(1) Extended Thermal Shock Immersion Test – IP67
Ref. Exceeds IP67 per standard EN60529
 |
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
 |
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
 |
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
 |
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
 |
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
 |
• 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
 |
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
 |
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
 |
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
 |
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.
|
(11) Maximum Load Cycling Test
 |
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
 |
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
 |
This test simulates high pressure steam-jet cleaning
of a component. |
(14) Combined Operating Voltage, Humidity
and Temperature Test
 |
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. |
