °C (exact value:
89,46 °C).
But because Tadapted < TField, 4 (i.e., 89,5 °C <100 °C), the 2nd partial test
must be performed at TField, 4 = 100 °C.
The test duration for the 2nd partial test is ttest, T_Field, 4 = tOper * p4 =
8 000 h * 8% = 640 h.
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
-40 6
23 20
50 65
100 0
105 0
In order to subsequently be able to determine the test temperature for

the 3rd partial test, the test temperature Tadapted must be calculated
using the Arrhenius model as per appendix C.1 in such a way that a test
duration with the magnitude of the remaining test duration tremaining, 2 =
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1 289 h results. Taking into account the adapted temperature
distribution of the ambient temperature, the required test duration of
1 289 h results for the temperature Tadapted = 82 °C (exact value:
82,17 °C).
Because Tadapted > TField, 3 (i.e., 82 °C >50 °C), no further iteration is
necessary. Therefore, the 3rd and last partial test is performed at
Tadapted = 82 °C for the test duration ttest, T_Field, 3 = tremaining, 3 = 1 289 h.
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.
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Appendix D (normative)
Computation models for the "temperature cycle test" life test

D.1 Coffin-Manson model
The calculation of the test duration for the "temperature cycle test" life test is based on
the average temperature change of the component in the field ∆TField (see Table 96) and
the number of temperature cycles during the service life in the field NTempCyclesField.
Two temperature cycles per day can typically be assumed for the number of
temperature cycles in the field. This results in:
NTempCyclesField = 2 * 365 * 15 (years) = 10 950 cycles
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.
The total number of test cycles is calculated as per
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)
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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:
1. The number of temperature cycles in the field:
NTempCyclesField = 2 * 365 * 15 (years) = 10 950 cycles
2. Temperature difference during a test cycle:
∆TTest = 105 °C - (-40 °C)= 145 °C
3. The acceleration factor of the Coffin-Manson model is calculated to ACM = 25,02

by means of equation (3)
.
4. This results in a number of test cycles on the basis of equation (4) of:
10950 cycles
N Prüf = = 438 cycles
25,02
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.
6. This results in a cycle time:
7. In the example:
8. For 438 cycles the total test duration is therefore 1 040 h.
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D.3 Coffin-Manson model for use with components on coolant circuits
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.
Case A: Ntest,environment > Ntest,CC
Number of test cycles:

For Ntest, environment > Ntest, CC, the number of test cycles for operating situation i is
Ntest, situation i = Ntest, environment.
Number of test cycles for coolant:
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.
with ∆TTest, 2 = TRT - TCC, min.
3. ½ * (Ntest,situation i - xCC) test cycles must be performed between TRT and TCC, max.
with ∆TTest, 3 = TCC, max – TRT.
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In total, Ntest,situation i temperature cycles result from 1. to 3.
The following results from equation (4) in appendix D.1:

NTempCyclesField = xKKL ⋅ ACM , KKL , 1 + ⋅ (N Pr üf , Mode, i − xKKL )⋅ ACM , KKL , 2 + ⋅ (N Pr üf , Mode, i − xKKL )⋅ ACM , KKL , 3
1 1
2 2
The number of test cycles xCC is calculated from this as follows:
⋅ (ACM , KKL , 2 + ACM , KKL , 3 )

N Pr üf , Mode, i
NTempCycleField −
xKKL = 2
ACM , KKL , 1 − ⋅ (ACM , KKL , 2 + ACM , KKL , 3 )
1
2
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.
Case B: Ntest, environment < Ntest, CC
Number of test cycles:

For Ntest, environment < Ntest, CC, the number of test cycles for operating situation i is
Ntest, situation i = Ntest, CC.
Number of test cycles for environment:
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.
In total, Ntest,situation i temperature cycles result from 1. to 3.
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The following results from equation (4) in appendix D.1:
NTempCyclesField = xEnvironmet ⋅ ACM , environmet , 1 + ⋅ (NTest , Mode, i − xenvironment )⋅ ACM , environment , 2
1
2
+ ⋅ (NTest Mode, i − xenvironment )⋅ ACM , environment , 3
1
2
The number of test cycles xenvironment is calculated from this as follows:

NTempCyclesField − Pr üf , Mode, i ⋅ (ACM , environment , 2 + ACM , environment , 3 )
N
xenvironment = 2
ACM , environment , 1 − ⋅ (ACM , environment , 2 + ACM , environment , 3 )
1
2
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.
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D.4 Example of Coffin-Manson model for use with components on coolant

circuits
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:
Number of test cycles for environment and coolant:

The calculation of the numbers of test cycles for the environment and the coolant
according to the Coffin-Manson model as per appendix D.1 provides the following
values:
Ntest, environment = 943 cycles

Ntest, CC = 540 cycles
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.
Adapting the number of test cycles for the coolant:

The number of test cycles for the coolant is adapted to Ntest, situation i = 943 cycles in three
parts:
1. xCC test cycles must be performed between TCC, min = -40 °C and TCC, max = 80 °C.
 80°C − (−40°C ) 
2,5
The acceleration factor ACM, CC, 1 =   = 20,29 is calculated as

 36°C 
per the Coffin-Manson model.
2. ½ * (943 – xCC) test cycles must be performed between TCC, min = -40 °C and TRT
 23°C − (−40°C ) 
2,5
= 23 °C. The acceleration factor ACM, CC, 2 =   = 4,05 is

 36°C 
calculated as per the Coffin-Manson model.
3. ½ * (943 – xCC) test cycles must be performed between TRT = 23 °C and TCC, max
 80°C − 23°C 
2,5
= 80 °C. The acceleration factor ACM, CC, 3 =   = 3,15 is calculated

 36°C 
as per the Coffin-Manson model.
Thus, the following results for xCC:
⋅ (ACM , KKL , 2 + ACM , KKL , 3 )

N Pr üf , Mode, i
N TempZyklenFeld − 10950 −
943
⋅ (4,05 + 3,15)
x KKL = 2 = 2 = 453 cycles
ACM , KKL , 1 − ⋅ (ACM , KKL , 2 + ACM , KKL , 3 )
1
20,29 − ⋅ (4,05 + 3,15)
1
2 2
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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.
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Appendix E (normative)
Computation models for the test

constant damp heat – severity 2
E.1 Lawson model
The calculation of the test duration of the constant damp heat test - severity 2 is based
on the average ambient humidity RHFieldParked and the average temperature TFieldParked of
the component in the parked vehicle.
Unless otherwise specified in the Component Performance Specification, the following
values must be assumed for the calculation:
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
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Where:
tTest Test duration in h
tFieldParked Non-operating time (parking time) in h during the service life in the
field (131 400 h, in the least favorable case if the vehicle
is not used)
AT/RH Acceleration factor of the Lawson model as per equation (5)
E.2 Example:
For an electronic control unit installed in the engine compartment, the test duration is
calculated as follows:
1. An average temperature of TFeldParken = 23 °C and a relative humidity of

RHFeldParken = 65% are assumed for the component in the parked vehicle.
The test conditions are TTest = 65 °C and RHPrüf = 93%.
By means of equation (5), these values result in a combined acceleration factor

of the Lawson model of AT/RH = 82,5.
2. The parking time in the field is tFeldParken = 131 400 h.

This results in a total test duration on the basis of equation (6) of:
131 400 hours

t Test = = 1 593 hours
82,5
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Appendix F (informative)
Condensation test, chamber programming and graphs
Figure 49: Programming of the test chamber
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).
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Figure 50: Sequence of the condensation test, 1 cycle
1. Controlled water bath temperature

2. Resulting test room temperature
3. Actual humidity in the test chamber
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Figure 51: Sequence of the condensation test, 5 cycles
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Appendix G (informative)
Sample examination methods for physical analysis

• Screw loosening torques (housing fastening, screws for fastening the component,
etc.)
• Solder point defects
• Part/PCB discolorations (especially due to thermal causes)
• Rough/smooth running, grinding, backlash (for mechanically moved parts)
• Traces of abrasion
• Jumps, cracks, deformation of materials (especially for potting and sealing
materials). A suitable test method (x-ray, CT, microsections, etc.) must be selected
in agreement.
• Turbidity (especially for parts of optical sensor systems)
• State of latching mechanism and clips
• Traces of corrosion and migration, especially silver and tin migration
• Evaluation of plastics for hydrolysis resistance (especially for components with
inserted punched grids and T.30 circuitry)
• Damage to through-plating of printed circuit boards, especially thermal vias
• Damage to the internal connection (paddles) of large electrolytic capacitors after
mechanical load (vibration, mechanical shock, drop test)
• Connector pin damage (e.g., due to current, temperature, rubbing, oxidation)
• Other irregularities
• ICT result (if possible)
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Group standard VW 80000

Electric and Electronic Components in Motor Vehicles up to 3,5 t

– Transfer of supply specification LV 124 to VW 80000

Page 1 of 1. Continued on 161 pages of LV 124.

Technical responsibility The Standards department

Electric and Electronic Components in Motor Vehicles

Part I – Electrical requirements and tests of the 12 V electric

Part II – Environmental requirements and tests:

Part I – Electrical requirements and tests of the 12 V electric system ..................... 6

Part I – Electrical requirements and tests of the 12 V

3 Terms and definitions

3.2 Voltages and currents

3.5 Internal resistance, terminal designation, frequency

Figure 1: Internal resistance

All edge descriptions refer to the 10% or 90% voltage values.

4.2 Temperature specifications

4.3 Standard tolerances

4.4 Standard values

4.5 Sampling rate and measured value resolution

4.6 Test voltages

4.7 Operating voltage ranges and encoding

This encoding must only be used if the component cannot

4.8 Functional statuses

4.8.2 Functional status A

4.8.3 Functional status B

4.8.4 Functional status C

4.8.5 Functional status D

4.8.6 Functional status E

4.9 Operating modes

4.9.2 Operating mode I - DUT not electrically connected

4.9.2.2 Operating mode I.b

4.9.3 Operating mode II - DUT electrically connected

4.9.3.1 Operating mode II.a

4.9.3.2 Operating mode II.b

4.9.3.3 Operating mode II.c

4.10 Interface description

4.11 Procedural limitations

4.12 Electrical tests

A set of sensitive parameters, so-called key parameters, e.g. closed-circuit current

4.12.2 Parameter test (small)

All results must be documented in the test report.

4.12.3 Parameter test (large)

All results must be documented in the test report.

4.12.4 Physical analysis

5 Test selection table

6 Electrical requirements and tests

Figure 2: Test pulse E-01 Long-term overvoltage

b) For all other components:

6.2 E-02 Transient overvoltage

Figure 3: Test pulse E-02 Transient overvoltage

6.3 E-03 Transient undervoltage

Figure 4: Test pulse E-03 Transient undervoltage

6.4 E-04 jump start

Figure 5: Test pulse E-04 jump start

b) All other components:

6.5 E-05 Load dump

Figure 6: Test pulse E-05 Load dump

b) All other components:

6.6 E-06 Superimposed alternating voltage

Figure 7: Test pulse E-06 Superimposed alternating voltage

6.6.2.1 Test setup

Test case 1: Functional status A

b) For all other components: