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Group standard
VW 80000
Issue 2021-01
Class. No.: 8MA00
Descriptors: PCBA, electric application, electronic application, test condition, unit
Electrical and Electronic Units in Motor Vehicles up to 3,5 t
General Requirements, T
est Conditions, and Tests
Previous issues
VW 80101: 1987-06, 1988-08, 1992-01, 1993-04, 1994-05, 1995-06, 1998-01, 1999-06, 2000-09,
2001-04, 2003-05, 2004-07, 2005-06, 2006-10, 2009-03; VW 80000: 2009-10, 2013-06, 2017-10,
2020-12
Changes
The following changes have been made to VW 80000: 2020-12:
a) This new version has been editorially revised exclusively:
b) Section 4.11.9: "the maximum ambient temperature range T
max
" has been changed to "the
maximum ambient temperature T
max
";
c) Section 5.2: "K-19 Climate components with watertight housing" has been changed to "K-19
Climate test for components with watertight housings";
d) Section 5.4.11.2: "and their combinations" has been changed to "and status combinations";
e) Section 5.6.19.2: "K-15b" deleted.
Always use the latest version of this standard.
This electronically generated standard is authentic and valid without signature. A comma is used as the decimal sign.
The English translation is believed to be accurate. In case of discrepancies, the German version controls.
Page 1 of 179
All rights reserved. No part of this document may be provided to third parties or reproduced without the prior consent
of one of the Volkswagen Group’s Standards departments. | internal
© Volkswagen Aktiengesellschaft
VWNORM-2019-10
Page 2
VW 80000: 2021-01
Contents
Page
Scope ......................................................................................................................... 6
Definitions .................................................................................................................. 7
Abbreviations ........................................................................................................... 10
General requirements .............................................................................................. 11
Requirements for test laboratories ........................................................................... 11
Test procedure ......................................................................................................... 11
Voltages and currents .............................................................................................. 11
Test voltages ............................................................................................................ 12
Sampling rates and measured value resolutions ..................................................... 12
Reaching a constant temperature throughout .......................................................... 12
DUTs connected to a coolant circuit ......................................................................... 13
Functional states ...................................................................................................... 13
General .................................................................................................................... 13
Functional state A .................................................................................................... 13
Functional state B .................................................................................................... 13
Functional state C .................................................................................................... 13
Functional state D1 .................................................................................................. 13
Functional state D2 .................................................................................................. 14
Functional state E .................................................................................................... 14
Function classes and operating voltage ranges ....................................................... 15
Operating situations ................................................................................................. 16
Operating modes ...................................................................................................... 16
General .................................................................................................................... 16
Operating modes for validation ................................................................................ 16
Operating modes for real operating loads ................................................................ 17
Operating modes for low operating loads - min index .............................................. 17
Operating modes for high operating loads - max index ........................................... 17
Overview of operating modes .................................................................................. 17
Application of the operating modes .......................................................................... 18
Service life requirements .......................................................................................... 19
Temperature load spectra ........................................................................................ 19
Key parameters and key functions ........................................................................... 20
Interface description ................................................................................................. 21
Parameter tests ........................................................................................................ 21
P-01 Parameter test (function check) ....................................................................... 21
P-02 Parameter test (small) ..................................................................................... 22
P-03 Parameter test (large) ...................................................................................... 22
P-04 Physical analysis ............................................................................................. 23
Continuous parameter monitoring with drift analysis ............................................... 23
Standard tolerances ................................................................................................. 24
Standard values ....................................................................................................... 24
Requirements and tests ........................................................................................... 25
Test selection table for electrical tests ...................................................................... 25
Test selection table for environmental tests ............................................................. 26
Test sequence plan .................................................................................................. 29
Electrical requirements and tests ............................................................................. 29
General .................................................................................................................... 29
Test sequence for electrical tests ............................................................................. 29
E-01 Long-term overvoltage ..................................................................................... 31
E-02 Transient overvoltage ...................................................................................... 32
1
2
3
4
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.8.1
4.8.2
4.8.3
4.8.4
4.8.5
4.8.6
4.8.7
4.9
4.10
4.11
4.11.1
4.11.2
4.11.3
4.11.4
4.11.5
4.11.6
4.11.7
4.11.8
4.11.9
4.12
4.13
4.14
4.14.1
4.14.2
4.14.3
4.14.4
4.15
4.16
4.17
5
5.1
5.2
5.3
5.4
5.4.1
5.4.2
5.4.3
5.4.4
Page 3
VW 80000: 2021-01
E-03 Transient undervoltage .................................................................................... 34
E-04 Jump start ........................................................................................................ 36
E-05 Load dump ....................................................................................................... 38
E-06 Ripple voltage .................................................................................................. 39
E-07 Slow decrease and increase of the supply voltage ......................................... 41
E-08 Slow decrease, quick increase of the supply voltage ...................................... 42
E-09 Reset behavior ................................................................................................ 43
E-10 Brief interruptions ............................................................................................ 45
E-11 Start pulses ...................................................................................................... 47
E-12 Voltage curve with vehicle electrical system control ........................................ 50
E-13 Pin interruption ................................................................................................ 52
E-14 Connector interruption ..................................................................................... 54
E-15 Reverse polarity ............................................................................................... 55
E-16 Ground potential difference ............................................................................. 58
E-17 Short circuit in signal cable and load circuits ................................................... 59
E-18 Insulation resistance ........................................................................................ 61
E-19 Quiescent current ............................................................................................ 62
E-20 Dielectric strength ............................................................................................ 64
E-21 Backfeeds ........................................................................................................ 65
E-22 Overcurrents .................................................................................................... 67
E-23 Equalizing currents of multiple supply voltages ............................................... 68
E-24 ON/OFF durability testing ................................................................................ 69
Mechanical requirements and tests ......................................................................... 71
M-01 Free fall ........................................................................................................... 71
M-02 Stone impact test ............................................................................................ 72
M-03 Dust test .......................................................................................................... 73
M-04 Vibration test ................................................................................................... 75
M-05 Mechanical shock ........................................................................................... 85
M-06 Mechanical shock durability testing ................................................................ 86
M-07 Coolant circuit pressure pulsation test ............................................................ 87
M-08 Protection against foreign bodies - IP0x to IP4x, A, B, C, D ........................... 89
M-09 Leak test ......................................................................................................... 90
Climatic requirements and tests ............................................................................... 92
K-01 High-/low-temperature aging ........................................................................... 92
K-02 Incremental temperature test ........................................................................... 93
K-03 Low-temperature operation ............................................................................. 94
K-04 Repainting temperature ................................................................................... 95
K-05 Thermal shock (component) ............................................................................ 96
K-06 Salt spray test with operation, exterior ............................................................ 97
K-07 Salt spray test with operation, interior ............................................................. 99
K-08 Damp heat, cyclic .......................................................................................... 101
K-09 Damp heat, cyclic (with frost) ........................................................................ 102
K-10 Water protection – IPX0 to IPX6K ................................................................. 103
K-11 High-pressure/steam-jet cleaning .................................................................. 104
K-12 Thermal shock with splash water .................................................................. 105
K-13 Thermal shock – immersion .......................................................................... 108
K-14 Damp heat, constant ..................................................................................... 109
K-15 Condensation test with PCBAs ...................................................................... 112
K-16 Thermal shock (without housing) ................................................................... 117
K-17 Solar radiation ............................................................................................... 118
K-18 Harmful gas test ............................................................................................ 119
K-19 Climate test for components with watertight housings .................................. 120
5.4.5
5.4.6
5.4.7
5.4.8
5.4.9
5.4.10
5.4.11
5.4.12
5.4.13
5.4.14
5.4.15
5.4.16
5.4.17
5.4.18
5.4.19
5.4.20
5.4.21
5.4.22
5.4.23
5.4.24
5.4.25
5.4.26
5.5
5.5.1
5.5.2
5.5.3
5.5.4
5.5.5
5.5.6
5.5.7
5.5.8
5.5.9
5.6
5.6.1
5.6.2
5.6.3
5.6.4
5.6.5
5.6.6
5.6.7
5.6.8
5.6.9
5.6.10
5.6.11
5.6.12
5.6.13
5.6.14
5.6.15
5.6.16
5.6.17
5.6.18
5.6.19
Page 4
VW 80000: 2021-01
Chemical requirements and tests ........................................................................... 122
C-01 Chemical tests ............................................................................................... 122
Service life tests ..................................................................................................... 123
L-01 Service life test – Mechanical/hydraulic durability testing .............................. 123
L-02 Service life test - high-temperature durability testing ..................................... 125
L-03 Service life test – Temperature cycle durability testing .................................. 128
Applicable documents ............................................................................................ 132
Test sequence ........................................................................................................ 134
Test sequence plan ................................................................................................ 134
Test group I - electrical tests .................................................................................. 135
Test group II - tests ................................................................................................. 136
Test group III - environmental tests ........................................................................ 137
Test group IV - service life tests ............................................................................. 138
Test group V - tests ................................................................................................ 139
Typical temperature load spectra for various installation areas ............................. 140
Overview of installation areas ................................................................................ 140
Temperature load spectrum 1 ................................................................................ 140
Temperature load spectrum 2 ................................................................................ 141
Temperature load spectrum 3 ................................................................................ 141
Temperature load spectrum 4 ................................................................................ 141
Calculation for the "Mechanical/hydraulic durability testing" service test
procedure ............................................................................................................... 142
Calculation ............................................................................................................. 142
Example calculation ............................................................................................... 144
Calculation models for the "High-temperature durability testing" service life test .. 148
Adaptation of the test temperatures to reduce the test duration ............................ 148
Arrhenius model ..................................................................................................... 149
Example of Arrhenius model: ................................................................................. 151
Arrhenius model to be used for components with reduced performance at high
temperatures .......................................................................................................... 152
Example Arrhenius model to be used for components with reduced
performance at high temperatures ......................................................................... 153
Arrhenius model to be used for components on coolant circuits ............................ 155
General .................................................................................................................. 155
Case A: t
test,ambient
< t
test,CC
........................................................................................ 155
Case B: t
test,ambient
> t
test,CC
........................................................................................ 158
Example Arrhenius model to be used for components on coolant circuits ............. 162
Temperature load spectrum ................................................................................... 162
Test duration ........................................................................................................... 162
Test temperature (coolant) ..................................................................................... 162
Iterative calculations for test temperatures for ambient temperature tests ............ 163
Calculation models for the "Temperature cycle durability testing" service life test . 165
Adaptation of the test temperatures to reduce the test cycles ............................... 165
Coffin-Manson model ............................................................................................. 166
Example ................................................................................................................. 167
Coffin-Manson model to be used for components on coolant circuits .................... 169
General .................................................................................................................. 169
Test A: N
test,ambient
> N
test,CC
....................................................................................... 169
Case B: N
test,ambient
< N
test,CC
..................................................................................... 170
Number of test cycles for ambient temperature: .................................................... 170
Example Coffin-Manson model to be used for components on coolant circuits ..... 172
General .................................................................................................................. 172
5.7
5.7.1
5.8
5.8.1
5.8.2
5.8.3
6
Appendix A
A.1
A.2
A.3
A.4
A.5
A.6
Appendix B
B.1
B.2
B.3
B.4
B.5
Appendix C
C.1
C.2
Appendix D
D.1
D.2
D.3
D.4
D.5
D.6
D.6.1
D.6.2
D.6.3
D.7
D.7.1
D.7.2
D.7.3
D.7.4
Appendix E
E.1
E.2
E.3
E.4
E.4.1
E.4.2
E.4.3
E.4.4
E.5
E.5.1
Page 5
VW 80000: 2021-01
Number of test cycles for ambient temperature and coolant temperature ............. 172
Adapting the number of test cycles for the coolant temperature ............................ 172
Calculation models for the test Damp heat, constant - severity 2 .......................... 174
Lawson model ........................................................................................................ 174
Example ................................................................................................................. 176
Condensation test, programming the chamber, and diagrams .............................. 177
E.5.2
E.5.3
Appendix F
F.1
F.2
Appendix G
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