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STANDARD SPECIFICATION FOR ELECTRONIC CONTROL UNITS

SK-E
(PCB + mechanical) Environmental requirements for automotive application
-car body installation-
From Our Reference Telephone Facsimile Schwieberdingen
K8/EKM5 Mnch (07 11) 8 11- 1323 (07 11) 8 11- 3803 20.5.1997
Y 280 P61 148 page 1 of 14
Robert Bosch GmbH reserves all rights even in the event of industrial poperty. We reserve all rights of disposal such as copying and passing on
to third parties.
W6 82 5.00
This specification includes the environmental conditions for electronic
control units with printed circuit boards applied in automotive car body
installations (passenger compartment, engine compartment).
The test severity referenced represents the requirements as defined in the
STANDARD SPECIFICATION TEAM.
Connectors (including supplied connectors) are tested and evaluated.
date changes prepared by checked
K8/EKM5
07.07.1994
09.09.1994
14.09.1994
13.12.1995
20.05.1997
Initial release
Items: 1.1, 1.2, 1.3, 2.2.2, 3.1
and 4.0
Item: 1.1; page 13
Items: 1.1 and 3.1; page 10 and
14
translated and formal redesign
auth. Mnch
auth. Mnch
auth. Mnch
auth. Mnch
auth. Mnch
auth. Mller
auth. Mller
auth. Mller
auth. Mller
auth. Kraft
STANDARD SPECIFICATION FOR ELECTRONIC CONTROL UNITS
SK-E
(PCB + mechanical) Environmental requirements for automotive application
-car body installation-
From Our Reference Telephone Facsimile Schwieberdingen
K8/EKM5 Mnch (07 11) 8 11- 1323 (07 11) 8 11- 3803 20.5.1997
Y 280 P61 148 page 2 of 14
Robert Bosch GmbH reserves all rights even in the event of industrial poperty. We reserve all rights of disposal such as copying and passing on
to third parties.
W6 82 5.00
0. TABLE OF CONTENTS
1. Temperature resistance and electrial endurance
1.1 Operating temperature
1.2 Storage temperature
1.3 Temperature cycling (shock)
1.4 Temperature cycling endurance (practical)
1.5 High temperature endurance
2. Climatic and chemical resistance
2.1 Climate restistance
2.1.1 Passenger compartment
2.1.1.1 Humidity test
2.1.1.2 Industrial climates
2.1.1.3 Salt mist test
2.1.2 Engine compartment
2.1.2.1 Humidity test
2.1.2.2 Industrial climates
2.1.2.3 Salt mist test
2.2 Chemicals restistance
2.2.1 Passenger compartment
not forseen
2.2.2 Engine compartment
2.2.2.1 Resistance to fuel
2.2.2.2 Resistance to diesel fuel
2.2.2.3 Resistance to engine oil
2.2.2.4 Resistance to decalcifying agents
3. Mechanical resistance
3.1 Broadband noise
3.2 Shocks
3.3 Freefalls
4. Type of protection
4.1 Passenger compartment
4.2 Engine compartment
STANDARD SPECIFICATION FOR ELECTRONIC CONTROL UNITS
SK-E
(PCB + mechanical) Environmental requirements for automotive application
-car body installation-
From Our Reference Telephone Facsimile Schwieberdingen
K8/EKM5 Mnch (07 11) 8 11- 1323 (07 11) 8 11- 3803 20.5.1997
Y 280 P61 148 page 3 of 14
Robert Bosch GmbH reserves all rights even in the event of industrial poperty. We reserve all rights of disposal such as copying and passing on
to third parties.
W6 82 5.00
5. Notes on connectors
6. Standard inspection procedure
6.1 Engine compartment (sealed version)
6.2 Passenger compartment (non-sealed version)
1. Temperature resistance and electrical endurance
1.1 Operating temperature
ECU ambient temperature, active (Tu): -40C / +70C
ECU inside air temperature, upper limit (Ti): +85C (standard)
The above limits apply for one vehicle life-time.
Supplementary conditions:
For conditions anticipated to exceed the limiting
values, Rth =(Ti-Tu)/Pv 1.5 K/W
appropriate measures are to be jointly agreed upon,
e.g. - use of heatsinks,
- provisions for convection,
- reduction of power loss,
- use of higher-specified components (costs)
Mounting position: customer-specific, to be determined
Operating conditions: ECU-specific, to be determined
1.2 Storage temperature (passive)
A storage temperature of max.+90C for short periods is
permissible.
1.3 Temperature cycling (shock)
Standards: DIN-IEC 68-2-14 Na
DIN 40 046 sh. 14
RB N42 AP 216
Temperature range: -40C ...+90C
Transition time: max. 10 sec.
Soak time at max. temperatures: * min. 15 minutes
* (upon attainment of temperature environment)
STANDARD SPECIFICATION FOR ELECTRONIC CONTROL UNITS
SK-E
(PCB + mechanical) Environmental requirements for automotive application
-car body installation-
From Our Reference Telephone Facsimile Schwieberdingen
K8/EKM5 Mnch (07 11) 8 11- 1323 (07 11) 8 11- 3803 20.5.1997
Y 280 P61 148 page 4 of 14
Robert Bosch GmbH reserves all rights even in the event of industrial poperty. We reserve all rights of disposal such as copying and passing on
to third parties.
W6 82 5.00
test duration: 100 temperature
cycles
Operation mode: passive
1.4 Temperature cycling endurance test TWDL
Standards: DIN-IEC 68-2-14 Nb
Temperature range: -40C to +85C
Variation of temperature: = 4,3 min.
Test duration: 500 temp.-cycles
Operation conditions: operating during
temperature-rise
and upper temperature
Note: The input signals applied during electrical operation must
be inside the specified ranges and representative of
practical applications.
Test details: see page 14
1.5 High temperature enduration
Standards: DIN-IEC 68-2-2
DIN 40 046
Inside air temperature: Ti = 85C
(higher if necessary under consideration of
the respective upper operating temperatures
of the components).
Test duration: 1500 hrs
Operation mode: continuous operation
Note: The input signals applied during electrical operation must
be meaningful inside the specified ranges
and representative of practical applications.
2. Climate and chemical resistance
To be tested with connected harness connector.
2.1 Climate resistance
2.1.1 Passenger compartment
STANDARD SPECIFICATION FOR ELECTRONIC CONTROL UNITS
SK-E
(PCB + mechanical) Environmental requirements for automotive application
-car body installation-
From Our Reference Telephone Facsimile Schwieberdingen
K8/EKM5 Mnch (07 11) 8 11- 1323 (07 11) 8 11- 3803 20.5.1997
Y 280 P61 148 page 5 of 14
Robert Bosch GmbH reserves all rights even in the event of industrial poperty. We reserve all rights of disposal such as copying and passing on
to third parties.
W6 82 5.00
2.1.1.1 Humidity test
Standards: DIN-IEC 68-2-30 Db
Test severity: variant 2, +55C
Test duration: 9 cycles
Operation mode: intermittent supply
voltage,
1 hr. on / 1 hr. off
(standby mode)
2.1.1.2 Industrial climates
Standards: DIN 50 018 - KFW 0.2 S
Test duration: 2 cycles
Operation mode: passive
2.1.1.3 Salt mist test
Standards: DIN 50 021 - SS (5 % NaCl)
Test duration: 8 hrs
Operation mode: passive
2.1.2 Engine compartment
2.1.2.1 Humidity test
See item 2.1.1.1
2.1.2.2 Industrial climates
Standards: DIN 50 018 - KW 2.0 S
Test duration: 2 cycles
Operation mode: passive
2.1.2.3 Salt mist test
Standards: DIN 50 021 - SS (5 % NaCl)
Test duration: 144 hrs
Operation mode: passive
STANDARD SPECIFICATION FOR ELECTRONIC CONTROL UNITS
SK-E
(PCB + mechanical) Environmental requirements for automotive application
-car body installation-
From Our Reference Telephone Facsimile Schwieberdingen
K8/EKM5 Mnch (07 11) 8 11- 1323 (07 11) 8 11- 3803 20.5.1997
Y 280 P61 148 page 6 of 14
Robert Bosch GmbH reserves all rights even in the event of industrial poperty. We reserve all rights of disposal such as copying and passing on
to third parties.
W6 82 5.00
2.2 Chemicals resistance
2.2.1 Passenger compartment test not forseen
2.2.2 Engine compartment
2.2.2.1 Resistance to fuel
Description of test cycle:
Spraying with gasoline fuel, duration: 5 sec.
Storage at Tu = Rt, duration: 48 hrs
Test duration: 4 cycles
2.2.2.2 Resistance to diesel fuel
Description of test cycle:
Spraying with diesel fuel, duration: 5 sec.
Storage at Tu = 80C, duration: 24 hrs
Test duration: 4 cycles
2.2.2.3 Resistance to motor oil
Description of test cycle:
Spraying with motor oil (SAE 10 W40],duration:5 sec.
Storage at Tu = 80C, duration: 24 hrs
Test duration: 4 cycles
2.2.2.4 Resistance to decalcifying agents
Description of test cycle:
Storage at Tu = 80C, duration: 1 hr
Spraying with decalcifying agent
(Henkel P3), duration: 5 sec.
Test duration: 4 cycles
Subsequent water spray test (immediate) in
accordance with N42 AP 315: IP X4 K
STANDARD SPECIFICATION FOR ELECTRONIC CONTROL UNITS
SK-E
(PCB + mechanical) Environmental requirements for automotive application
-car body installation-
From Our Reference Telephone Facsimile Schwieberdingen
K8/EKM5 Mnch (07 11) 8 11- 1323 (07 11) 8 11- 3803 20.5.1997
Y 280 P61 148 page 7 of 14
Robert Bosch GmbH reserves all rights even in the event of industrial poperty. We reserve all rights of disposal such as copying and passing on
to third parties.
W6 82 5.00
3. Mechanical resistance
3.1 Broadband noise
Frequency range 10 ... 1000 Hz
Acceleration density spectrum: see page 12
Effective value of total acceleration: 33 m/s
Acceleration density at 10 Hz: 20 (m/s )2/Hz
30 Hz: 20 (m/s )2/Hz
200 Hz: 0.5 (m/s )2/Hz
1000 Hz: 0.1 (m/s )2/Hz
Test duration per main axis: 8 hrs
(new parts are to be
used for each
direction)
ambient temperature
(passive) -40/+85C,
1 cycle 8 hrs
Operation mode: active (0.5 hr after
end of test)
Test details: see page 12
Temperature-function test: see page 13
3.2 Shocks
Standards: DIN IEC 68-2-27
DIN 40 046 sh. 7
Shock acceleration: 400 m/s
Duration of nominal shock: 11 ms
Shock form: semisoidal
Number of shocks: 18 (3/direction)
3.3 Freefalls
Standards: DIN-IEC 68-2-32 Ed
RB Y 261 R20 004
Fall impact: concrete
Fall height: 1 m
Number of fall: 2 / ECU
Number of samples: 3
By the use of 3 samples, all 6 possible directions of load can be
tested.
(A) + (C), (B) + (C-), (A-) + (B-)
STANDARD SPECIFICATION FOR ELECTRONIC CONTROL UNITS
SK-E
(PCB + mechanical) Environmental requirements for automotive application
-car body installation-
From Our Reference Telephone Facsimile Schwieberdingen
K8/EKM5 Mnch (07 11) 8 11- 1323 (07 11) 8 11- 3803 20.5.1997
Y 280 P61 148 page 8 of 14
Robert Bosch GmbH reserves all rights even in the event of industrial poperty. We reserve all rights of disposal such as copying and passing on
to third parties.
W6 82 5.00
Evaluation criteria:
The test is considered passed when,
- the control unit shows definite signs of visible damage and the
unit would be designated as being defective
- there are no obvious defects visible to the control unit or its
components, and the functions are fully assured.
4. Type of protection
Test without attachment of dummy harness connector under
consideration of the permissible installation positions in
accordance with the offer drawing.
To be tested for new connection systems.
Standard: DIN 40 050 sh. 9 (May 93).
4.1 Passenger compartment
Ventilation via cable harness or
housing/lid opening without sealing elements.
Degree of protection: IP 50
(B-) (A-)
(C-)
A B
C
A B
C
STANDARD SPECIFICATION FOR ELECTRONIC CONTROL UNITS
SK-E
(PCB + mechanical) Environmental requirements for automotive application
-car body installation-
From Our Reference Telephone Facsimile Schwieberdingen
K8/EKM5 Mnch (07 11) 8 11- 1323 (07 11) 8 11- 3803 20.5.1997
Y 280 P61 148 page 9 of 14
Robert Bosch GmbH reserves all rights even in the event of industrial poperty. We reserve all rights of disposal such as copying and passing on
to third parties.
W6 82 5.00
4.1.1. Dust
Standards: DIN 40 046 sh. 48
RB N 42 AP 310
Test duration: 10 min.
Dust concentration 5 g +2g/m3
Ambient temperature: 25C
4.2 Engine compartment
Water spray (increased pressure)
Ventilation via pressure compensation element
Degree of protection: IP 54 K
Test using revolving pipe
Test duration: 10 min.
Mains pressure: 400 kPa
Water temperature: room temperature
5. Notes on connectors
The connections developed by RB are tested and approved by the
development departments responsible. In addition, evaluations of
the connection systems are conducted within the scope of equipment
and system testing.
For connectors from outside sources (connector is prescribed by the
customer --> no RB-connector), the approval testing must be
conducted by the supplier of the
connectors and documented within the scope of evidential testing
(Test Reports). In addition, these connectors are subjected to a
reduced evaluation (e.g. abrasion, contact, sealing....) within
the scope of equipment testing.
As a matter of principle, the connector must comply with the
control unit specification.
6. Standard inspection procedure
STANDARD SPECIFICATION FOR ELECTRONIC CONTROL UNITS
SK-E
(PCB + mechanical) Environmental requirements for automotive application
-car body installation-
From Our Reference Telephone Facsimile Schwieberdingen
K8/EKM5 Mnch (07 11) 8 11- 1323 (07 11) 8 11- 3803 20.5.1997
Y 280 P61 148 page 10 of 14
Robert Bosch GmbH reserves all rights even in the event of industrial poperty. We reserve all rights of disposal such as copying and passing on
to third parties.
W6 82 5.00
6.1 Engine compartment (sealed version)




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STANDARD SPECIFICATION FOR ELECTRONIC CONTROL UNITS
SK-E
(PCB + mechanical) Environmental requirements for automotive application
-car body installation-
From Our Reference Telephone Facsimile Schwieberdingen
K8/EKM5 Mnch (07 11) 8 11- 1323 (07 11) 8 11- 3803 20.5.1997
Y 280 P61 148 page 11 of 14
Robert Bosch GmbH reserves all rights even in the event of industrial poperty. We reserve all rights of disposal such as copying and passing on
to third parties.
W6 82 5.00
6.2 Passenger compartment (non-sealed version)




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STANDARD SPECIFICATION FOR ELECTRONIC CONTROL UNITS
SK-E
(PCB + mechanical) Environmental requirements for automotive application
-car body installation-
From Our Reference Telephone Facsimile Schwieberdingen
K8/EKM5 Mnch (07 11) 8 11- 1323 (07 11) 8 11- 3803 20.5.1997
Y 280 P61 148 page 12 of 14
Robert Bosch GmbH reserves all rights even in the event of industrial poperty. We reserve all rights of disposal such as copying and passing on
to third parties.
W6 82 5.00
Standard housing SK-E
Broadband noise test
1. Test conditions
2. Test duration: 8 hrs per compartment direction
(new parts to be used for each
direction)
3. Number of test samples: 6 (2 pieces per direction)
4. Environmental temperature
(passive): -40 / 85C (1 cycle: 8 hrs)
5. Operation mode: passive (during testing)
active (0.5 hr after end of test)
Environmental temperature
soak time at
T = 85C: 1.5 hrs
soak time at
T = -40C: 0.5 hrs
electrical operation after end of test:
top of vibration table opened
ECU with vibrational load,
ECU cools down to room temperature:
Tu = RT + 65C
6. Test frequency 10 ... 1000 Hz
0,01
0,1
1
10
100
1 10 100 1000
Frequency in Hz
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85C
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-40C
0C
0h 4,5h 8h Zeit
STANDARD SPECIFICATION FOR ELECTRONIC CONTROL UNITS
SK-E
(PCB + mechanical) Environmental requirements for automotive application
-car body installation-
From Our Reference Telephone Facsimile Schwieberdingen
K8/EKM5 Mnch (07 11) 8 11- 1323 (07 11) 8 11- 3803 20.5.1997
Y 280 P61 148 page 13 of 14
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to third parties.
W6 82 5.00
ECU testing
Temperature-function test
Objective:
to detect possible errors within a "temperature window"
Note:
Warming of component during t1 to be kept as low as possible
STANDARD SPECIFICATION FOR ELECTRONIC CONTROL UNITS
SK-E
(PCB + mechanical) Environmental requirements for automotive application
-car body installation-
From Our Reference Telephone Facsimile Schwieberdingen
K8/EKM5 Mnch (07 11) 8 11- 1323 (07 11) 8 11- 3803 20.5.1997
Y 280 P61 148 page 14 of 14
Robert Bosch GmbH reserves all rights even in the event of industrial poperty. We reserve all rights of disposal such as copying and passing on
to third parties.
W6 82 5.00
20
0
-40
-20
40
60
80
Soak time
Soak time
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Off
On
Number of temperature cycles
500
1 Test cycle
t > 30 min.
(at Ti=+85C)
t > 30 min.
(at Ti=-40C)
t=2...4h (depending on ECU type)
temperature gradient : 3,5 - 5 K/min