From smartphones to outdoor lighting, from control cabinets to electric vehicle batteries: all kinds of electrical devices and components can suffer damage due to penetration by foreign bodies and water. The international IP protection rating standards describe how well their casings protect against these hazards. Manufacturers carry out impermeability tests to ascertain whether or not their products comply with the IP protection ratings desired. Environment simulation expert Weiss Technik offers the corresponding dust and splash water testing devices for this purpose.
IP protection ratings: measurable safety for users
IP protection ratings are intended to guarantee the safe operation of electrical devices. They relate to the suitability of the electronic equipment for various environmental conditions. Specifically, this means: how well-protected a device casing is against the penetration of solid foreign bodies, including dust and sand, and of water. The IP protection ratings are defined in two international standards. DIN EN 60529 is the general standard for protection ratings relating to casings, whereas ISO 20653 relates specifically to the protection of the electronic equipment in road vehicles. While terms such as “waterproof” or “dustproof” by themselves are quite imprecise, the IP protection classes offer an evaluation system with measurable, standardised criteria. This means that users can reliably select devices that are sure to withstand the operational and environmental conditions to which they are exposed.
The IP code, comprised of letters and numbers
The IP protection rating is described in an IP code comprising two letters and two numbers. The letters “IP” stand for “International Protection” or, in the English-speaking world, also for “Ingress Protection” (protection against penetration). The first number indicates the extent to which a casing protects against contact and solid objects; the second number indicates the extent of the protection against humidity and water. If one of the two protection ratings is not relevant, the irrelevant number is replaced by an “X” (e.g. IPX1). If the ISO 20653 standard is applied for road vehicles, a “K” is added for the individual tests (e.g. IPX9K). For both indicator digits, the scale starts at 0, which indicated that there is no protection against contact/foreign bodies or moisture.
More than just dust-protection: IP protection rating against contact and foreign bodies
For everyday purposes, the first IP number is often associated with protection against dust. This is just at the upper end of the scale, however. Protection against penetration by foreign bodies starts at IP1X with protection against ingress by solid objects larger than 50 mm in diameter and ends at IP6X with dust impermeability.
From rain to high-pressure cleaners: IP protection rating against water
The second number indicates the extent to which the product is protected against the ingress of water. The standards define very precisely in each case how water affects the casing. For protection rating IPX1, the casing must withstand drops of water falling on to it vertically, e.g. during a light shower of rain. Maximum protection is achieved with IPX9: the casing must be impermeable to water hitting the casing at high pressure, high temperatures and from all directions.
An example: Protection rating IP65
One common protection rating is IP65. A product with this rate of protection is completely protected against solid objects. Dust cannot penetrate it and it is impermeable against jets of water from every direction. This is particularly important when, for example, mobile components such as motors or drives have to be protected. Generally speaking, protection rating IP65 is recommended for all types of outdoor electric and electronic devices so that they are protected against dust, rain and humidity.
Not to be confused: protection rating and protection class
The terms protection rating and protection class are often used synonymously or confused. Whereas the protection ratings define the level of protection against contact, foreign bodies and water, the protection class describes the measures, in accordance with DIN EN 61140(VDE 0140-1) that protect against hazardous voltages, i.e. the risk of electric shock.
DustEvent: standard solution in two sizes
Dust tests check to see if foreign bodies such as sand or dust can permeate the casing of the test object. Typical dust tests are the tests IP5X and IP6X in accordance with testing standard DIN EN 60529 and the tests IP5KX / IP6KX in accordance with the standards ISO 20653 and SAE J 575. Weiss Technik has the DustEvent chambers in its portfolio for these standardised IP dust tests. They are available in two sizes with a test chamber volume of 1,000 and 2,000 litres.
For the dust tests, standard-compliant composite dust material is introduced into the test space. Depending on requirements, this could be, for example, a very fine talc dust (<75 μm), Portland cement, fly ash or Arizona dust. The dust introduced into the chamber is distributed homogeneously in the test system for standard-compliant tests and is stored as dry and lump-free as possible. The DustEvent test chambers can be upgraded with optional additional equipment for tests according to other standards, including IEC 60068-2-68.
Splash water test: standard for common tests
Weiss Technik offers the WaterEvent test chamber for the very common IP protection rating tests IPX3 and IPX4 in accordance with DIN EN 60529. The chambers are used to test an object’s resistance against the ingress of splash water from all sides. The test chambers are available with swivel tube radii of 200 to 800 mm. The devices can be upgraded simply with the required additional equipment for tests according to further standards and protection ratings. This means, for example, that the requirements for all splash water tests protection rating tests in accordance with ISO 20653 and DIN EN 60529 as well as for the international standards SAE J 575, JIS D 0203, and IEC 60598-1 can be met.
Solutions for special requirements
In addition to tried-and-tested standard test chambers, Weiss Technik develops customised special solutions for demanding IP protection rating tests. These include testing systems for the automotive industry in which lithium-ion batteries for electric vehicles are checked for water and dust impermeability. FEV Group GmbH, for example, uses a Weiss Technik splash water testing system in the world’s largest development and testing centre for high-voltage batteries.
The testing system is used to conduct IP protection rating tests IPX5, IPX6, IPX6K (jets of water, strong jets of water, under high pressure) and IPX9K (high pressure/ steam jet cleaning). Weiss Technik has also developed a dust test chamber for dust tests for protection ratings IP5X, IP6x, IP5KX and IP6KX in the FEV testing centre, which can fit whole battery packs with weights of up to 1,000 kg.
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