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Coils for Solenoid-Operated On/Off and Proportional Valves

E-Coils - Rigorous Durability Testing
Waterproof, Weather-Resistant, IP69K Rated

E-Coils 08-Size
E-Coils 10-Size
E-Coils 70-Size
E-Coils EHPR-Size

E-Coils Introduction
E-Coils PDF brochure
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OUR COIL TESTING PROGRAM IS THE MOST STRINGENT AND RIGOROUS IN THE INDUSTRY

(1) Extended Thermal Shock Immersion Test – IP67
Ref. Exceeds IP67 per standard EN60529

Thermal Shock Immersion Test
The purpose of this test is to try to induce cracks in the encapsulation of the coil.
The coil is heated for two hours at an ambient temperature of 105°C (±5°C), then immediately immersed in a solution of water, detergent and salt at a temperature of 0° to 5°C for two hours. The coils is then visually inspected for cracks and water penetration. This process is repeated ten times.


(2) Salt Spray Test DIN 50 021 Level 1
Ref: Standard ASTM B117

Salt Spray Test

This accelerated test is designed to simulate the corrosive environment that the coil will encounter during the life of the vehicle.
The coil is subjected to a continuous salt spray as per ASTN B117 for a period of 20 hours. The coil is then rinsed and dried.



(3) Inorganic Dust Test
ANSI/ASAE EP455 Section 5.3

Inorganic Dust Test

This tests for the effects of dust on the coil.
The coil is placed in a dust
chamber containing the equivalent
of air cleaner fine dust.
Suffi cient air movement is
provided to maintain a minimum
0.88g per cubic meter with the
coil positioned in its normal
mounting position. The test is
run for a minimum of 24 hours.



(4) Vibration Test

Vibration Test

This accelerated test
simulates random vibration
that the coil will encounter
when used on heavy-duty
equipment.

Functional performance is
monitored under the following
vibration levels shown in the
table below for 72 hours in each
of the three perpendicular axes.
The coil is then checked for
impaired function, loose parts
and fatigue cracks induced by
the test.


Vibration Test Profile
Frequency
(Hz)
Measured
PSD
(G^2/Hz)
Acceler-
ation
Factor
Accelerated
Test PSD
(G^2/Hz)
20 0.422 x2 0.844
25 0.781 x2 1.562
76 0.174 x2 0.348
137 0.00283 x7.2 0.020374
216 0.00073 x7.2 0.005256
261 0.00119 x7.2 0.008568
320 0.00042 x7.2 0.003024
399 0.0000415 x7.2 0.000298
626 0.0000265 x7.2 0.0001908
712 0.000452 x7.2 0.0032544
799 0.0000491 x7.2 0.00035352
966 0.00117 x7.2 0.008424
1424 0.00000965 x7.2 0.00006948
1597 0.00012 x7.2 0.000864
1996 0.0000154 x7.2 0.0001108


(5) Operating Shock Test

Shock Test

This test simulates sudden,
severe shock induced when
the vehicle is driven over
rough terrain.

The coil must withstand a 5
ms pulse of 490 m/sec2 (50 g).
Impaired function, loose parts,
and fatigue cracks caused by
this test result in part rejection.
The test is repeated a total of
five times in each of the three
perpendicular axes.



(6) Chemical Resistance Test

Chemical Resistance • Gasoline
• Engine Oil
• Hydraulic Fluid
• Bearing Grease
• Antifreeze
• Diesel Fuel
• Phosphate Wash
• Degreaser
• Windshield
  Washer Fluid
• Battery Acid
• Fertilizer: 28%
  nitrogen with
  ammonium nitrate
  and urea of 5 pH
Coils may be subjected to
various chemicals throughout
their life. In this test a coil is
completely immersed in only
one each of the following fluids
for a period of 5 minutes.
Twelve coils are used at a time. After immersion the coils are
heated for four hours at 50°C
and the cycle is repeated for
a total of ten trials. Impaired
function as a result of this test
is cause for failure.

(7) Bench Handling Shock Test

Bench Handling Shock

This test simulates the effects
of dropping a coil while it is
being handled.

The coil is dropped from a
distance of 450mm (±5mm) onto
a solid oak bench top at least
44mm thick. The test is repeated
by dropping the coil once on all
practical edges and faces.
Impaired function as a result of
this test is cause for rejection.



(8) Storage Temperature Test

Storage Temperature
This test simulates the effects of storage in extreme
temperatures for some time.

While not in operation, the coil is subjected to +105°C and
then –55°C for 20 hours each. Impaired function as a result
of this test is cause for rejection.

(9) Humidity Test

Humidity

This test simulates the
effects of relative humidity
on the coil.

The coil is soaked at 40°C
and 95% relative humidity for
168 hours each while the coil
is not in operation. Impaired
function as a result of this test
is cause for rejection.

(10) Continuous Immersion Test – IP68
Ref. Standard EN60529

Continuous Immersion

In this test the coil is immersed while powered on.
The coil is immersed in 1 meter of water at an ambient
temperature of 25°C (±5°C) for 120 hours while powered
according to the chart below. Impaired function as a result
of this test is cause for rejection.

Immersion Test Voltage



(11) Maximum Load Cycling Test

Load Cycling
This accelerated test simulates temperature cycling
to induce cracks or separation between components
of the coil.

Coils are installed in an environmental chamber set to
85°C and 133% of nominal voltage is applied for 1 hour. After 1 hour, the power is immediately switched off and back on within 2 seconds. 133% of nominal voltage is
then applied for a period of 5 minutes. After 5 minutes, power is immediately switched off and then back on
within 2 seconds. This 5-minute cycle is repeated for
a total of 168 hours (power is turned off and on within
2 minutes every 5 minutes). Cracks in the encapsulation, separation in components, or impaired function are
cause for rejection.

(12) Jump Start Test

Jump Start Test
This test simulates the voltage required to jump start
heavy equipment.

The coil is thermally soaked in an environmental chamber
at 70°C for 2 hours. It is then subjected to 220% of nominal
voltage for 5 minutes.

(13) High Pressure Cleaning Test – IP69K
Ref. Standard DIN 40 050, part 9

High Pressure Cleaning

This test simulates high pressure steam-jet cleaning
of a component.



(14) Combined Operating Voltage, Humidity
and Temperature Test

Voltage Humidity Temperature
This test simulates the combined effects of some of the previous tests.
The coil is simultaneously subjected to the voltage, temperature and humidity profi les shown in the graphs below. The cycle is repeated for a total of 600 hours
(25 days). The coils are inspected every 20 cycles for cracks in the encapsulation, separation of components,
or impaired function as a result of this test. Any induced flaws will result in rejection.


Voltage Temperature Humidity

 


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