LV124

BMW Group Standard GS 95024--3--1
2010--01
Deskriptoren: Komponente, Kraftfahrzeug, Prüfung, Umweltanforde- Ersatz für GS 95003--1 : 2008--11,

rung GS 95003--3 : 2006--08,
GS 95003--4 : 2003--03 und
GS 95003--5 : 2001--10
Descriptors: Component, Motor vehicle, Environmental require- Replacement for GS 95003--1 :
ment, Testing 2008--11, GS 95003--3 : 2006--08,
GS 95003--4 : 2003--03 and
GS 95003--5 : 2001--10
Elektrische und elektronische Komponenten in Kraftfahrzeugen

Umweltanforderungen und Prüfungen
Electrical and electronic components in motor vehicles

Environmental requirements and testings
Ausdrucke unterliegen nicht dem Änderungsdienst.

Print-outs are not subject to the change service.
Fortsetzung Seite 2
und 83 Seiten LV
Continued on page 2
and 83 pages LV
BMW AG Normung: 80788 München
E BMW AG Alle Rechte vorbehalten / All rights reserved

interleaf-doc Bearbeiter / Author: Robert Maier
Seite/Page 2
GS 95024--3--1 : 2010--01
Vorwort Foreword
Grundlage dieses Group Standards ist die LV 124 “Elektri- This Group Standard is based on LV 124 “Electrical and
sche und elektronische Komponenten in Kraftfahrzeugen bis electronic components in motor vehicles up to 3.5 t; General
3,5 t; Allgemeine Anforderungen, Prüfbedingungen und Prü- requirements, test conditions and tests”.
fungen”.
Diese Prüfrichtlinie wurde in Zusammenarbeit mit den Firmen This test guideline has been compiled jointly by the following
Audi AG, Daimler AG, Porsche AG, Volkswagen AG erarbei- companies: Audi AG, Daimler AG, Porsche AG,
tet. Volkswagen AG.
Die LV 124 wurde unverändert übernommen und in folgende LV 124 was adopted without change and subdivided into the
Teile der GS 95024 untergliedert: following parts of GS 95024:
GS 95024--1 Allgemeine Anforderungen GS 95024--1 General requirements
GS 95024--2--1 Elektrische Anforderungen (LV 124 Teil 1) GS 95024--2--1 Electrical requirements (LV 124 Part 1)
GS 95024--2--2 Ergänzende Anforderungen aus GS 95003 GS 95024--2--2 Additional requirements from GS 95003
GS 95024--2--3 VDA-Merkblatt “Hochstromverbraucher” GS 95024--2--3 VDA data sheet “High-current consumer”
GS 95024--3--1 Umweltanforderungen (LV 124 Teil 2) GS 95024--3--1 Environmental requirements (LV 124
Part 2)
GS 95024--3--2 Ergänzende Anforderungen aus GS 95003 GS 95024--3--2 Additional requirements from GS 95003
Die bisherige GS 95003--1 und GS 95003--3 bis --5 ist für In case of new designs the previously applicable Stan-
Neukonstruktionen nicht mehr anzuwenden. dard GS 95003--1 and GS 95003--3 to --5 is no longer valid.
Änderungen Amendments
Gegenüber GS 95003--1 : 2008--11, GS 95003--3 : 2006--08, The following amendments have been made to GS 95003--1
GS 95003--4 : 2003--03 und GS 95003--5 : 2001--10 wurden : 2008--11, GS 95003--3 : 2006--08, GS 95003--4 : 2003--03
folgende Änderungen vorgenommen: and GS 95003--5 : 2001--10:
-- Inhalt der LV 124 übernommen. -- Content of LV 124 adopted.
Frühere Ausgaben Previous editions

GS 95003--1 : 2000--03, 2001--10, 2007--10, 2008--11
GS 95003--3 : 2000--03, 2001--10, 2006--08
GS 95003--4 : 2000--03, 2001--10, 2003--03
GS 95003--5 : 2000--03, 2001--10
1 Anwendungsbereich 1 Scope
Aus der Prüfauswahltabelle (Abschnitt 3.1) sind die Umwelt- Refer to test selection table (Subsection 3.1) to select the
prüfungen für die entsprechenden Beanspruchungen der zu environmental tests for the respective loads on the
prüfende Komponente auszuwählen. Diese Prüfungen sind component to be tested. These test according to test
gemäß der Anordnung aus dem Prüfablaufplänen (Ab- sequence plans (Subsections 8.1.1 to 8..1.3) are considered
schnitte 8.1.1 bis 8.1.3) für eine Produktvalidierung (Frei- to be binding for product validation (release).
gabe) bindend.
Für die Berechnung der Lebensdauerprüfungen sind die Tem- Temperature profiles and cycles according to Subsection 8.2
peraturprofile und -hübe nach den Abschnitten 8.2 bis 8.2.1.4 to 8.2.1.4 are to be used for calculation of endurance tests
zu verwenden, sofern der BMW Fachstelle keine eigenen provided that the BMW specialist department does not have
Temperaturmessungen für die zu prüfende Komponente vor- its own temperature measurements.
liegen.
K--14: Feuchte Wärme konstant ist in der Regel mit dem K--14: Humid heat constant is to be applied with severity
Schärfegrad 1 anzuwenden. level 1 as a rule.
Für den Einsatz von elektronischen Baugruppen in wasser- Electronic components in watertight housings shall be subject
dichten Gehäusen ist GS 95011--4 anzuwenden. to GS 95011--4.
Version 1,3 LV 124 Creation date 18.01.2010
LV124
Electric and Electronic Components in Motor Vehicles up to

3.5 t - General Component Requirements, Test Conditions
and Tests
Page 1 of 83
Contents
1 General part ............................................................................................................ 5
1.1 Referenced standards ........................................................................................... 5
1.2 Terms and definitions ............................................................................................ 6
1.3 Operating modes ................................................................................................... 8
1.4 Maintaining temperature ........................................................................................ 9
1.5 Parameter test ..................................................................................................... 10
1.6 Continuous parameter monitoring with drift analysis ........................................... 10
1.7 Physical analysis ................................................................................................. 10
2 Use profile ............................................................................................................. 11
2.1 Service life requirements ..................................................................................... 11
2.2 Temperature spectrum ........................................................................................ 11
3 Test selection ....................................................................................................... 12
3.1 Test selection table .............................................................................................. 12
3.2 Test sequence plan ............................................................................................. 14
4 Mechanical requirements and tests .................................................................... 15
4.1 M-01 Free fall....................................................................................................... 15
4.2 M-02 Stone impact test ........................................................................................ 16
4.3 M-03 Dust test ..................................................................................................... 17
4.4 M-04 Vibration test............................................................................................... 18
4.5 M-05 Mechanical shock ....................................................................................... 28
4.6 M-06 Endurance shock test ................................................................................. 29
5 Climatic requirements and tests ......................................................................... 30
5.1 K-01 High-/low-temperature storage .................................................................... 30
5.2 K-02 Incremental temperature test ...................................................................... 31
5.3 K-03 Low-temperature operation ......................................................................... 32
5.4 K-04 Repainting temperature ............................................................................... 33
5.5 K-05 Temperature shock (component) ................................................................ 34
5.6 K-06 Salt spray test with operation, exterior ........................................................ 35
5.7 K-07 Salt spray test with operation, interior ......................................................... 37
5.8 K-08 Humid heat, cyclic ....................................................................................... 39
5.9 K-09 Humid heat, cyclic (with frost) ..................................................................... 40
5.10 K-10 Water protection - IPX0 to IPX6K ................................................................ 41
5.11 K-11 High-pressure cleaning ............................................................................... 42
5.12 K-12 Temperature shock with splash water ......................................................... 43
5.13 K-13 Temperature shock - immersion .................................................................. 46
5.14 K-14 Humid heat, constant .................................................................................. 47
5.15 K-15 Condensation test with electr. assemblies .................................................. 50
5.16 K-16 Temperature shock (without housing) ......................................................... 54
5.17 K-17 Sun radiation ............................................................................................... 55
5.18 K-18 Harmful gas test .......................................................................................... 56
6 Chemical requirements and tests ....................................................................... 57
7 Life tests................................................................................................................ 60
7.1 L-01 Life test - mechanical/hydraulic endurance test ........................................... 60
7.2 L-02 Life test - high-temperature endurance test ................................................. 61
7.3 L-03 Life test - temperature cycle test.................................................................. 63
Page 2 of 83
8 Appendix ............................................................................................................... 66
8.1 Test sequence plan ............................................................................................. 66
8.2 Typical temperature spectrums for different installation areas ............................ 70
8.3 Calculation models for the life test 'High-temperature endurance test' ............... 72
8.4 Calculation models for the life test 'temperature cycle test'.................................. 76
8.5 Calculation models for the test 'constant humid heat - severity 2'....................... 78
8.6 Condensation test, chamber programming and diagrams ................................... 80
8.7 Glossary .............................................................................................................. 83
Page 3 of 83
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 must be

defined in the respective Component Performance Specifications.
Note: The represented tests do not serve for component qualification or a

qualification of the manufacturing process.
Page 4 of 83
Part II - Environmental requirements

1 General part
1.1 Referenced standards
DIN 75220 Aging of Automotive Components in Solar Simulation Units
DIN EN 60068-2-1 Environmental testing - Part 2-1: Tests -
Test A: Cold
DIN EN 60068-2-2 Environmental testing - Part 2-2: Tests -
Test B: Dry Heat
DIN EN 60068-2-11 Environmental Testing - Part 2: Tests - Test Ka: Salt Mist
DIN EN 60068-2-14 Environmental Testing - Part 2: Tests - Test N: Change of
Temperature
DIN EN 60068-2-29 Environmental Testing - Part 2: Tests; Test Eb and Guidance:
Bump
DIN EN 60068-2-30 Environmental Testing - Part 2-30: Tests -
Test Db: Damp Heat, Cyclic (12 h + 12 h)
DIN EN 60068-2-38 Environmental Testing - Part 2: 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: Tests; Test Fh: Vibration, Broad-
Band 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 Road Vehicles — Environmental Conditions and Testing for
Electrical and Electronic Equipment
ISO 20653 Road Vehicles - Degrees of Protection (IP-Code) - Protection of
Electrical Equipment Against Foreign Objects, Water and
Access
Page 5 of 83
1.2 Terms and definitions

1.2.1 Voltages
Table 1: Abbreviations for voltage definitions
UBmin Lower operating voltage limit
UB Operating voltage
UBmax Upper operating voltage limit
1.2.2 Temperatures
Table 2: 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
TPrüf Test temperature
1.2.3 Times/durations
Table 3: Time definitions
tPrüf Test duration
tBetrieb Operating hours over service life
tParkFeld Parking time over service life
1.2.4 Standard tolerances

Unless otherwise indicated, the tolerances acc. to Table 4 apply.
The tolerances refer to the required measured value.
Table 4: Standard tolerances
Frequencies ± 1%
Temperatures ± 2°C
Humidity ± 5%
Times/durations + 5%; -0%
Vibrations ± 3 dB
Vibration PSD ± 5%
Voltages ± 2%
Page 6 of 83
1.2.5 Standard values

Unless otherwise indicated, the standard values acc. to Table 5 apply:
Table 5: Standard values
Room temperature TRT = 23°C ±5°C
Humidity Frel = 45% - 75% RH
Test temperature TPrüf = TRT
Operating voltage UB = 14 V
(for test)
1.2.6 Sampling rate and measured value resolution

The sampling rate and bandwidth of the measuring system must be adapted to the
respective test.
The resolution of the measured values must be adapted to the respective test.
Page 7 of 83
1.3 Operating modes

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.
triggering, original sensors, original actuators or replacement circuitry) and the required
boundary conditions must be coordinated between contractor and purchaser and must
be documented.
1.3.1 Operating mode I - DUT not electrically connected

1.3.1.1 Operating mode I.a
The DUT is not electrically connected, without plug and harness.
1.3.1.2 Operating mode I.b

The DUT is not electrically connected, but with connected plugs and harness.
1.3.2 Operating mode II - DUT electrically connected

1.3.2.1 Operating mode II.a
The DUT must be operated without operating load.
1.3.2.2 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
means of a reduction of a continuous output performance or unfrequent
activation of external loads).
1.3.2.3 Operating mode II.c

The DUT must be operated with 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).
Page 8 of 83
1.3.2.4 Sample operating modes

Table 6: 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 (sleep). Component switched switched on (CD,
Follow-on off by driver, BUS/µC navigation system, final
current active, T. 15 "ON". stage), BUS/navigation
stopped 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. misuse, such as
Follow-on uninterrupted brake
current control operation).
stopped.
1.4 Maintaining temperature

The temperature of a component that is kept at a constant ambient temperature under
defined operating conditions is said to be maintained at that point in time as of which the
temperature will not change by more than ±3°C at an y 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.
Note:
For temperature cycle tests, the DUTs must additionally be kept in the condition in
which the temperature is maintained at the specified temperature basic values for a
defined time, so that tensions in the component can be transferred to elongations. This
additional holding time must be indicated for the respective tests.
Page 9 of 83
1.5 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 Specifications. Prior to testing and after each test, it must be
checked whether these parameters meet the specifications.
1.5.1 Parameter test (small)

The key parameters TRT and UB must be measured.
The basic functionalities of the components must be measured and documented in the
test report.
1.5.2 Parameter test (large)

The key parameters must be measured at three different temperatures (Tmax, TRT, Tmin)
and with three different voltage levels (UBmin, UB and UBmax) each.
test report.
1.5.3 Parameter test (functional test)

The key parameters must be measured at three specified temperatures and three
different voltage levels (UBmin, UB and UBmax).
test report.
1.6 Continuous parameter monitoring with drift analysis

The key parameters to be monitored must be recorded during the whole test.
For components with event log, the event log 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.
1.7 Physical analysis

For the physical analysis, the DUT must be opened and evaluated visually.
Additional analyses (e.g. X-ray examinations and metallographic examinations of the
assembly and joining technology) must be coordinated between purchaser and
contractor.
Page 10 of 83
2 Use profile
2.1 Service life requirements
Table 7 shows the typical parameters for the service life requirements.
Table 7: Service life requirements
Service life 15 years
Operating hours 8 000 h
Mileage 300 000 km
2.2 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.
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 8.3), this continuous
distribution can be described sufficiently by means of several discrete temperature
nodes TFeld, i. For each node, the percentage pi of the operating time must be indicated
for which the component is subjected to the node temperature.
The respective temperature spectrum therefore has the following general form:
Table 8: Temperature spectrum

Temperature in °C Distribution
TFeld.1 = Tmin p1
TFeld.2 p2
… …
TFeld.n = Tmax pn
It is based mainly on field measurements and technical experiences.
Typical temperature spectrums for different installation locations are indicated in

Appendix 8.2.
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
Specifications.
In addition to the typical temperature spectrums, typical values for an average
temperature rise of a component in a vehicle are indicated in Appendix 8.2.
Page 11 of 83
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 Component
Performance Specifications.
3 Test selection
3.1 Test selection table
Table 9: 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 None
- Degree of protection IP6KX for components
for which the ingress of dust is not allowed
- Degree of protection IP5KX for components
for which the ingress of dust is allowed as
long as functionality and safety are not
impaired
M-04 Vibration test All components None
- Acc. to vibration profile A for components

installed on the engine
- Acc. to vibration profile B for components
installed on the gearbox
- Acc. to vibration profile C for components
installed on the decoupled intake plenum
- Acc. to vibration profile D for components
installed on sprung masses (body)
- Acc. to vibration profile E for components
installed on unsprung masses (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
Page 12 of 83

specifications
K-05 Temperature shock All components Test method (Na or
(component) - Acc. to DIN EN 60068-2-14 Na (air - air) for Nc),
components that are not permanently if Nc: test medium
operated in a fluid
- Acc. to DIN EN 60068-2-14 Nc (medium -
medium) for components that are
permanently operated in a fluid (IP X8)
K-06 Salt spray test with Components installed on the vehicle exterior, Number of test
operation, exterior underbody or in the engine compartment cycles
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 Humid heat, cyclic All components None
K-09 Humid heat, cyclic All components None
(with frost)
K-10 Water protection - IPX0 to All components None
IPX6K - Degree of protection IPX0 for components
that do not require water protection
- Degree of protection IPX1 for components
on which perpendicularly falling drops must
not cause any damage
with an inclination of up to 15° in as-
installed position on which perpendicularly
falling drops must not cause any damage
on which spray water must not cause any
damage
- Degree of protection IPX4K for components
on which spray water with increased
pressure must not cause any damage
on which water jets must not cause any
damage
- Degree of protection IPX6K for components
on which strong water jets with increased
pressure must not cause any damage
K-11 High-pressure cleaning Components that may be directly subjected to a None
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 Humid heat, constant All components Severity
K-15 Condensation test with The necessity of the test must be evaluated for None
electr. assemblies each component. If required, the necessity of the
test must be specified in the Performance
Specifications.
K-16 Temperature shock (without Electr. assemblies of all components None
housing)
K-17 Sun radiation Components exposed to direct sunlight None
Page 13 of 83

specifications
K-18 Harmful gas test Components with switching contacts that are not None
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 actuation, functional/actuation
test seat adjustment cycles, switch/tip switch cycles
actuations
L-02 Life test - high-temperature All components Test duration
endurance test
L-03 Life test - temperature cycle All components Number of test
test cycles
3.2 Test sequence plan

A component-specific test sequence plan must be defined in the Component
Performance Specifications.
A test sequence plan is contained in Appendix 8.1 as basis for discussions for
cooperation projects between several OEMs (e.g. Industrial Assembly (IBK - German
abbreviation)).
Page 14 of 83
4 Mechanical requirements and tests

4.1 M-01 Free fall
4.1.1 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 serves to ensure that a part that does not show any outwardly visible damage
and therefore is installed in the vehicle, does not have any hidden damages or pre-
damages, e.g. internal part displacement or cracks.
4.1.2 Test
Table 10: Test parameters M-01 Free fall
DUT operating mode Operating mode I.a
Drop height 1m
Impact surface Concrete floor
Test cycle For each of the 3 DUTs one drop in both directions of
a spatial axis (1st DUT: ±X,
2nd DUT: ±Y, 3rd DUT: ±Z)
Number of DUTs 3
4.1.3 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) acc. to Section 1.5. Hidden damages are not
permissible.
Page 15 of 83
4.2 M-02 Stone impact test

4.2.1 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.
4.2.2 Test
The test is carried out acc. to DIN EN ISO 20567-1 with the following parameters:
Table 11: Test parameters M-02 Stone impact test
Quantity of blasting medium 500 g
Test pressure 2 bar
Blasting material Hard-cast granulate acc. to 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 acc. to
DIN EN ISO 20567-1
Number of cycles 2
Number of DUTs 6
4.2.3 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)
acc. to Section 1.5.
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 acc. to the characteristic values of DIN EN ISO 20567-1 is not required.
Page 16 of 83
4.3 M-03 Dust test

4.3.1 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.
4.3.2 Test
The test is carried out acc. to ISO 20653 with the following parameters:
Table 12: Test parameters M-03 Dust test

DUT operating mode For electric/electronic components: Operating mode II.a
For mechatronic components

(e.g. for components with fan):
Intermitting operating mode II.c and operating mode II.a
acc. to Figure 1
Degree of protection to be As specified in the Component Performance
achieved Specifications
Number of DUTs 6
Figure 1: 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.
4.3.3 Requirement
The degree of protection specified in the Component Performance Specifications acc. to
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) acc. to Section 1.5.
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.
Page 17 of 83
4.4 M-04 Vibration test

4.4.1 Aim
This test simulated 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.
4.4.2 Test
The test is carried out acc. to 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 13: Test parameters for general vibration

DUT operating mode Repeating, acc. to Figure 2: Temperature
profile - vibration
Superimposed temperature profile Repeated profile acc. to Figure 2:
Temperature profile - vibration
Frequency sweep time for sinusoidal 1 octave/min, logarithmic
excitation
Vibration profile A Vibration excitation, sinusoidal acc. to
(for engine-mounted parts) Figure 3 and Table 14
Vibration excitation, wide-band random

vibration
acc. to Figure 4 and Table 15
vibration profile B Vibration excitation, sinusoidal acc. to
(for gearbox-mounted parts) Figure 5 and Table 16
Vibration excitation, wide-band random

vibration
Vibration profile C Vibration excitation, sinusoidal acc. to
(for components installed on the decoupled Figure 7 and Table 18
intake plenum)
Vibration profile D Vibration excitation, wide-band random
(body-mounted parts for components vibration
installed on sprung masses) acc. to Figure 8 and Table 19
Vibration profile E Vibration excitation, wide-band random
for unsprung masses (chassis) vibration
Number of DUTs 6
The test must be performed without bracket or add-on parts.

Additional tests with bracket or add-on parts must be coordinated with the purchaser, if
required.
Page 18 of 83
For components that are installed on the bracket or vehicle through damping elements,
it must be specified in the Component Performance Specifications 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.
Figure 2: Temperature profile - vibration
Page 19 of 83
4.4.2.1 Vibration profile A (for engine-mounted parts)

Table 14: 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 Figure Frequency in Hz Amplitude of the
3 acceleration in m/s²
100 100
200 200
240 200
270 100
440 100
Characteristic 2 in Figure Frequency in Hz Amplitude of the
3 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
Page 20 of 83
Figure 3: Vibration profile, sinusoidal for engine-mounted parts
Page 21 of 83
Table 15: 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 4 Frequency in Hz Power density spectrum
in (m/s²)²/Hz
10 10
100 10
300 0,51
500 20
2 000 20
Figure 4: Vibration profile, wide-band random vibration for engine-mounted parts
Page 22 of 83
4.4.2.2 Vibration profile B (for gearbox-mounted parts)

Table 16: Test parameters - vibration, sinusoidal for gearbox-mounted parts
Vibration profile Figure 5 Frequency in Hz Amplitude of the
100 30
200 60
440 60
Figure 5: Vibration profile, sinusoidal for gearbox-mounted parts
Page 23 of 83
Table 17: Test parameters - vibration, wide-band random vibration for gearbox-mounted parts
RMS value of acceleration 96,6 m/s²
Vibration profile Figure 6 Frequency in Hz Power density
spectrum (m/s²)²/Hz
10 10
100 10
300 0,51
500 5
2000 5
Figure 6: Vibration profile, wide-band random vibration for gearbox-mounted parts
Page 24 of 83
4.4.2.3 Vibration profile C (for components installed on the intake plenum,

decoupled)
Table 18: Test parameters, sinusoidal for components on the intake plenum, decoupled.
Vibration profile Figure 7 Frequency in Hz Amplitude of the
100 90
200 180
325 180
500 80
1500 80
Figure 7: Vibration profile, sinusoidal for components on the intake plenum, decoupled
Page 25 of 83
4.4.2.4 Vibration profile D (body-mounted parts (for components installed on

sprung masses))
Table 19: Test parameters, wide-band random vibration for sprung masses
Test duration for each spatial axis 8h
Vibration profile Figure 8 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
2000 0,14
Figure 8: Vibration profile, wide-band random vibration for sprung masses
Page 26 of 83
4.4.2.5 Vibration profile E for unsprung masses (chassis)

Table 20: Test parameters, wide-band random vibration for unsprung masses
Test duration for each spatial axis 8h
Vibration profile Figure 9 Frequency Power density spectrum
(Hz) in (m/s²)²/Hz
20 200
40 200
300 0,5
800 0,5
1000 3
2000 3
Figure 9: Vibration profile, wide-band random vibration for unsprung masses
4.4.3 Requirement
must meet the specifications. Verification takes place by means of continuous
parameter monitoring and a parameter test (small) acc. to Section 1.5.
Page 27 of 83
4.5 M-05 Mechanical shock

4.5.1 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.
4.5.2 Test
The test is carried out acc. to DIN EN 60068-2-27 with the following parameters:
Table 21: Test parameters M-05 Mechanical shock
DUT operating mode Operating mode II.c

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
4.5.3 Requirement
Page 28 of 83
4.6 M-06 Endurance shock test

4.6.1 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.
4.6.2 Test
Table 22: Test parameters M-06 Endurance shock test

DUT operating mode 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 100000
Front passenger's 50000
door/rear doors
Liftgats/rear gates 30000
Engine hood 3000
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 acc.
to the installation conditions in the vehicle.
Number of DUTs 6
4.6.3 Requirement
Page 29 of 83
5 Climatic requirements and tests

5.1 K-01 High-/low-temperature storage
5.1.1 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.
5.1.2 Test
Table 23: Test parameters K-01 High-/low-temperature storage
Test duration and test 2 cycles for 24 h each (consisting of 12 h storage at
temperature Tmin and 12 h storage at Tmax each)
Number of DUTs As specified in the test sequence plan in the
Component Performance Specifications
5.1.3 Requirement
meet the specifications. Verification takes place by means of a parameter test (large)
Page 30 of 83
5.2 K-02 Incremental temperature test

5.2.1 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.
5.2.2 Test
Table 24: 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 acc. to Figure 10 must be applied to the
DUTs.
The temperature change per increment is 5 °C.
Test sequence At every temperature increment, the DUT must be kept until it
completely maintains the temperature (see Section 1.4).
Subsequently, a parameter test (functional test) acc. to the
parameter test section (see Section 1.5) must be performed.
Number of DUTs 6
Figure 10: Temperature profile for incremental temperature test
5.2.3 Requirement
All DUT parameters must meet the specifications during the parameter test (functional
test).
Page 31 of 83
5.3 K-03 Low-temperature operation

5.3.1 Aim
This test simulates the load of the component at low temperatures.
The test serves to verify functioning of the component after a long parking time or
operation time at extremely low temperatures.
5.3.2 Test
The test is carried out acc. to DIN EN 60068-2-1, test Ab, with the following parameters:
Table 25: Test parameters K-03 Low-temperature operation

DUT operating mode Intermitting 12 h operating mode II.a and 12 h operating
mode II.c each
Test duration 48 h
Test temperature Tmin
Number of DUTs 6
Note: For components dissipating heat, the test must also be carried out acc. to
DIN EN 60068-2-1, test Ab.
5.3.3 Requirement
Page 32 of 83
5.4 K-04 Repainting temperature

5.4.1 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.
5.4.2 Test
Table 26: Test parameters K-04 Repainting temperature
DUT operating mode Operating mode II.a
Test duration and test temperature 15 min at 130 °C and 1 h at 110 °C
Number of DUTs 6
5.4.3 Requirement
meet the specifications. Verification takes place by means of a parameter test (small)
Page 33 of 83
5.5 K-05 Temperature shock (component)

5.5.1 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.
5.5.2 Test
Table 27: Test parameters K-05 Temperature shock (component)

DUT operating mode Operating mode I.b
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 1.4)
Transfer duration ≤ 30s
(air - air, medium -
medium)
Test fluid for test Nc Fluid in which the component is operated in the vehicle
Test Acc. to DIN EN 60068-2-14 NA for components that are not
permanently operated in a fluid
Acc. to DIN EN 60068-2-14 Nc for components that are

permanently operated in a fluid
(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 cycles 100
Number of DUTs 6
5.5.3 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 (chapter 3.2).
Page 34 of 83
5.6 K-06 Salt spray test with operation, exterior

5.6.1 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.
5.6.2 Test
The test is carried out acc. to DIN EN 60068-2-11 Ka with the following parameters:
Table 28: Test parameters K-06 Salt spray test with operation, exterior
DUT operating During spray phase: Intermitting 1 h operating mode II.a and 1 h
mode operating mode II.c each.
During rest phase: 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 acc. to Figure 11
Number of test For components on the underbody/in the engine compartment: 12
cycles cycles
For other components: 8 cycles
Number of DUTs 6
be simulated.
Page 35 of 83
Figure 11: Salt spray test with operation, exterior - spray phases
5.6.3 Requirement
Page 36 of 83
5.7 K-07 Salt spray test with operation, interior

5.7.1 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.
5.7.2 Test
The test is carried out acc. to DIN EN 60068-2-11 Ka with the following parameters:
Table 29: Test parameters K-07 Salt spray test with operation, interior
DUT operating mode During spray phase: Intermitting 55 min operating mode II.a
and 5 min operating mode II.c each
During rest phase: operating mode II.a

Test cycle Each test cycle consists of a spray phase of 8 h and a rest
phase of 4 h acc. to Figure 12
Number of test cycles 2
Number of DUTs 6
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.
Page 37 of 83
Figure 12: Salt spray test with operation, interior - spray phases
5.7.3 Requirement
Page 38 of 83
5.8 K-08 Humid heat, cyclic

5.8.1 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 humid heat.
5.8.2 Test
Table 30: Test parameters K-08 Humid heat, cyclic

Total test duration 144 h
Test variant Variant 1
Upper test temperature 55 °C
Number of cycles 6
Number of DUTs 6
5.8.3 Requirement
In addition, a parameter test (functional test) must be carried out after the upper and the
lower test temperature have been reached.
Page 39 of 83
5.9 K-09 Humid heat, cyclic (with frost)

5.9.1 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 humid heat.
5.9.2 Test
Table 31: Test parameters K-09 Humid 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
5.9.3 Requirement
Page 40 of 83
5.10 K-10 Water protection - IPX0 to IPX6K

5.10.1 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.
5.10.2 Test
Table 32: Test parameters K-10 Water protection - IPX0 to IPX6K
DUT operating mode Intermitting 1 min operating mode II.a and 1 min operating
mode II.c each
Required degree of As specified in the Component Performance Specifications
protection
5.10.3 Requirement
The degree of protection specified in the Component Performance Specifications acc. to
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.
Page 41 of 83
5.11 K-11 High-pressure cleaning

5.11.1 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.
5.11.2 Test
Table 33: 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
5.11.3 Requirement
The degree of protection IP X9K acc. to ISO 20653 must be achieved.
completion of the complete test sequence (chapter 3.2).
Page 42 of 83
5.12 K-12 Temperature shock with splash water

5.12.1 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.
5.12.2 Test
Table 34: Test parameters K-12 Temperature shock with splash water
DUT operating mode Intermitting, acc. to Figure 13
Test procedure Heating of the DUT to test temperature.
Then cyclical exposure of the DUT with splash water acc. to
Figure 13. The complete width of the DUT must be subjected to
splash water.
Cycle duration 30 minutes
Test temperature Tmax
Test medium for Tap water containing Arizona dust in a weight percentage of 3%,
splashing fine acc. to ISO 12103-1. Permanent mixing must be ensured.
Splash water 0 to +4 °C
temperature
Splash nozzle See Figure 14
Splashing time 3 seconds
Water flow rate 3 to 4 liters per splash/nozzle
Distance between 300 to 350 mm
nozzle and DUT
Number of DUTs 6
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.
Test setup acc. to Figure 15
Page 43 of 83
Figure 13: Splash water test splashing times
Figure 14: Splash water test - splash nozzle
Page 44 of 83
Figure 15: Splash water test setup
5.12.3 Requirement
completion of the complete test sequence.
Page 45 of 83
5.13 K-13 Temperature shock - immersion

5.13.1 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.
5.13.2 Test
Table 35: Test parameters K-13 Temperature shock - immersion

DUT operating Operating mode II.c
mode
Required degree IP X7
of protection
Test procedure Heating of the DUT to test temperature.
Maintaining test temperature until the DUT completely maintains its
temperature (see Section 1.4) plus 15 min
The DUT is then completely immersed into the test medium within
maximum five seconds so that all sides of the DUT are covered by
at least 25 mm with the test medium.
Test medium 0 °C cold water with a salt content of 5%
Immersion time 5 min
Number of 20
cycles
Number of DUTs 6
5.13.3 Requirement
completion of the complete test sequence (chapter 3.2).
Page 46 of 83
5.14 K-14 Humid heat, constant

5.14.1 Constant humid heat - severity 1
5.14.1.1 Aim
This test simulates the load of the component through humid heat.
The test serves to verify the resistance of the component with respect to faults caused
by humid heat, e.g. corrosion, migration/dendrites, swelling and degradation of plastics,
sealing and filling compounds.
5.14.1.2 Test
Table 36: Test parameters K-14 Humid heat, constant - severity 1

Humidity Frel= 93%
Test duration 21 days
Number of DUTs 6
5.14.1.3 Requirement
In addition, a parameter test (functional test) must be carried out every 7 days.
Page 47 of 83
5.14.2 Constant humid heat - severity 2

5.14.2.1 Aim
This test simulates in compact form the load of the component through humid heat
during vehicle service life.
The test serves to verify the quality and reliability of the component with respect to faults
caused by humid heat, e.g. corrosion, migration/dendrites, swelling and degradation of
plastics, sealing and filling compounds.
5.14.2.2 Test
Table 37: Test parameters K-14 Humid 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 Specifications
Test duration
acc. to Section 8.5.1 (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 coordinate the adaptation of the test temperature and test humidity
while increasing the test duration acc. to 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).
5.14.2.3 Deviating test for components with reduced performance at high

temperatures
For components with reduced performance (e.g. reduction of background lighting of
LCD displays) at high temperatures from Top,max (Top, max < 65 °C), the test must not be
performed at a constant temperature of 65 °C, but d eviating from Table 37 with the
following parameters (see Table 38):
Page 48 of 83
Table 38: Test parameters K-14 Humid heat, constant for components with reduced
performance at high temperatures
DUT operating
Intermitting operation acc. to Figure 16
mode
As specified in the Component Performance Specifications acc. to
Section 8.5.1 (Lawson model).
Test duration
The respective ramp times between 65 °C and T op, max are not
included in the test duration.
Acc. to Figure 16
Test temperature The temperature gradient must be selected so that no condensation
occurs on the DUT.
Test humidity 93% relative humidity
Interval time t1 47 h
Interval time t2 1h
Number of DUTs 6
t1
65°C
Top,max
t2
II.a II.c II.a II.c II.a
Figure 16: Temperature profile for the test of components with reduced performance at high
temperatures above Top,max
5.14.2.4 Requirement
Page 49 of 83
5.15 K-15 Condensation test with electr. assemblies

5.15.1 Aim
This test simulates the condensation on electronic assemblies in motor vehicles.
It serves to evaluate the resistance of electronic assemblies with respect to
condensation.
5.15.2 Test
Table 39: Test parameters K-15 Condensation test with electr. assemblies
DUT operating Operating mode II.a
mode
In addition, parameter tests (functional tests) as described in line
"Test procedure" must be carried out.
Test equipment Climatic chamber with condensation option (specifically controlled
water bath by means of which the required water quantity 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 (acc. to Figure 19) until
30 min before the end of this phase, however only at the
voltage UB,.
Note: 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 temperature See Figure 19
Relative test See Figure 19
room humidity
Test duration 35 h (5 cycles à 7 h)
Test medium Distilled water with a maximum conductivity of 5 µS/cm
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.
Page 50 of 83
Test setup See Figure 17

During the test, a plastic cover acc. to Figure 18 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 cov er
acc. to DIN EN ISO 6370-2.
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 DUTs manufactured under conditions similar to
standard production, to optimize detected condensation sensitivities,
e.g. by means of layout and circuit modifications.
Note: If the manufacturing process of the electr. assembly is
changed (e.g. PCB, soldering agent, flux, solder, layout, location or
parts), the test must be repeated.
Subsequently, the test must be performed with 5 standard
production parts.
Number of 5
cycles
Number of DUTs 5
Figure 17: Test setup K-15 Condensation test
Page 51 of 83
Figure 18: Plastic cover

°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 1K Water bath temperature < 20°C

3) Transition from climate chamber control to
water bath control
Test chamber temperature 3K Humidity curve not defined
**) Recording of test chamber humidity and temperature, temperature difference < 15 °C
Figure 19: Sequence K-15 Condensation test
Page 52 of 83
5.15.3 Requirement
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 8.6.
Page 53 of 83
5.16 K-16 Temperature shock (without housing)

5.16.1 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.
5.16.2 Test
The test is carried out acc. to DIN EN 60068-2-14 Na with the following parameters:
Table 40: 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 1.4)
Transfer duration ≤ 10 s
Number of DUTs 6 electr. assemblies
5.16.3 Requirement
Page 54 of 83
5.17 K-17 Sun radiation

5.17.1 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.
5.17.2 Test
The test is carried out acc. to DIN 75220 with the following parameters:
Table 41: Test parameters K-17 Sun radiation

DUT operating Operating mode I.a
mode
Used test profiles The test profiles acc. to DIN 75220 must be used depending on
the installation location of the component.
Components in the Use of the Z-OUT profile acc. to Table 2 and Table 5 of DIN
exterior 75220
Components in the Use of the Z-IN profile acc. to DIN 75220
interior
Test duration 25 days (15 days dry, 10 days humid)
Number of cycles 1
Number of DUTs 6
5.17.3 Requirement
In addition, the DUT must be evaluated visually with the naked eye.
Changes or damages must be documented in the test report and evaluated with the
purchaser.
Page 55 of 83
5.18 K-18 Harmful gas test

5.18.1 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.
5.18.2 Test
The test is carried out acc. to DIN EN 60068-2-60, method 4, with the following
parameters:
Table 42: Test parameters K-18 Harmful gas test
DUT operating mode Operating mode I.b
Temperature TRT
Humidity 75%
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
5.18.3 Requirement
In addition, the contact resistances of switches and contacts must be measured. The
measured values must meet the specifications.
Page 56 of 83
6 Chemical requirements and tests

6.1.1 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.
6.1.2 Test
Table 43: Test parameters - chemical tests
DUT operating mode As specified in the Component Performance
Specifications
Chemicals As specified in the Component Performance
Specifications
Typical chemicals for different installation locations are
indicated in Table 44.
Conditioning Unless otherwise specified, the DUTs and the
chemicals must be aged in standard climate.
Test procedure 1. The chemical must be applied to the DUT at
TRT. Unless otherwise defined in the
Component Performance Specifications, an
appropriate type of application must be selected
for each chemical acc. to Table 81. 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 44 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
Note: Safety instructions and warnings for the chemicals must be observed.
Page 57 of 83
6.1.2.1 Chemicals
Table 44: Overview of chemicals
ID Chemical agent
Sample chemicals
DUT temperature
Exposure time
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
1
16 Cavity sealing medium TRT 22 h e.g. underbody protection, 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)
19 Windshield cleaner TRT 2h 5% anionic tensides, distilled water
20 Automotive washing chemicals TRT 2h CAS 25155-30-0

CAS 9004-82-4
1
21 Interior cleaner/cockpit spray TRT 2h e.g. Cockpit-spray (by Motip)
22 Glass cleaner TRT 2h CAS 111-76-2
1
23 Rim cleaner TRT 2h e.g. Xtreme (Sonax)
1
24 Cold-cleaning agent TRT 22 h e.g. P3-Solvclean AK (by Henkel)
25 Acetone TRT 10 min CAS 67-64-1
26 Petroleum ether TRT 10 min DIN 51 635
1
27 Cleaner containing ammonia TRT 22 h e.g. Ajax (by Henkel)
28 Methylated spirits TRT 10 min CAS 64-17-5 (ethanol)

1
29 Contact spray Tmax 22 h e.g. WD 40
30 Sweat TRT 22 h DIN 53 160
1
31 Cosmetic products, e.g. creams TRT 22 h e.g. Nivea, Kenzo
32 Refreshment containing caffeine and sugar TRT 22 h Cola
33 De-icer (aviation) TRT 2h SAE AMS 1435A

34 Other chemicals
Page 58 of 83
ID Chemical agent
Sample chemicals
DUT temperature
Exposure time
1
) Sample manufacturer, exact chemicals must be coordinated with the responsible department
Table 45: 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
6.1.3 Requirement
Changes to letterings or markings must be documented in the test report and

coordinated with the purchaser.
Page 59 of 83
7 Life tests
7.1 L-01 Life test - mechanical/hydraulic endurance test
7.1.1 Aim
This test simulates the functioning/actuation cycles of the component during vehicle
service life.
The test serves to verify the quality and reliability of the component with respect to
functioning/actuation cycles, e.g. brake actuation, seat adjustment cycles, switch/tip
switch actuation.
7.1.2 Test
Test details must be defined in the Component Performance Specifications acc. to the
functioning/actuation cycle.
Table 46: Test parameters L-01 Life test - mechanical/hydraulic endurance test
DUT operating mode Operating mode II.c acc. to 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 Specifications
cycles
Number of DUTs 6
7.1.3 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 acc. to 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.
Page 60 of 83
7.2 L-02 Life test - high-temperature endurance test

7.2.1 Aim
This test simulates in compact form the thermal load of the component during vehicle
service life.
that occur due to thermal load, e.g diffusion, migration and oxidation.
7.2.2 Test
Table 47: Test parameters L-02 Life test - high-temperature endurance test
Intermitting, 47 h operating mode II.c an 1 h
DUT operating mode
Operating mode II.a
The test duration must be calculated acc. to Section 8.3.1
Test duration (Arrhenius model) and specified in the Component Performance
Specifications.
Test temperature Tmax
Number of DUTs 6
7.2.2.1 Deviating test for components with reduced performance at high

temperatures
LCD displays) at high temperatures starting with Top,max, the test must not be performed
at a constant test temperature of Tmax, but deviating from Table 48 with the following
parameters:
Table 48: Test parameters L-02 Life test - high-temperature endurance test for components with
reduced performance at high temperatures
Operating statuses Acc. to Figure 20
To be calculated acc. to Section 8.3.2 (Arrhenius model for
components with reduced performance at high temperatures)
and to be defined in the Component Performance
Test duration
Specifications.
The respective ramp times between Tmax and Top, max are not
included in the test duration.
Test temperature Acc. to Figure 20
To be calculated acc. to Section 8.3.2 and to be specified in the
Interval time t1
Component Performance Specifications.
Interval time t2
Number of DUTs 6
Page 61 of 83
t2
Tmax
Top,max
t1
II.c II.c* II.c II.c* II.c
*) A performance decrease is permissible for T > Top,max
Figure 20: Temperature profile for the test of components with reduced performance at high
temperatures
7.2.3 Requirement
Page 62 of 83
7.3 L-03 Life test - temperature cycle test

7.3.1 Aim
This test simulates in compact form the thermal load of the component during
temperature changes that occur during vehicle service life.
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.
7.3.2 Test
Table 49: Test parameters L-03 Life test - temperature cycle test
DUT operating Intermitting operating mode II.c and operating mode II.a acc. to
mode Figure 21.
Temperature
Acc. to Figure 21
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 1.4)
Number of cycles
Number of DUTs 6
Page 63 of 83
Figure 21: Temperature profile L-03 Life test - temperature cycle test
7.3.2.1 Deviating test for components with reduced performance at low or

high temperatures
LCD displays) at low or high temperatures below Top,min and above Top,max, the test must
be performed with the following parameters.
Table 50: Test parameters L-03 Life test - temperature cycle test - Deviating test for components
with reduced performance at high temperatures
Operating mode II.a and operating mode II.c acc. to Figure
DUT operating mode
22.
Temperature profile Acc. to Figure 22
Minimum test
Tmin
temperature
Maximum test
Tmax
temperature
Temperature gradient 4 °C/min
15 min after the component has achieved the condition at
Holding times at Tmin,
which it maintains the temperature
Tmax, Top,min and Top,max
(see Section 1.4)
To be calculated acc. to Section 8.4.1 (Coffin-Manson
Number of cycles model) and to be specified in the Component Performance
Specifications.
Number of DUTs 6
Page 64 of 83
Figure 22: Temperature profile for the Deviating test for components with reduced performance
at low or high temperatures
7.3.3 Requirement
Page 65 of 83
8 Appendix
8.1 Test sequence plan
The tests that are not required for a component acc. to 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 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.
Note: If the test "Humid heat, cyclic (with frost)" is carried out instead of the test "Humid
heat, cyclic" in the sequence test, the test "Humid heat, cyclic (with frost)" can be
omitted in the parallel tests.
Page 66 of 83
8.1.1 Sequence tests
Figure 23: Test sequence plan - sequential

Note: All components must be tested with original connector or adapter starting with the
test M-01 Free fall.
Page 67 of 83
8.1.2 Tests outside the sequence (parallel tests)
Figure 24: Test sequence plan - parallel tests
Page 68 of 83
8.1.3 Life tests
Figure 25: Test sequence plan - service life
Page 69 of 83
8.2 Typical temperature spectrums for different installation

areas
Table 51: Overview of installation location, typical spectrums and temperature rises
Installation location of the component Spectrum no. Temperature rise in K
Interior, without special requirement 1 36
Body-mounted part, without special requirements 1 36
Interior exposed to sun radiation 2 46
Body-mounted 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
Page 70 of 83
8.2.1.1 Temperature spectrum 1

Table 52: Temperature spectrum 1
Temperature Distribution
-40 °C 6%
23 °C 20%
40 °C 65%
75 °C 8%
80 °C 1%

-40 °C 6%
23 °C 20 %
50 °C 65 %
100 °C 8%
105 °C 1%

-40 °C 6%
30 °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%
Page 71 of 83
8.3 Calculation models for the life test 'High-temperature

endurance test'
8.3.1 Arrhenius model
The calculation of the test duration of the high-temperature endurance test life test is
based on the temperature spectrum percentage acc. to the use profile in the
Component Performance Specifications
Table 56: Temperature spectrum
Temperature in °C Distribution
TFeld.1 p1
TFeld.2 p2
… …
TFeld.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   Prüf +273,15 T +273,15
A T,i = e 
Feld,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)
TPrüf Test temperature [°C], normally T max
TFeld,i Field temperature [°C] acc. to temperature spectru m based on use profile
-273,15 °C Absolute zero of the temperature
The total test duration for the high-temperature endurance test results from the
acceleration factor acc. to
pi
t Prüf = t Betrieb ⋅ ∑ (2)
i A T,i
Page 72 of 83
Where:
tprüf Test duration (hours) of the high-temperature endurance test life test
tBetrieb 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
8.3.1.1 Example:
For a control unit with the temperature spectrum indicated in the following table
Table 57: Sample spectrum
Temperature [°C] Distribution
-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 57) 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 tBetrieb = 8 000 h.
The total test duration of the temperature cycle test life test results from equation (2) as:
 0,06 0,20 0,65 0,08 0,01

t Prüf = 8000 hours⋅  + + + +  = 1452 hours .
 5369 45,8 6,46 1,20 1,00 
Page 73 of 83
8.3.2 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 acc. to the use profile in the Component Performance
Specifications is divided into the two temperature ranges T ≤ Top,max and T>Top,max.
Table 58: Temperature spectrum for T ≤ Top,max with test temperature Top,max
TFeld.1 p1
TFeld.2 p2
… … m<n
TFeld.m (≤ Top,max) pm
Table 59: Temperature spectrum for Top,max < T ≤ Tmax with test temperature Tmax
TFeld.m+1(> Top,max) pm+1
TFeld.m+2 pm+2
… …
TFeld.n pn m<n
For each temperature TFeld,1 … TFeld,m … TFeld,n an acceleration factor AT,1 … AT,m … AT,n
is calculated by means of equation (1), where for temperature range T ≤ Top,max a test
temperature of Tprüf = Top, max and for temperature range T >T op,max a test
temperature Tprüf = 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 20).
The typical interval of 48 h is divided at the ratio of the part test durations top, max and
tmax.
Page 74 of 83
8.3.2.1 Example:
The temperature spectrum acc. to Table 60 and Table 61 applies to the control unit. The
test duration for the high-temperature endurance test for components with reduced
performance starting with a temperature of Top, max = 90 °C for an operating time of
8 000 h is calculated as follows:
The proportionate temperature distribution acc. to the use profile is divided into the
ranges T ≤ Top,max and T > Top,max.
Table 60: Sample spectrum for T > 90 °C

-40 6
23 20
60 65
Table 61: Sample spectrum for T > 90 °C

100 8
105 1
By means of equation (1) and TPrüf = 90 °C, the acceleration factors A T,i for all
temperatures T ≤ 90°C (see Table 60) of the first part of the tempe rature 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 (TPrüf = 90°C) = 8000 hours ⋅  + +  = 1485 hours
 3060,78 25,95 3,65 
By means of equation (1) and TPrüf = 105 °C, the acceleration factors A T,i for all
temperatures T > 90 °C (see Table 61) 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 (TPrüf = 105°C) = 8000 hours ⋅  +  = 612 hours
 1,20 1,00 
The total test duration for the temperature cycle test life test is the sum of the two test
durations
Page 75 of 83
t Ges = t op, max + t max = 1485 hours + 612 hours = 2097 hours
The test is carried out acc. to Figure 20 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.
8.4 Calculation models for the life test 'temperature cycle test'
8.4.1 Coffin-Manson model
The calculation of the test duration for the temperature cycle test life test is based on
the average temperature changes of the component in the field ∆TFeld and the number
of temperature cycles during service life in the field NTempZyklenFeld.
Depending on the average temperature change in the field, the acceleration factor of
the Coffin-Manson model is calculated as follows:
c
 ∆TTest 
A CM =   (3)

 ∆TFeld 
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 acc. to
NTempZyklenFeld
NPrüf = (4)
A CM
Page 76 of 83
Where:
NPrüf Required number of test cycles
NTempZyklenFeld Number of temperature cycles during service life in the field
ACM Acceleration factor of the Coffin-Manson model acc. to equation (3)
8.4.1.1 Example:
The number of test cycles (NPrüf) is calculated for a 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 ∆TFeld = 40 °C as described below:
1. The number of temperature cycles in the field:
NTempZyklenFeld = 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.
Page 77 of 83
8.5 Calculation models for the test

'constant humid heat - severity 2'
8.5.1 Lawson model
The calculation of the test duration of the constant humid heat test - severity 2 is based
on the average ambient humidity RHFeldParken and the average temperature TFeldParken of
the component in the parked vehicle.
Unless otherwise specified in the Component Performance Specifications, the following
values must be assumed for the calculation:
Mounting location Average ambient humidity in Average temperature in

the parked vehicle the parked vehicle
RHFeldParken TFeldParken
In the passenger
60% rH 23 °C
compartment/trunk
Outside the passenger
65% rH 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:
  
EA   1 1  2
 
2
  + b⋅  RHPrüf  −  RHFeldParken  
    
 − ⋅ −
  T
k   Prüf + 273,15 T + 273,15 
 




A T/RH = e FeldParken
(5)
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)
TPrüf Test temperature [°C]
TFeldParken Average temperature [°C] in the parked vehicle
RHPrüf Relative humidity [%] during the test
RHFeldParken Average relative humidity [%] in the parked vehicle
-273,15°C Absolute zero of the temperature
The test duration for the constant humid heat test - severity 2 - is calculated by means
of:
t FeldParken
t Prüf = (6)
A T/RH
Page 78 of 83
Where:
tPrüf Test duration [h]
tFeldParken Non-operating time (parking time) [h] during the service life in the field
(131 400 h, in the unfavorable case if the vehicle is not used)
AT/RH Acceleration factor of the Lawson model acc. to equation (5)
8.5.1.1 Example:
For a 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% is assumed for the component in the parked vehicle.
The test conditions are TPrüf = 65 °C and RH Prüf = 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:
131400 hours
t Prüf = = 1593 hours
82,5
Page 79 of 83
8.6 Condensation test, chamber programming and diagrams
Figure 26: 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 cham ber is switched over to temperature
control (standard operation).
Page 80 of 83
Figure 27: Sequence of the condensation test, 1 cycle

1. Controlled water bath temperature
2. Resulting test room temperature
3. Actual humidity in the test chamber
Page 81 of 83
Figure 28: Sequence of the condensation test, 5 cycles
Page 82 of 83
8.7 Glossary
This glossary describes the terms used in this standard.
Term/abbreviation Definition
Electr. assembly PCB with circuit parts (without housing)
Parts Electric, electronic or mechatronic component
(e.g. resistor, capacitor, transistor, IC, relay)
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
Climatic chamber with This is a specifically controlled water bath in the climatic
condensation option chamber by means of which the required water quantity is
converted into water vapor.
The intensity of the condensation film on the PCB 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, control unit or mechatronic (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) must also be covered.
A short circuit may be permanently present (component in
operation/not in operation).
PKW Passenger car (German abbreviation)
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 (PCB,
ceramic, leadframe, flexband etc. without mounted parts) )
System Functionally linked components, e.g.
brake control system (control unit, hydraulic, sensors)
Page 83 of 83

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BMW Group Standard GS 95024--3--1

Deskriptoren: Komponente, Kraftfahrzeug, Prüfung, Umweltanforde- Ersatz für GS 95003--1 : 2008--11,

Elektrische und elektronische Komponenten in Kraftfahrzeugen

Electrical and electronic components in motor vehicles

Ausdrucke unterliegen nicht dem Änderungsdienst.

BMW AG Normung: 80788 München

E BMW AG Alle Rechte vorbehalten / All rights reserved

Frühere Ausgaben Previous editions

Electric and Electronic Components in Motor Vehicles up to

Additional or deviating requirements, test conditions and tests must be

Note: The represented tests do not serve for component qualification or a

Part II - Environmental requirements

1.2 Terms and definitions

1.2.4 Standard tolerances

1.2.5 Standard values

1.2.6 Sampling rate and measured value resolution

1.3 Operating modes

1.3.1 Operating mode I - DUT not electrically connected

1.3.1.2 Operating mode I.b

1.3.2 Operating mode II - DUT electrically connected

1.3.2.2 Operating mode II.b

1.3.2.3 Operating mode II.c

1.3.2.4 Sample operating modes

1.4 Maintaining temperature

1.5 Parameter test

1.5.1 Parameter test (small)

1.5.2 Parameter test (large)

1.5.3 Parameter test (functional test)

1.6 Continuous parameter monitoring with drift analysis

1.7 Physical analysis

2.2 Temperature spectrum

In principle, this temperature distribution is a continuous distribution, as the ambient

Table 8: Temperature spectrum

It is based mainly on field measurements and technical experiences.

Typical temperature spectrums for different installation locations are indicated in

For temperature spectrums defined or adopted on a component-specific basis, this

- Acc. to vibration profile A for components

K-01 High-/low-temperature All components None

Test Applicable to Required

Test Applicable to Required

3.2 Test sequence plan

4 Mechanical requirements and tests

4.2 M-02 Stone impact test

4.3 M-03 Dust test

Table 12: Test parameters M-03 Dust test

For mechatronic components

Figure 1: Test sequence M-03 Dust test

4.4 M-04 Vibration test

Table 13: Test parameters for general vibration

Vibration excitation, wide-band random

Vibration excitation, wide-band random

The test must be performed without bracket or add-on parts.

- all DUTs with damping elements,

Figure 2: Temperature profile - vibration

4.4.2.1 Vibration profile A (for engine-mounted parts)

The characteristics must be combined for components that

Figure 3: Vibration profile, sinusoidal for engine-mounted parts

Figure 4: Vibration profile, wide-band random vibration for engine-mounted parts

4.4.2.2 Vibration profile B (for gearbox-mounted parts)

Figure 5: Vibration profile, sinusoidal for gearbox-mounted parts

Figure 6: Vibration profile, wide-band random vibration for gearbox-mounted parts

4.4.2.3 Vibration profile C (for components installed on the intake plenum,

4.4.2.4 Vibration profile D (body-mounted parts (for components installed on

Figure 8: Vibration profile, wide-band random vibration for sprung masses