LV 124 laboratory tests - An overview of the testing of electrical and electronic car components (12V)
Overview
The LV 124 test standard defines in detail the requirements, the test conditions and the tests to be carried out on electrical and electronic components for passenger cars (up to 3.5 tons) with an on-board power supply of 12V. It is a technical test standard that is primarily used in the German automotive industry. The standard was developed jointly by several German car manufacturers, including Audi, BMW, Daimler, Porsche and Volkswagen, and published by the VDA. Most OEMs (“Original Equipment Manufacturers”) have derived their own version of the standard for internal use and for their suppliers, e.g. Volkswagen as “VW 80000”, BMW as “BMW GS 95024-2-1" and "BMW GS 95024-3-1” and Mercedes as “Mercedes-Benz MBN LV 124” test standard.
Scope
The standard defines electrical, mechanical, chemical and climatic tests of parts and components such as sensors, control units and cabling systems. The standard also includes service life tests.
LV 124 is intended to ensure that all components used can withstand the real conditions in vehicles. For example, severe temperature fluctuations, vibrations or exposure to moisture or electrical interference are tested. It is important to emphasize that the LV 124 test standard only refers to cars with on-board power supply voltages of 12V. Cars with a 48V vehicle electrical system voltage are tested in accordance with test standard LV148.
Which components are to be tested according to the LV 124 standard? Here is a list of some of the components to be tested in this way:
Control Units (ECUs, Electronic Control Units):
- Engine control units
- Transmission control units
- Airbag control units
- ABS/ESP control units
- Control units for infotainment systems
Sensors:
- Temperature sensors
- Pressure sensors
- Speed sensors
- Distance and radar sensors
- Speed sensors
Actuators:
- Electric servomotors (for power windows, seat adjustment, etc.)
- Valves (e.g. for fuel or exhaust gas control)
- Electromagnetic relays
Displays und Control elements:
- LCD and OLED displays (for instrument clusters, infotainment systems)
- Switches and buttons (for lights, windshield wipers, etc.)
- Touchscreens
Battery and energy management systems:
- Battery monitoring systems (BMS)
- Chargers and rectifiers
- Voltage converters (DC/DC converters)
Communication modules:
- CAN-Bus-e (Controller Area Network)
- LIN-Bus-modules (Local Interconnect Network)
- FlexRay-modules
- Bluetooth- und Wi-Fi-modules
Light systems:
- LED and xenon headlight modules
- Tail lights and brake lights
- Interior lighting
Cables and connectors:
- Cable harnesses and electrical connections
- Connectors for various systems in the vehicle
Air conditioning and heating components:
- Air conditioning control units
- Heating control units
- Fan motors
Navigation and GPS-systems:
- GPS modules and antennas
- Navigation control units
Tests
The LV 124 test standard is divided into 2 parts:
- Part 1 covers the requirements and tests of the 12V electrical system
- Part 2 covers the requirements and environmental tests of the components of the electrical system
The tests in Part 1 are purely electrical tests. These tests are used to check the various possible malfunctions of electrical and electronic parts and components. For example, the reaction of components to a prolonged overvoltage supply (test E-01), to a slow decrease or increase in the supply voltage (test E-07) or to a connection interruption (test E-14) are tested, to name but a few.
The tests in Part 2 are environmental tests, which in turn can be divided into 4 sub-areas. These are:
(1) Mechanical tests
(2) Climatic tests
(3) Service life tests
(4) Chemical tests
For the tests in the second part of LV 124, the standard also defines two different operating modes under which the respective tests must be performed. Operating mode I is divided into a low and high electrical load, which is applied to the device under test (referred to in the standard as DUT, or “device under test”):
(1) Operating mode I - DUT is not electrically connected
(1.1) Operating state (A) - Electrically connected and low operating load
(1.2) Operating state (B) - Electrically connected and high operating load
(2) Operating mode II - DUT is electrically connected
Electrical tests
The electrical tests of LV 124 are extensive and contain a total of 23 different tests (“E-01” to “E-23”), whereby the electrical tests can be carried out in any order. The electrical tests can also be carried out during, i.e. in parallel with, one of the environmental tests. However, this is only permissible if all test requirements can still be met. The following table provides an overview of all electrical tests. It can be seen that not all tests must be carried out for all components. In detail, the electrical tests include the following tests:
| Test no. | Test title | Applicability to components |
|---|---|---|
| E-01 | Long-term overvoltage | Components supplied via the 12V electric system |
| E-02 | Transient overvoltage | Components supplied via the 12V electric system |
| E-03 | Transient undervoltage | Components supplied via the 12V electric system |
| E-04 | Jump start | Components supplied via the 12V electric system |
| E-05 | Load dump | Components in vehicles with a 12V alternator |
| E-06 | Ripple voltage | Test case 1 for all components. Test cases 2 and 3 only for vehicles with a 12V alternator. Test case 4 only for vehicles with a DC-DC converter. |
| E-07 | Slow decrease and increase of the supply voltage | All components |
| E-08 | Slow decrease, quick increase of the supply voltage | All components |
| E-09 | Reset behavior | All components |
| E-10 | Brief interruptions | All components |
| E-11 | Start pulses | Components supplied via the 12V electric system; may not be applicable to vehicles without a 12V starter |
| E-12 | Voltage curve with electric system control | Components supplied via the 12V electric system |
| E-13 | Pin interruption | All components |
| E-14 | Connector interruption | All components |
| E-15 | Reverse polarity | Components that can be exposed to reverse polarity in the vehicle |
| E-16 | Ground potential difference | All components |
| E-17 | Short circuit in signal line and load circuits | All components |
| E-18 | Insulation resistance | Components with galvanically isolated portions |
| E-19 | Quiescent current | Components that are continuously supplied with voltage |
| E-20 | Dielectric strength | Components with inductive parts |
| E-21 | Backfeeds | Components that are electrically connected to t.15 or to other terminals with a wake-up function |
| E-22 | Overcurrents | Components that have an output |
| E-23 | Equalizing currents of multiple supply voltages | Components supplied via an independent t.30 |
Mechanical tests
In the area of mechanical testing within the scope of LV 124, the effects of mechanical influences on electrical and electronic car components are tested. For example, the effects of vibrations, impacts and other mechanical stresses on components can be assessed by carrying out tests with such loads. The effects of an impact after a free fall are tested in test M-01, for example. The LV 124 test M-02, on the other hand, simulates the effects of stone impact, while test M-03 simulates the dust load on components during real vehicle operation, to name just a few of the tests as examples. In detail, the mechanical tests include the following tests:
| Test no. | Test title | Applicability to components | Applicable standard |
|---|---|---|---|
| M-01 | Free fall test | All components For components that will obviously be damaged during the test (e.g., glass bodies, highly sensitive transducers), this test may be omitted in agreement with the purchaser. This must be documented | - |
| M-02 | Stone impact test | Components installed in areas that may be affected by stone impact | IEC 20567-1 |
| M-03 | Dust test | All components | IEC 20653 |
| M-04 | Vibration test | All components | ISO 16750-3, IEC 60068-2-6 (sinusoidal vibration), IEC 60068-2-64 (wide-band vibration) |
| M-05 | Mechanical shock test | All components | IEC 60068-2-27 |
| M-06 | Continous shock test | Components mounted in or on doors, hoods, and tailgates/trunk lids | IEC 60068-2-29 |
| M-07 | Coolant circuit pressure pulsation test | Applied only to components that are connected to a coolant circuit | - |
| M-08 | Protection against foreign bodies - IP0x to IP4x, A, B, C, D | All components | IEC 20653 |
| M-09 | Leak test | Applied only to components that may be subject to leaking | - |
Climate tests
The climatic tests of the LV 124 standard are used, for example, to test the effects of thermal loads, loads caused by very high and/or very low temperatures, thermal shocks, moisture or exposure to salty media.
Testing the thermal load on the component is used, for example, to simulate the conditions during storage and transportation of components. Salt spray tests simulate environmental conditions in winter or near the sea, to name just a few examples. In detail, the climatic tests include the following tests:
| Test no. | Test title | Applicability to components | Applicable standard |
|---|---|---|---|
| K-01 | High-/low-temperature aging test | All components | IEC 60068-2-1, IEC 60068-2-2 |
| K-02 | Incremental temperature test | All components | IEC 16750-4 |
| K-03 | Low-temperature operation test | All components | IEC 60068-2-1 |
| K-04 | Repainting temperature test | Components installed in the exterior area which may be subjected to increased temperatures in the event of repainting | - |
| K-05 | Thermal shock (component) test | All components | IEC 60068-2-14 |
| K-06 | Salt spray test with operation, exterior | Components mounted in the exterior, underbody or engine compartment | IEC 60068-2-11, IEC 60068-2-52, IEC 9227 |
| K-07 | Salt spray test with operation, interior | Components installed at exposed points in the vehicle interior (e.g., side pockets in the luggage compartment, door wet space, spare wheel well) | IEC 60068-2-11, IEC 60068-2-52, IEC 9227 |
| K-08 | Damp heat, cyclic test | All components | IEC 60068-2-30 |
| K-09 | Damp heat, cyclic test (with frost) | All components | IEC 60068-2-38 |
| K-10 | Water protection – IPX0 - IPX6K test | All components | IEC 20653 |
| K-11 | High-pressure cleaning/pressure washing test | Components that may be directly exposed to high-pressure cleaning/pressure washing or underbody washing | IEC 20653 |
| K-12 | Thermal shock with splash water test | Components installed in the exterior area or engine compartment which are expected to be exposed to splash water (e.g., when driving through puddles) | IEC 12103-1 |
| K-13 | Thermal shock – immersion test | Components installed below the fording depth for which temporary immersion in (salt) water is to be expected (e.g., when driving through water) (IPX7) | IEC 20653 |
| K-14 | Damp heat, constant test | All components | IEC 60068-2-78, IEC 60068-2-67 |
| K-15 | Condensation and climatic test | The necessity of the test must be evaluated on a component-specific basis. If required, the necessity of the test must be indicated in the Performance Specification. | IEC 60068-2-78, IEC 60068-2-38 |
| K-16 | Thermal shock (without housing) test | Modules of all components | IEC 60068-2-14 |
| K-17 | Solar radiation test | Components exposed to direct solar radiation in the installation position | IEC 75220, IEC 60068-2-5 |
| K-18 | Harmful gas test | Components with open plug contacts and switching contacts | IEC 60068-2-60 Method 4 |
| K-19 | Climatic test for components with watertight housing | For components with watertight housing only. | - |
Service life tests
The service life tests within the scope of standard LV 124 include mechanical, hydraulic and thermal loads. Test L-02, for example, is a high-temperature endurance test, while test L-03 is an endurance test with temperature changes. The aim of these tests is a time-accelerated simulation of the thermal loads that occur and the resulting mechanical stresses and their effects on components, e.g. in the form of cracking. In detail, the climatic tests include the following tests:
| Test-Nr. | Test title | Applicability to components | Applicable standard |
|---|---|---|---|
| L-01 | Mechanical/hydraulic durability testing | Components with mechanical/hydraulic actuation/function cycles | - |
| L-02 | High-temperature durability testing | All components | IEC 60068-2-2 |
| L-03 | Temperature cycle durability testing | All components | - |
Chemical tests
In addition to the tests already mentioned, the LV 124 standard also includes a series of chemical tests. The aim of these chemical tests is to check the resistance of components and assemblies to a wide range of chemicals such as fuels, oils and cleaning agents, de-icers, etc. The tests are carried out on the basis of the ISO 16750 standard. The tests are carried out on the basis of the ISO 16750 standard. The chemicals must be applied using a suitable method.
The table below lists the chemicals to be used in detail.
| No. | Chemical agents | DUT temperature | Exposure time | Description/reference |
|---|---|---|---|---|
| 01 | Diesel fuel | T_max | 22h | EN 590 |
| 02 | "Bio" diesel | T_max | 22h | EN 14214 |
| 03 | Petrol/gasoline unleaded | T_RT | 10min | EN 228 |
| 04 | Kerosene | T_RT | 10min | ASTM 1655 |
| 05 | Methanol | T_RT | 10min | CAS 67-56-1 |
| 06 | Engine oil | T | 22h | Multigrade oil SAE 0W-40, API SL/CF |
| 07 | Differential oil | T_max | 22h | Hypoid gear oil SAE 75W-140, API GL-5 |
| 08 | Transmission fluid | T_max | 22h | ATF Dexron III |
| 09 | Hydraulic fluid | T_max | 22h | DIN 51524-3 (HVLP ISO VG 46) |
| 10 | Greases | T_max | 22h | DIN 51502 (KP2K-30) |
| 11 | Silicone oil | T_max | 22h | CAS 63148-58-3 (AP 100) |
| 12 | Battery fluid | T_RT | 22h | 37% H2SO4 |
| 13 | Brake fluid | T_max | 22h | ISO 4926 |
| 14 | Antifreeze fluid | T_max | 22h | Ethylene glycol (C2H6O2) – Water mixture 1:1 |
| 15 | Urea NOx (reduction agent) | T_max | 22h | ISO 22241-1 |
| 16 | Cavity protection | T_RT | 22h | e.g., Teroson1 Underbody Coating Spray |
| 17 | Protective lacquer | T | 22h | e.g., W550 (supplied by Pfinder Chemie) |
| 18 | Protective lacquer remover | T_max | 22h | e.g., Friapol 750 (supplied by Pfinder Chemie) |
| 19 | Windscreen washer fluid | T_RT | 2h | 5% anionic tenside, deionized water |
| 20 | Vehicle washing chemicals | T_RT | 2h | CAS 25155-30-0, CAS 9004-82-4 |
| 21 | Interior cleaner | T_RT | 2h | e.g. cockpit spray (Motip) |
| 22 | Glass cleaner | T_RT | 2h | CAS 111-76-2 |
| 23 | Wheel cleaner | T_RT | 2h | e.g. Xtreme (Sonax) |
| 24 | Cold cleaning agent | T_RT | 22h | e.g. P3-Solvclean AK (Henkel) |
| 25 | Acetone | T_RT | 10min | CAS 67-64-1 |
| 26 | Cleaning solvent | T_RT | 10min | DIN 51 635 |
| 27 | Ammonium-containing cleaner | T_RT | 22h | e.g. Ajax (Henkel) |
| 28 | Denatured alcohol | T_RT | 10min | CAS 64-17-5 (Ethanol) |
| 29 | Contact spray | T_max | 22h | e.g. WD 40 |
| 30 | Sweat/perspiration | T_RT | 22h | DIN 53 160 |
| 31 | Cosmetic products such as creams | T_RT | 22h | e.g. Nivea, Kenzo |
| 32 | Refreshment containing caffeine and sugar | T_RT | 22h | Cola |
| 33 | Runway de-icer | T_RT | 2h | SAE AMS 1435A |
| 34 | E85 fuel | T_RT | 10min | DIN 51625 |
OEM test requirements and specifications
The LV 124 standard describes in detail useful and necessary tests, which in turn have been adopted by automotive OEMs in the specifications for electronic and electrical components. Here are some examples of relevant OEM standards that refer to the requirements and tests defined in the LV 124 standard:
- Volkswagen VW 80000
- BMW GS 95024-2-1
- BMW GS 95024‑3‑1
- Mercedes-Benz MBN LV 124
- Tesla TS-0002476
- Ford CETP: 00.00-E-412
- Stellantis (FCA) CS.00056
- General Motors GMW3172
- MAN M 3256-1
- Scania TB1900
International alternatives to LV 124
As mentioned above, LV 124 is mainly used as a standard in the German automotive industry. Outside Germany, several other standards are used to test the reliability of electrical and electronic automotive components. These are, for example:
- USA: SAE J1455 and AEC-Q100/AEC-Q200
- Japan: JASO D001-94
- Globally: ISO 16750
- China: QC/T 413, GB/T 28046 (the chinese publication of ISO 16750)
Conclusion
The LV 124 standard is an essential guideline for the automotive industry that defines specific test requirements for electronic components. Its scope covers many electrical and electronic components in vehicles and ensures that the high demands placed on these components in terms of reliability and durability are met. The content of the standard covers a variety of test areas, including environmental tests, mechanical tests and electrical tests. These tests are crucial to ensure the functionality and safety of components under real operating conditions.
The test requirements and specifications of the automotive OEMs based on these tests play a central role in the implementation of LV 124, as they contain specific specifications of the vehicle manufacturers, some of which go beyond the standard requirements. These manufacturer requirements are often the key to successful implementation of the standard in development and production processes.
International alternatives to LV 124 offer similar testing requirements, but differ in terms of regional specifications and use cases. Despite these alternatives, LV 124 remains an indispensable standard in the European automotive industry due to its comprehensive and specific requirements.
A relatively simple way to commission suitable testing laboratories for tests in accordance with LV 124 is to submit a free request via the online platform testxchange. A short online inquiry form is used to describe which tests are to be carried out. The request is then forwarded to various laboratories at the same time. These laboratories can then respond to the request and submit offers for the required LV 124 tests.