Ingress protection test is one of the significant quality assurance measures of present day electrical and mechanical products. An IP test machine enables the engineers to test the resistance to solid particles and moisture of a product based on international IP rating. The accuracy of the performance will be dependent on the machine set up and appropriate testing procedure transferring to the invention of IP54, IP65, IP66, and the more challenging IP67 waterproof test. This guide describes the entire setup procedure, testing requirements and best practice required to achieve good ingress protection test results.
IP testing should be done to products utilized in the open field, in wet places, in dusty factories, or those with frequent wash down operations before they are released to the market. Unless they are adequately tested, customers will get products that fail due to dust deposits, water intrusions, corrosions, or electrical shortages. The IP testing machine hence is an investment that is critical in the laboratories, the manufacture and certification center.

Understanding the Purpose

An IP test machine will mimic environmental factors that dust and water has access to a product enclosure. The machine enables engineers to test the ability of seals, gaskets, housing materials, and other internal parts to handle the real-world stresses by exposing the device to the controlled conditions.
Dust tests and water tests are the two major types of IP tests. Dust tests determine the capacity of the enclosure to keep the large or small particles out. Water tests determine the dripping ability of the enclosure, the spraying water, jet water, immersion and full submersion where the ip67 waterproof test is used to assess it in the extreme case. These measurements enable manufacturers to categorize merchandise in standardized IP scores which are relied upon by consumers and industries.

Preparing the Equipment Before Setting Up the IP Test Machine

All the parts of a machine of IP testing should be inspected before starting the testing. Engineers should ensure that the machine is clean, properly assembled and properly devoid of any remnants of previous test such as particles or moisture. Nozzles of water should be clear and unhindered. There should be no leakage in the hoses and piping because the water pressure can vary and thus compromising the accuracy of outcomes.
In the case of dust chambers, the airflow system and dust circulation mechanism are to be checked. To have consistent results the dust should be dry and even. One should start by removing any humidity in the chamber. In case the pressure levels are disturbed, filters can be replaced. It is necessary to ensure that the systems are functional to develop repeatable data.
It is also necessary to clean up and dry the device under test. The result might be influenced by any dust or moisture that might be due to the previous handling and undermine the evaluation.

Setting Up the IP Test Machine for Dust Testing

These dust tests are usually done on IP5X and IP6X category. These are the type of tests that imitate dusty conditions like those found in workshops, construction and in industrial premises. The IP test machine on which these assessments will be performed has a closed chamber in which the pressure of the air and the level of dust could be carefully regulated.
The initial process is setting up the pressure of the chamber. Certain products need negative pressure to provide the effect of suction in case of air being sucked into the device by opening small holes.
A circulation system introduces dust in the chamber. Airflow has to be altered in such a way that dust remains suspended evenly during the test by the engineer. Misaligned airflow may lead to premature dust to settle thus leading to inconsistent exposure. It is necessary to attain a steady level of dust concentration in the chamber until testing.
The product once subjected to environment is put into the chamber when the environment is stable. The test depends on whether the device should be turned off or on. The device is also removed after a given duration of time and checked thoroughly on whether dust has penetrated the device or not. Engineers compare dust traces with the anticipated pass standards to come up with the final result.

Setting Up the IP Test Machine for Water Testing

Water tests are divided into various groups among them dripping water and full immersion. The water system should be correctly established. In any test associated with nozzles and jet spray, water pressure, distance to the test subject and spray angle would have to be adjusted strictly within IEC 60529.
The intensity of the spray is dependent on the nozzle size and pressure. Excessive pressure will lead to unfair failure of the product. Where the pressure is low, the product would not be able to pass even when it is not really resistant. Before the test, engineers have to check the pressure gauge reading and correct them meticulously, prior to the test.
In immersion testing like during the IP67 waterproof test, depth of immersion and time is an important parameter. IP67 normally needs to be immersed at one meter depth within thirty minutes. The IP test machine should have water tank well marked to have the depth and temperature-controlled condition to avoid the possibilities of thermal expansion which could affect the sealing materials. The tank should be ensured that the device does not move during the test, so it has to be firmly placed.
Once the period of immersion is over, then the product shall be taken out and dried outside and then checked. One of the failures is any water inside the enclosure. Engineers might be expected to open the device and check its being dry inside.

Figure: IP Test Machine

Ensuring Test Accuracy Through Proper Machine Calibration

Calibration is important in getting accuracy in IP testing. Air flow, concentration of dust, water pressure, nozzle output, depth of immersion and spray pattern should conform to the IEC standards. Any little change in pressure or airflow may change the results.
Calibration involves the determination of the flow rate of water with a calibrated measuring device. Calibration of dust testing may involve establishment of consistent particle size of dust, and a stable chamber pressurization. Professional systems available in LISUN laboratories frequently provide an inbuilt calibration indicator and automatic monitoring so that the environment is stable in the course of the test.

Best Practices

The engineers need to adhere to certain best practices to achieve credible findings. Product need to be operating in its target orientation. Doors, panels, and access points are supposed to be closed just like how they would be during actual usage. Gasket and seals should be ensured to be installed correctly without any deformations.
Other pieces of sealing material to be used solely due to the test must not be over tightened or the screws tighter than before. The product should have quality production but not lab enhanced conditions. The repeated number of tests serves to confirm consistency.
When testing water, engineers should be able to make sure that the machine contains clean water that does not have impurities. Spray characteristics may be due to dirt or suspended solids. In immersion testing, the water tank is to be washed on a regular basis to avoid the accumulation of contamination.

Conclusion

Serving the IP test machine well is one of the keys to successful tests of ingress protection. With either dust or more rigorous IP67 waterproof test, the proper step-by-step will give reliable and traceable outcomes. The knowledge of machine preparation, calibration needs, environmental control, and best practices will help an engineer have a high level of confidence in determining product durability and sealing performance. The right testing methodology coupled with the good quality equipment supplied by such manufacturers as LISUN becomes a very reliable procedure in ensuring the product is reliable, safe and ready to hit the market.