GMKOREA EDS-T-5241-2008 CONNECTING FINISHED ELECTRIC CABLES FOR MOTOR VEHICLES.pdf

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1、GM DAEWOO Auto & Technology EDS Engineering, GM DAEWOO Auto & Technology Standards CONNECTING FINISHED ELECTRIC CABLES FOR MOTOR VEHICLES Do Not Use on New Programs. Being Replaced by GMW3191 EDS-T-5241 ISSUED DATE: 1985. 05. 01 REVISED DATE: 2008. 10. 21 VERSION: 3(Superceded) EDS-T-5241CONNECTING

2、FINISHED ELECTRIC CABLES FOR MOTOR VEHICLES PAGE: 1/7 ISSUED DATE:1985. 05. 01 REVISED DATE: 2008. 10. 21 VERSION: 3 GM DAEWOO Auto & Technology Note: This standard may be applied only for current project (incl. T255 Program). It is Superceded for all future projects and replaced by GMW3191. 1. PURP

3、OSE This test specification determines the requirements and test conditions for individual and bundled electrical cables, which are fitting- and connecting finished delivered. It is not valid for high frequency cables and high tension ignition cables. 2. REMARK Samples of material released to this s

4、pecification shall be tested according to this spec. and approved by GMDAT TECHNICAL CENTER, prior to the commencement of this bulk supplies. In the event of any intentional deviation from the requirement of this spec.,it is the sole responsibility of the supplier to submit the purchaser unsolicited

5、 the samples for reapproval by GMDAT TECHNICAL CENTER prior to the commencement of delivery of deviant bulk supplies. 3. TEST SAMPLE AND TEST QUANTITY If other things are not indicated for the first sampling and release test according to this specification at individual cables and cable sets, which

6、are shorter than 2m, cut goods of every cable kind are to be delivered. Uniform plugs and sockets must be sampled at least 5 fold and uniform plug housings must be sampled at least 3 fold. The samples are to be delivered with a works test certificate according to DIN 50 049-2.3. It is expected, that

7、 at the given test samples the values of all required characteristic values describe the tolerance range of the production strewing width. If this supposition of the test samples is not fulfilled, the tolerance range of the production strewing width must be indicated for all required characteristic

8、values in the works test certificate, with disregard to thd individual values. 4. SAMPLE PRETREATMENT If other things are not indicated at the individual tests, the tests without sample pretreatment are performed in the delivery condition at +235K. 5. TESTING DEVICES 5.1. Testing apparatus correspon

9、ding to the indicated GMDAT test procedures, test specifications and DIN-standards. Measuring apparatus and instructions for the dimensional tests. EDS-T-5241CONNECTING FINISHED ELECTRIC CABLES FOR MOTOR VEHICLES PAGE: 2/7 ISSUED DATE:1985. 05. 01 REVISED DATE: 2008. 10. 21 VERSION: 3 GM DAEWOO Auto

10、 & Technology CABLE LENGTH mm TOLERANCE mm to 100 +10 0 over 100 to 1000 +20 0 over 1000 +30 0 CONDUCTOR OUTSIDE DIAMETER nominal section mm2 number of wires max 1) diameter of single wires max 1) d1 max 1) resistance= m /m insulating hull wall thickness2) nominal values d2 max. tolerance 0 -. weigh

11、t kg/1000m= 0,5 19 0,19 1,0 37 0,3 1,6 -0,2 6,0 0,75 19 0,23 1,2 24,5 0,3 1,8 -0,2 8,9 1 19 0,26 1,4 18,3 0,3 2,0 -0,2 10,7 1,5 19 0,32 1,7 12,5 0,3 2,3 -0,2 16,5 2,5 19 0,41 2,2 7,5 0,35 2,9 -0,3 25,0 4 19 0,52 2,8 4,6 0,4 3,6 -0,4 40,4 6 19 0,64 3,4 3 0,4 4,2 -0,4 61,3 6. REQUIREMENTS 6.1. Require

12、ments for the individual component parts. 6.1.1. Cables. 6.1.1.1 The cables must correspond to the indications according to DIN ISO 6722, part 1 to E part 3. The indications determined in the following chart must be correspondingly considered for electrical cables with reduced insulation 1) Number o

13、f the wires and diameter of the single wires optionally according to DIN 72 551. The cable assembly must approximately correspond to a proportionately stranded wire in the cross section. 2) The wall thickness may be fallen below about more than 20% of the nominal values in no place. 6.1.1.2 The cabl

14、e - and cable cutting lengths must correspond to the drawing indications. The tolerances indicated in chart 1 are permissible. CHART 1. EDS-T-5241CONNECTING FINISHED ELECTRIC CABLES FOR MOTOR VEHICLES PAGE: 3/7 ISSUED DATE:1985. 05. 01 REVISED DATE: 2008. 10. 21 VERSION: 3 GM DAEWOO Auto & Technolog

15、y 6.1.1.3 At every bare, skinned cable end, the wires must be twined and non-acidly tinned. For the skinned conductor length, the tolerance amounts to +1mm 6.1.1.4 Conductor connections must optionally manufactured as following and must be unobjectionbly insulated : 6.1.1.4.1 Conductor is fast conne

16、cted with a clamp and non-acidly soldered or 6.1.1.4.2 Conductor is fast connected by pressure welding, without wires to damage or 6.1.1.4.3 Conductor is fast connected by shrinking connector. 6.1.1.5 Branching cables are to be contained at the branch with a sitting fast insulating tubing or at main

17、 cable line with insulating tape. The branching cables must be easily put on at the main cable line. 6.1.1.6 Several cables must be held together by covering of an insulating tubing or by covering with insulating tape, corresponding to the determination on the drawings. The overlapping of the insula

18、ting tape must amount to at least 50%. 6.1.1.7 In order to obtain a greater inflexion of the cables, an overlapping is renounced at use of textile tape at the winding. This so-called economy tapping is permissible only in the vehicle inside. In this case it must be guaranteed, that at the laying of

19、the cable a damage of the cable insulation is to be excluded. Besides no damage may be caused at intrusion of dampness in the cable line. This model is not permitted for laying in the engine space. 6.1.2. Insulating tape 6.1.2.1 Self- sealing insulating tape must correspond to the requirements accor

20、ding to DIN 40 633, sheet 1, type K 10. 6.1.2.2 Textile tape must fulfil the requirements, which are determined in the drawing NO.08935249. 6.1.2.3 Nonsealing insulating tape is likewise judged according to 6.2.1 or 6.2.2, except the specifications, which concern the adhesive coat. 6.1.3. Insulating

21、 tubings 6.1.3.1 The insulating tubings must correspond to DIN 40 621 color black. 6.1.3.2 Every insulating tubing must be determined at least in the end by adhesion or bonding at the cable or the cables. 6.1.3.3 The insulating tubings must be into one another pushed at the cable branches 20mm to 25

22、mm and must be together pasted. 6.1.3.4 In operation of deep-groove tubing, this method adapted by splicing tape or another thing in the end must be connected with the cables. EDS-T-5241CONNECTING FINISHED ELECTRIC CABLES FOR MOTOR VEHICLES PAGE: 4/7 ISSUED DATE:1985. 05. 01 REVISED DATE: 2008. 10.

23、21 VERSION: 3 GM DAEWOO Auto & Technology 6.1.4. Insulating sockets The insulating sockets must be manufactured from chloroprene or PVC. Their measurements are to be appropriately chosen for the achievement of a certain insulation. Resistance to aging according to EDS-T-7421 : No cracks of the surfa

24、ce sighted with the magnifier and no nominal valued embrittlement. For parts from chloroprene : Ozone resistance according to EDS-T-7405-2B1U-degree OPVC is considered as ozone resistant. 6.1.5. Cable terminal The cable terminal must correspond to DIN 46 225, form A. Deviation are to be indicated in

25、 the respective drawing. 6.1.6. Plug connections 6.1.6.1 The blade sockets must correspond to the requirements determined in ON 5584. 6.1.6.2 The pin terminal connections must correspond to the requirements placed in the technical delivery conditions EDS-T-5212. 6.1.6.3 According to application case

26、, other plug-connection cables can come into operation. These must be fulfilled according to the respectively coordinated test specifications. 6.1.6.4 The bare connection ends must be so fast enclosed at the crimping of the plugs or sockets, that no wire is pulled out. Besides the cable must be free

27、 from projecting wire end. The ends of the cable insulation must be so fast enclosed at the crimping of the plugs or sockets, that an enough traction relief of the contact crimping is obtained and the insulation is not shifted. 6.1.7. Housing Housings for multiple plug connection must contain chambe

28、rs, which permit an insulated support of the plug connectors. The chambers and holding bars must be so formed, that at the pinning or disconnecting of the connection, plug or socket are not pressed from the housing. The extension-and pull-off forces coordinated for the respective connection must cor

29、respond to the respectively proper determinations. The insulation resistance according to VDE 0623/03,7219 must amount to at least 5M . The contact parts struck on cables and halted in the housing may cause no rattling housing at the shaking of the cables. 6.1.8. Passing nozzles The passing nozzles

30、must be from elastomer (black or grey), hardness according to EDS-T-7403-(555 shore A, resistance to aging according to EDS-T-7421-charge of the hardness +10 shore A max. - ozone resistance according to EDS-T-7405-2B1U-degree 0. EDS-T-5241CONNECTING FINISHED ELECTRIC CABLES FOR MOTOR VEHICLES PAGE:

31、5/7 ISSUED DATE:1985. 05. 01 REVISED DATE: 2008. 10. 21 VERSION: 3 GM DAEWOO Auto & Technology 6.2. Test of the water protection. All passing nozzles must be dense opposite to the cable and the passing in the sheet corresponding the determination according to DIN 40 050 protection kind IPX4A. Altern

32、ative for the test according to DIN 40 050, a test with slack water can be performed in the water case. The nozzle with cable set part in the opening determined drawing like is mounted in the bottom of a water container. The water height in the container amounts to maximum 170mm. After 2 min testing

33、 duration water may be penetrated neither at the nozzle nor over cable branch. All plugs characterized correspondingly in the respective parts-drawing for cables and connections with electronic components must be tested in the assembly according to DIN 40 050 protection kind IPX4A and must be dense.

34、 6.3. Function test The manufacturer must guarantee for the switching-required according to the cable set drawing-of individual cables in the cable set by function test. 6.4. Combustibility test for insulating tubings, insulating sockets, cable set-retaining ring, housing for plug connector, fuse bo

35、xes and passing nozzles in the delivery condition. For the performance of the combustibility test for the called parts, the position of the test sample for the flame, flame size and ignition are to be chosen, how they are indicated in EDS-T-7602. Parts with a maximum length of 80 must be self-quench

36、ing, that is within of 30s after taking away of the igniting flame. During this time the mass of the part may be burned to 60%. For parts with a maximum length of 80mm, the burning rate 1.25mm/s (75mm/min) may be not exceeded. The procedure for the specification of the burning rate is determined in

37、EDS-T-7602, pos.5.3.6 last paragraph. Multiple plug housings and insulating nozzles are to be tested with their fitted plug connector parts. Insulating nozzoles for the multiple plug housings are to be separately tested. The cables are to be cut behind the test samples. The ignition must occurred on

38、 the plug side. 7. CHARACTERIZATIONS 7.1. Characterization of the cables 7.1.1. Every cable must be characterized by one-or multicolored insulation or by a number printed on the insulation. It is determined by drawing, which one of the both characteristics must be available. EDS-T-5241CONNECTING FIN

39、ISHED ELECTRIC CABLES FOR MOTOR VEHICLES PAGE: 6/7 ISSUED DATE:1985. 05. 01 REVISED DATE: 2008. 10. 21 VERSION: 3 GM DAEWOO Auto & Technology NOMINAL CROSS SECTION mm2 COLOR OF INSULATION 0.75 White 1 Yellow 2.5 Red 7.1.2. In the case of the characterization by the color of the insulatim, to DIN 47

40、002, however with capital Remark : On circuit diagrams the cable characteristic is indicated according to scheme : conductor nominal diameter basic color 1. indicating color, if necessary 2. indicating color, if necessary Example : 2.5WS BLGN 7.1.3. In the case of the characterization by a cable num

41、ber, this corresponds to the number, which stands at the drawings beside connection. It must be applyed in both cable ends multiple, durable and with a contrast color. The color of the insulation characterizes the nominal cross section in this case, as indicated in chart 2. Chart 2 7.1.4. If a postp

42、oned insulating tubing hinders the recognition of the cable characteristic, a connection characteristic must be fixed in the cable end, for cxample, in form of a printed socket. 7.2. Characterization of the cables sets 7.2.1. Every cable set must be provided with a nameplate or characteristic tape.

43、It is determined by drwing, which one of the both characteristics must be available. 7.2.2. The nameplate must : 7.2.2.1 Contain manufacturer (name or sign) and part number (manufacturing date and test certificate desired), 7.2.2.2 Have basic-and writing color according to drawing indication (genera

44、l black writing colored basis), 7.2.2.3 Be fastened good readable and durable. EDS-T-5241CONNECTING FINISHED ELECTRIC CABLES FOR MOTOR VEHICLES PAGE: 7/7 ISSUED DATE:1985. 05. 01 REVISED DATE: 2008. 10. 21 VERSION: 3 GM DAEWOO Auto & Technology 7.2.3. The characteristic tape must : 7.2.3.1 Be from w

45、hite plastics, 7.2.3.2 Contain black identification letter, according to drawing indication. 8. ADDITIONAL REQUIREMENTS 8.1. Approved suppliers see release or release of the part drawing. 8.2. Further indications see part drawing. 8.3. Automotive restricted hazardous substances to GMW3059. 9. INDICA

46、TION IN DRAWINGS, TEST SPECIFICATIONS AND SUCH THINGS In drawings for cable sets and cables, this specification is indicated as following : “ Test specification according to EDS-T-5241“ In assembly drawings for components, test specifications and such things : “ Electrical cables according to EDS-T-5241“ 10. DEVIATIONS Deviations from this specification or additional requirements must be respectively especially arranged