ISO 19453-4:2018

INTERNATIONAL ISO
STANDARD 19453-4
First edition
2018-03
Road vehicles — Environmental
conditions and testing for electrical
and electronic equipment for
drive system of electric propulsion
vehicles —
Part 4:
Climatic loads
Véhicules routiers — Spécifications d'environnement et essais
de l'équipement électrique et électronique pour les véhicules à
propulsion électrique —
Partie 4: Contraintes climatiques
Reference number
©
ISO 2018
© ISO 2018
All rights reserved. Unless otherwise specified, or required in the context of its implementation, no part of this publication may
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Published in Switzerland
ii © ISO 2018 – All rights reserved

Contents Page
Foreword .v
1 Scope . 1
2 Normative references . 1
3 Terms and definitions . 2
4 Operating temperature ranges . 2
5 Tests and requirements . 4
5.1 Tests at constant temperature . 4
5.1.1 Low-temperature tests . 4
5.1.2 High-temperature tests . 4
5.2 Temperature cycling tests . 5
5.2.1 Temperature cycle with specified change rate . 5
5.2.2 Rapid change of temperature with specified transition duration . 8
5.3 Cold water shock tests . 8
5.3.1 Purpose . 8
5.3.2 Splash water test . 8
5.3.3 Submersion test .11
5.4 Salt spray tests.11
5.4.1 Corrosion test .11
5.4.2 Leakage and function test .12
5.4.3 Salt spray combined cycle test .13
5.5 Humid heat, cyclic test — Dewing test .17
5.5.1 Purpose .17
5.5.2 Test method .17
5.5.3 Requirements .19
5.6 Damp heat, steady state test.19
5.6.1 Purpose .19
5.6.2 Test method .19
5.6.3 Requirements .19
5.7 Condensation test .19
5.7.1 Purpose .19
5.7.2 Test method .19
5.7.3 Requirement .22
5.8 Corrosion test with flow of mixed gas .23
5.8.1 Purpose .23
5.8.2 Test method .23
5.8.3 Requirement .23
5.9 Solar radiation test .23
5.10 Dust test .23
5.10.1 Purpose .23
5.10.2 Test method .23
5.10.3 Requirement .24
5.11 Atmospheric pressure test .24
5.11.1 Purpose .24
5.11.2 Test method .24
5.11.3 Requirements .25
6 Code for climatic loads .26
7 Protection against dust and water .26
8 Documentation .26
Annex A (informative) Usual tests and requirements for equipment depending on the
mounting location .27
Annex B (informative) Background information to determine the number of cycles of the
salt spray combined test .29
Annex C (informative) Insulation tests .33
Annex D (informative) The necessity of testing atmospheric pressure .36
Bibliography .40
iv © ISO 2018 – All rights reserved

Foreword
ISO (the International Organization for Standardization) is a worldwide federation of national standards
bodies (ISO member bodies). The work of preparing International Standards is normally carried out
through ISO technical committees. Each member body interested in a subject for which a technical
committee has been established has the right to be represented on that committee. International
organizations, governmental and non-governmental, in liaison with ISO, also take part in the work.
ISO collaborates closely with the International Electrotechnical Commission (IEC) on all matters of
electrotechnical standardization.
The procedures used to develop this document and those intended for its further maintenance are
described in the ISO/IEC Directives, Part 1. In particular the different approval criteria needed for the
different types of ISO documents should be noted. This document was drafted in accordance with the
editorial rules of the ISO/IEC Directives, Part 2 (see www .iso .org/ directives).
Attention is drawn to the possibility that some of the elements of this document may be the subject of
patent rights. ISO shall not be held responsible for identifying any or all such patent rights. Details of
any patent rights identified during the development of the document will be in the Introduction and/or
on the ISO list of patent declarations received (see www .iso .org/ patents).
Any trade name used in this document is information given for the convenience of users and does not
constitute an endorsement.
For an explanation on the voluntary nature of standards, the meaning of ISO specific terms and
expressions related to conformity assessment, as well as information about ISO's adherence to the
World Trade Organization (WTO) principles in the Technical Barriers to Trade (TBT) see the following
URL: www .iso .org/ iso/ foreword .html
This document was prepared by Technical Committee ISO/TC 22, Road vehicles, Subcommittee SC 32,
Electrical and electronic components and general system aspects.
A list of all parts in the ISO 19453 series can be found on the ISO website.
INTERNATIONAL STANDARD ISO 19453-4:2018(E)
Road vehicles — Environmental conditions and testing for
electrical and electronic equipment for drive system of
electric propulsion vehicles —
Part 4:
Climatic loads
1 Scope
This document specifies requirements for the electric propulsion systems and components with
maximum working voltages according to voltage class B. It does not apply to high voltage battery packs
(e.g. for traction) and systems and components inside. It describes the potential environmental stresses
and specifies tests and requirements recommended for different stress levels on/in the vehicle.
This document describes climatic loads.
2 Normative references
The following documents are referred to in the text in such a way that some or all of their content
constitutes requirements of this document. For dated references, only the edition cited applies. For
undated references, the latest edition of the referenced document (including any amendments) applies.
ISO 16750-1, Road vehicles — Environmental conditions and testing for electrical and electronic
equipment — Part 1: General
ISO 19453-1, Road vehicles — Environmental conditions and testing for electrical and electronic equipment
for drive system of electric propulsion vehicles — Part 1: General
ISO 20653, Road vehicles — Degrees of protection (IP code) — Protection of electrical equipment against
foreign objects, water and access
IEC 60068-1:2013, Environmental testing — Part 1: General and guidance
IEC 60068-2-1, Environmental testing — Part 2-1: Tests — Test A: Cold
IEC 60068-2-2, Environmental testing — Part 2-2: Tests — Test B: Dry heat
IEC 60068-2-11, Basic environmental testing procedures — Part 2-11: Tests — Test Ka: Salt mist
IEC 60068-2-14, Environmental testing — Part 2-14: Tests — Test N: Change of temperature
IEC 60068-2-30, Environmental testing — Part 2-30: Tests — Test Db: Damp heat, cyclic (12 h + 12 h cycle)
IEC 60068-2-52:2017, Environmental testing — Part 2-52: Tests — Test Kb: Salt mist, cyclic (sodium
chloride solution)
IEC 60068-2-60, Environmental testing — Part 2-60: Tests — Test Ke: Flowing mixed gas corrosion test
IEC 60068-2-78, Environmental testing — Part 2-78: Tests — Test Cab: Damp heat, steady state
IEC 60664-1:2007, Insulation coordination for equipment within low-voltage systems — Part 1: Principles,
requirements and tests
3 Terms and definitions
For the purposes of this document, the terms and definitions given in ISO 16750-1 and ISO 19453-1 apply.
ISO and IEC maintain terminological databases for use in standardization at the following addresses:
— IEC Electropedia: available at http:// www .electropedia .org/
— ISO Online browsing platform: available at https:// www .iso .org/ obp
4 Operating temperature ranges
Choose the applicable temperature range from Table 1 to be presented in the specifications of the
device under test (DUT).
In the case of hot soak, choose from Table 2 the relative temperature increase ΔT and add it to the
HS
maximum temperature T to have the absolute hot soak temperature (T ).
max maxHS
TT+=Δ T
maxHSmaxHS
For further details, refer to 5.2.1.
The paint repair temperature (T ) can be set to a higher value than the operating temperature.
maxPR
Specify this temperature in the specifications of the DUT.
2 © ISO 2018 – All rights reserved

Table 1 — Operating temperature ranges
Minimum operating temperature Maximum operating temperature
Code
T T
min max
°C °C
A −20 65
B −30 65
C 65
D 70
E 75
F 80
G 85
H 90
I 95
J 100
K 105
L 110
M 115
−40
N 120
O 125
P 130
Q 140
R 150
S 155
T 160
U 165
V 170
W 175
X 180
Z As agreed
Table 2 — Relative temperature increase in hot soak
ΔT
HS
Code
K
a 15
b 30
c 50
z As agreed
NOTE The code letter is defined as a combination of Tables 1 and 2, e.g. Hb (T = 90 °C and ΔT = 30 K).
max HS
5 Tests and requirements
5.1 Tests at constant temperature
5.1.1 Low-temperature tests
5.1.1.1 Storage test
5.1.1.1.1 Purpose
This test simulates the exposure of the DUT to low temperatures without electrical operation, e.g.
during shipment of the system/component. Failure mode is a malfunction due to insufficient frost
resistance, e.g. the freezing of a coolant.
5.1.1.1.2 Test method
Perform the test in accordance with IEC 60068-2-1 at a temperature of −40 °C for a duration of 24 h
unless otherwise indicated in the DUT specification. The operating mode of the DUT is 1.1, as defined in
ISO 19453-1.
5.1.1.1.3 Requirement
The functional status shall be class C as defined in ISO 19453-1.
5.1.1.2 Operation test
5.1.1.2.1 Purpose
The purpose of the test is to make sure that the device under test maintains the function even after
storage at low temperature.
5.1.1.2.2 Test method
Perform the test in accordance with IEC 60068-2-1 at a temperature of T for a duration of 24 h. The
min
operating mode is 3.2 and/or 4.2 as defined in ISO 19453-1.
5.1.1.2.3 Requirement
The functional status shall be class A as defined in ISO 19453-1.
5.1.2 High-temperature tests
5.1.2.1 Storage test
5.1.2.1.1 Purpose
This test simulates the exposure of the DUT to high temperatures without electrical operation, e.g.
during the shipment of the system/component. The failure mode is insufficient heat resistance, e.g.
warping of plastic housings.
5.1.2.1.2 Test method
Perform the test in accordance with IEC 60068-2-2 at a temperature of 85 °C for a duration of 48 h unless
otherwise indicated in the DUT specification. The operating mode is 1.1 as defined in ISO 19453-1.
4 © ISO 2018 – All rights reserved

5.1.2.1.3 Requirement
The functional status shall be class C as defined in ISO 19453-1.
5.1.2.2 Operation test
5.1.2.2.1 Purpose
This test simulates the exposure of the DUT to high temperatures with electrical operation, e.g. the
use of the system/component at a very high ambient temperature. The failure mode is an electrical
malfunction caused by high temperature, e.g. thermal degradation of components.
5.1.2.2.2 Test method
Perform the test in accordance with IEC 60068-2-2 at a temperature of T for a duration of 96 h. Use
max
operating mode 3.2 and/or 4.2 as defined in ISO 19453-1.
5.1.2.2.3 Requirement
The functional status shall be class A as defined in ISO 19453-1.
5.2 Temperature cycling tests
5.2.1 Temperature cycle with specified change rate
5.2.1.1 Purpose
This test simulates varying temperatures with electrical operation of the DUT, e.g. during the use of
the system/component at changing ambient temperature. If a system/component is exposed to hot-
soak temperatures (e.g. engine-mounted systems/components), an additional short temperature
peak is added during the high temperature stage of the profile to ensure proper function during short
temperature peaks. The electrical operation is switched off during stages of decreasing temperature to
avoid electrical heat dissipation of the system/component which would inhibit reaching T inside the
min
system/component. The failure mode is an electrical malfunction during temperature change.
NOTE This test is not intended to be a life test.
5.2.1.2 Test method
Perform the temperature cycling in accordance with IEC 60068-2-14.
Operate the DUT electrically (functional test) after the whole device has reached T for the shortest
min
possible duration to check the correct functioning of the device. In addition, an operation check should
be done at stable high temperature (see Figure 1). Use operating mode 3.2 and/or 4.2 as defined in
ISO 19453-1 for the stages with electrical operation.
The changes in temperature shall correspond to the specifications given in Table 3. For tests including
hot-soak temperature (T ), see Table 4 and Figure 2. The supplier and the customer shall agree on
maxHS
a complete profile of temperature cycle.
A long period of electrical operation is started at room temperature (RT) as defined in ISO 19453-1 in
order to allow possible condensation of humidity on the DUT. A permanent operation starting at T
min
would prevent this due to the electrical power dissipation.
Additional drying of the test chamber air is not permitted.
Perform 30 test cycles as specified.
Key
T temperature, in °C
t time, in min
t , t , t , t , t , t time parameter as defined in Table 3
1 2 3 4 5 6
a
Operating mode 3.2 and/or 4.2 as defined in ISO 19453-1.
b
Operating mode 2.1 as defined in ISO 19453-1.
c
One cycle.
Figure 1 — Temperature cycles with specified change rate
Table 3 — Temperature and time duration for temperature cycling (see Figure 1)
Duration Temperature
Parameter
min °C
t As agreed From RT to T
1 min
t > 30 Stabilized time at T
2 min
t As agreed From T to RT
3 min
t As agreed From RT to T
4 max
t > 30 Stabilized time at T
5 max
t As agreed From T to RT
6 max
6 © ISO 2018 – All rights reserved

Key
T temperature, in °C
t time, in min
t , t , t , t , t , t , t , t , t , t time parameter as defined in Table 4
1 2 3 4 5 6 7 8 9 10
a
Operating mode 3.2 and/or 4.2 as defined in ISO 19453-1.
b
Operating mode 2.1 as defined in ISO 19453-1.
c
One cycle.
Figure 2 — Example of a temperature cycle with hot-soak stage
Table 4 — Temperature and time duration for temperature cycling with hot-soak stage (see
Figure 2)
Duration Temperature
Parameter
min °C
t As agreed From RT to T
1 min
t >30 Stabilized time at T
2 min
t As agreed From T to RT
3 min
t As agreed From RT to T
4 max
t >30 Stabilized time at T
5 max
t As agreed From T to T
6 max maxHS
t > 30 Stabilized time at T
7 maxHS
t As agreed From T to T
8 maxHS max
t > 30 Stabilized time at T
9 max
t As agreed From T to RT
10 max
Instead of operating mode 3.2 and/or 4.2 in Figures 1 and 2, operating mode 2.1 may be used if agreed
between the customer and the supplier.
5.2.1.3 Requirement
The functional status shall be class A as defined in ISO 19453-1.
5.2.2 Rapid change of temperature with specified transition duration
5.2.2.1 Purpose
This is an accelerated test which simulates a very high number of slow temperature cycles in the vehicle.
The acceleration is possible due to a much higher temperature change rate and a bigger temperature
change in one cycle in comparison with real vehicle stress. The failure modes are a cracking of materials
or seal failures caused by ageing and different temperature expansion coefficients. Because this test
creates mechanical defects (cracks), electrical operation is not required during the test.
5.2.2.2 Test method
Perform the temperature cycling in accordance with IEC 60068-2-14.
Raise the temperature from T to T within 30 s or less. Keep the DUT at T or T for a given
min max min max
soak time after thermal stability is obtained. The soak time can be agreed between the customer and
the supplier, or the exposure time can be chosen among the values 20 min, 40 min, 60 min or 90 min,
depending on the size and other properties of the DUT. Use operating mode 1.2 as defined in ISO 19453-1.
See Table 9 for the number of cycles.
Upon agreement, this test may be performed during the development of a DUT with opened housing or
without housing.
5.2.2.3 Requirement
The functional status shall be class C as defined in ISO 19453-1.
5.3 Cold water shock tests
5.3.1 Purpose
This test simulates a thermal shock induced by cold water and applies to products in the splash areas of
the vehicle. The purpose of the test is to simulate ice water splashing over a hot system/component. This
happens when driving on wet roads in winter. The failure modes are a mechanical cracking of materials
or seal failures caused by different temperature expansion coefficients. An additional failure mode not
addressed in 5.2.2.1 is a loss of tightness and the intrusion of water into the system/component.
There are two possible methods to perform this test (see 5.3.2 and 5.3.3).
NOTE This is not a corrosion test.
5.3.2 Splash water test
5.3.2.1 Test method
Heat the DUT in a hot air oven at T for the specified holding time, t . Then splash the DUT with cold
max h
water for 3 s.
If the DUT is splashed in the vehicle from only one direction, splash it from this direction only while it
is in an as-installed position. If the equipment is splashed from various directions in the vehicle, then
these directions shall be taken into account. In this case, use a new DUT for each splash direction. The
width of the splash directed at the DUT shall always be greater than the width of the DUT. If DUTs of
considerable size are splashed and prove too big for one jet, arrange several jets in a row to produce a
line of splash impact on the DUTs, see Figures 3 to 5.
8 © ISO 2018 – All rights reserved

Test parameters include:
— Number of cycles: 100.
— Holding time, t , at T : 1 h or until DUT temperature stabilization is reached.
h max
— Transition duration: < 20 s (for manual transition of DUT between temperature storage and
splashing).
— Test fluid: de-ionized water.
— Water temperature: 0 °C to +4 °C.
— Water flow: between 3 l and 4 l per 3 s (splash duration).
— Distance between jet and DUT surface: (325 ± 25) mm (water shall be applied over the complete
width of the DUT).
— Operating mode: see Figure 4.
— Orientation of the DUT: as in the vehicle.
NOTE Substances such as colours or salt can be added to the water in order to improve detectability.
Figure 3 — Jet
Key
t time, in min t holding time, in min
h
a d
Operating mode 3.2 and/or 4.2 as defined in Splash off.
ISO 19453-1.
b e
Operating mode 1.2 as defined in ISO 19453-1. One cycle.
c
Splash on.
Figure 4 — Test cycle for splash water test
Key
1 DUT 4 splash water
2 slot jet 5 splash
3 pump
Figure 5 — Test set-up for splash water test
5.3.2.2 Requirement
The functional status shall be class A during the operating mode 3.2 and/or 4.2 as defined in ISO 19453-1.
10 © ISO 2018 – All rights reserved

5.3.3 Submersion test
5.3.3.1 Test method
Connect the DUT to the test equipment. Operate the DUT in a hot air oven at T for the specified
max
holding time, t . With the device still operating, submerge it for 5 min in an ice water tank, in a depth
h
equal to or greater than 10 mm (see Figure 6).
Test parameters include:
— Number of cycles: 10.
— Holding time t at T : 1 h or until DUT temperature stabilization is reached.
h max
— Transition duration: < 20 s.
— Test fluid: de-ionized water.
— Water temperature: 0 °C to +4 °C.
— Immersion time: 5 min.
— Operating mode: 3.2 and/or 4.2 as defined in ISO 19453-1.
— Orientation of the DUT: as in the vehicle.
NOTE Substances such as colours or salt can be added to the water in order to improve detectability.
Figure 6 — DUT in a cold water tank
5.3.3.2 Requirement
The functional status shall be class A, as defined in ISO 19453-1.
5.4 Salt spray tests
5.4.1 Corrosion test
5.4.1.1 Purpose
This test checks the resistance of materials and surface coatings of a system/component to de-icing
agents. This test generates corrosion similar to reality. The failure mode is corrosion.
Visual examination as detailed below shall allow identification, appearance, workmanship and finish of
the item to be checked against the relevant specification.
5.4.1.2 Test method
Perform the test in accordance with IEC 60068-2-52. Select a severity from Table 9. See also Annex A.
Use operating mode 1.2, as defined in ISO 19453-1.
Carry out a visual examination with the naked eye, normal strength of vision and normal colour
perception, at the most favourable distance and with suitable illumination.
5.4.1.3 Requirements
There shall be no changes that could impair normal performance, e.g. sealing function, marking and
labelling shall remain visible.
The minimum functional status shall be class C, as defined in ISO 19453-1.
5.4.2 Leakage and function test
5.4.2.1 Purpose
This test checks the resistance of a system/component to salt mist and salt water on winter streets. The
failure mode is an electrical malfunction due to leakage currents caused by the ingress of salt water.
5.4.2.2 Test method
Perform the test cycle shown in Figure 7, in accordance with IEC 60068-2-11. The duration of one cycle is
24 h. Spray the DUT for 8 h, then stop spraying for a rest period of 16 h. Operate the DUT with operating
mode 3.2 and/or 4.2 as defined in ISO 19453-1 between the fourth and fifth hours of each cycle.
Test duration: 6 cycles correspond to 6 days as a minimum.
Key
t time, in h
a
Operating mode 3.2 and/or 4.2 as defined in ISO 19453-1.
b
Operating mode 1.2 as defined in ISO 19453-1.
c
Salt spray on.
d
Salt spray off.
e
One cycle.
Figure 7 — Test cycle for salt spray test
12 © ISO 2018 – All rights reserved

5.4.2.3 Requirements
The intrusion of salt water into the housing is not permitted.
Functional status class A is required in stages with electrical operating mode 3.2 and/or 4.2 as defined
in ISO 19453-1.
5.4.3 Salt spray combined cycle test
5.4.3.1 Purpose
This test is an accelerated corrosion test based on the tests defined in 5.4.1 and 5.4.2. This test may be
used to substitute other salt spray tests (5.4.1 and 5.4.2).
This test checks the resistance of materials and surface coatings of a system/component to salt mist
and salt water on streets in winter. This test generates corrosion similar to reality. The failure mode is
corrosion.
5.4.3.2 Test method
5.4.3.2.1 Salt solution
The salt solution shall be in accordance with IEC 60068-2-52:2017, Clause 6.
5.4.3.2.2 Number of cycles
Select a number of cycles from Table 5 and Table 6. The number of cycles depends on the severity and
the kind of materials. Background information to determine the number of cycles of the salt spray
combined test to be carried out is given in Annex B.
Table 5 — Number of cycles for the corrosion test
Number of cycles
Severity
Steel Aluminium
1 3 8
2 9 23
3 12 30
4 24 60
Table 6 — Number of cycles for the leakage and function test
Number of cycles
Severity
Steel Aluminium
1 1 1
2 2 3
3 3 4
4 5 8
Figure 8 — Severity considered in vehicle corrosion evaluation
5.4.3.2.3 Initial measurement
The DUT shall be visually inspected and, if necessary, electrically and mechanically checked as required
by the relevant specification.
5.4.3.2.4 Pre-conditioning
The relevant specification shall prescribe the cleaning procedure to be applied immediately before the
test; it shall also state whether temporary protective coating shall be removed.
The cleaning method before the test usually has an impact on the effect of the salt mist on th
...