GMW GMW16848-2013 Fuel Immersion Resistant Single-Core Stranded ISO Cable Issue 1 English.pdf

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1、 WORLDWIDE ENGINEERING STANDARDS General Specification GMW16848 Fuel Immersion Resistant, Single-Core Stranded ISO Cable Copyright 2013 General Motors Company All Rights Reserved February 2013 Page 1 of 12 1 Introduction Note: Nothing in this standard supercedes applicable laws and regulations. Note

2、: In the event of conflict between the English and domestic language, the English language shall take precedence. 1.1 Scope. This standard defines test and validation requirements for fuel immersion resistant automotive single-core ISO cable for General Motors. The cable shall meet all requirements

3、of GMW15626 plus additional requirements defined in this standard. 1.2 Mission/Theme. This standard defines test and validation for single-core cables used in fuel tank immersion applications. 1.3 Classification. Not applicable. 1.4 Temperature Classes. For fuel resistant cables, there are three cla

4、sses defined in Table 1. Table 1: Temperature Class Rating Temperature Class Alternative Temperature Class Operating Temperature A T1 -40 C to + 85 C B T2 -40 C to + 100 C C T3 -40 C to + 125 C 1.5 Nominal System Voltage. The cables used for fuel resistant applications shall be rated for 60 V, where

5、 the nominal system voltage is 60 VDC or 25 VAC. 2 References Note: Only the latest approved standards are applicable unless otherwise specified. 2.1 External Standards/Specifications. ASTM B3 ASTM B33 ASTM B298 ISO 6722-1 2.2 GM Standards/Specifications. GMW3059 GMW15626 2.3 Additional References.

6、GMPT-4-002 GMPT-4-008 GMPT-5-020 GMPT-5-029 GMPT-6-019 GMPT-6-030 www.asg-analytik.de Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW1

7、6848 Copyright 2013 General Motors Company All Rights Reserved February 2013 Page 2 of 12 3 Test Preparation and Evaluation 3.1 Resources. 3.1.1 Calibration. The test facilities and equipment shall be in good working order and shall have a valid calibration label. 3.1.2 Alternatives. Alternative tes

8、t facilities and equipment may also be used. However, all measuring variables as specified in this standard shall be determined correctly with respect to their physical definition. 3.1.3 Facilities. Not applicable. 3.1.4 Equipment. Refer to Section 5 of this standard. 3.1.5 Test Vehicle/Test Piece.

9、Refer to Section 5 of this standard. 3.1.6 Test Time. Refer to Section 5 of this standard. 3.1.7 Test Required Information. Not applicable. 3.1.8 Personnel/Skills. Not applicable. 3.2 Preparation. See each individual test in Section 5. 3.3 Conditions. 3.3.1 Environmental Conditions. See each individ

10、ual test in Section 5. 3.3.2 Test Conditions. Deviations from the requirements of this standard shall have been agreed upon. Such requirements shall be specified on component drawings, test certificates, reports, etc. 3.4 Instructions. See each individual test in Section 5. 3.5 Data. Reference 3.7.1

11、. 3.6 Safety. This standard may involve hazardous materials, operations, and equipment. This standard does not propose to address all the safety problems associated with its use. It is the responsibility of the user of this standard to establish appropriate safety and health practices and determine

12、the applicability of regulatory limitations prior to use. 3.7 Documentation. Samples of components or material released to this standard shall be tested for conformity with the requirements of this standard and approved by the responsible GM Department prior to the start of delivery of production le

13、vel components or materials. Any change to the component or material, e.g., design, function, properties, manufacturing process and/or location of manufacture requires a new release of the product. It is the sole responsibility of the supplier to provide the customer, unsolicited, with documentation

14、 of any change or modification to the product/process, and to apply for a new release. If not otherwise agreed to, the entire verification test shall be repeated and documented by the supplier prior to start of delivery of the modified or changed product. In some cases, a shorter test can be agreed

15、to between the responsible GM department and the supplier. 3.7.1 Test Results. The results shall be reported in the test report summary. The standard tests to GMW15626 shall be reported as shown in Appendix C of GMW15626. The required tests to GMW16848 shall be reported as shown in Appendix B of thi

16、s standard. Name of the supplier. Date. Supplier Product Designation. GM Wire Code Designation. Production Location. Designation of Compound. International Material Data System Identification (IMDS ID) and information, if the IMDS datasheet has been approved by the customer. Test result and interpre

17、tation of test result. Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW16848 Copyright 2013 General Motors Company All Rights Reserved Fe

18、bruary 2013 Page 3 of 12 4 Requirements and Procedure 4.1 General. 4.1.1 Cable Types. See Appendix A (GM Wire Name Code System) on defining the cable types, based on construction, conductor, temperature class, wall thickness, and insulation materials. 4.2 Material. 4.2.1 Conductors. The conductor sh

19、all consist of plain or coated copper strands as in Table 2. 4.2.2 Conductor Stranding. The strand diameter and number of strands shall be according to Table 3. Table 2: Conductor Specification ASTM B3 Soft or annealed copper wire ASTM B33 Tin coated soft or annealed copper wire ASTM B298 Silver coa

20、ted soft or annealed copper wire Table 3: Conductor Stranding and Dimensions Note 1 Conductor Size (mm2) Structure A (Symmetrical) Structure B (Asymmetrical) Structure C (Flexible) Number of Strands (minimum) Strand Diameter maximum (mm) Number of Strands (minimum) Strand Diameter maximum (mm) Numbe

21、r of Strands (minimum) Strand Diameter maximum (mm) 0.22 7 0.21 NA NA NA NA 0.35 7 0.27 19 0.16 0.5 19 0.19 37 0.14 0.75 19 0.24 38 0.16 1 19 0.27 54 0.16 1.5 19 0.33 76 0.16 2 19 0.38 105 0.16 2.5 37 0.28 50 0.26 140 0.16 3 37 0.34 44 0.31 160 0.16 4 37 0.38 56 0.31 224 0.16 5 37 0.43 65 0.33 250 0

22、.16 6 37 0.45 84 0.31 320 0.16 8 98 0.33 62 0.41 240 0.21 Note 1: Other stranding configuration may be used, if approved by GM Engineering. Note: NA = Not applicable 4.3 Conductor and Cable Dimensions. The measurement is carried out according to ISO 6722-1. All measurements shall be within the limit

23、s of the appropriate values in Table 4. Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW16848 Copyright 2013 General Motors Company All R

24、ights Reserved February 2013 Page 4 of 12 Table 4: Dimensions ISO Conductor Thin Wall Thick Wall Ultra Thin Wall Outside Diameter Insulation Thickness Outside Diameter Insulation Thickness Outside Diameter Insulation Thickness Size mm2 mm max min max nom min min max nom min min max nom min 0.22 0.70

25、 1.10 1.20 0.25 0.20 NA NA 0.35 0.90 1.20 1.40 0.25 0.20 0.5 1.10 1.40 1.60 0.28 0.22 2.00 2.30 0.60 0.48 0.75 1.30 1.70 1.90 0.30 0.24 2.20 2.50 0.60 0.48 1 1.50 1.90 2.10 0.30 0.24 2.40 2.70 0.60 0.48 1.5 1.80 2.20 2.40 0.30 0.24 2.70 3.00 0.60 0.48 2 2.00 2.50 2.80 0.35 0.28 3.00 3.30 0.60 0.48 2

26、.5 2.20 2.70 3.00 0.35 0.28 3.30 3.60 0.70 0.56 3 2.40 3.10 3.40 0.40 0.32 3.80 4.10 0.70 0.56 NA 4 2.80 3.40 3.70 0.40 0.32 4.00 4.40 0.80 0.64 5 3.10 3.90 4.20 0.40 0.32 4.50 4.90 0.80 0.64 6 3.40 4.00 4.30 0.40 0.32 4.60 5.00 0.80 0.64 8 4.30 4.60 5.00 0.40 0.32 5.00 5.90 0.80 0.64 Note: max: Max

27、imum min: Minimum mm: Millimeter NA: Not applicable nom: Nominal 4.4 Conductor Resistance. See ISO 6722-1. The corrected value shall not exceed the appropriate maximum and minimum resistance specified in Table 5. Copyright General Motors Company Provided by IHS under license with General Motors Comp

28、anyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW16848 Copyright 2013 General Motors Company All Rights Reserved February 2013 Page 5 of 12 Table 5: Conductor Resistance Requirement Conductor Size mm2 Conductor Resistance per

29、 length m/m at 20 C Plain Copper Sn-plated Copper Ag-plated Copper Maximum Minimum Maximum Minimum Maximum Minimum 0.22 84.8 Note 1 77.9 86.5 79.5 84.8 Note 1 77.9 0.35 54.4 50 55.5 51 54.4 50 0.5 37.1 34.1 38.2 35.1 37.1 34.1 0.75 24.7 22.7 25.4 23.3 24.7 22.7 1 18.5 17 19.1 17.6 18.5 17 1.5 12.7 1

30、1.7 13.0 11.9 12.7 11.7 2 9.42 8.66 9.69 8.91 9.42 8.66 2.5 7.6 6.99 7.82 7.19 7.6 6.99 3 6.15 5.66 6.36 5.85 6.15 5.66 4 4.71 4.33 4.85 4.46 4.71 4.33 5 3.94 3.62 4.02 3.7 3.94 3.62 6 3.14 2.89 3.23 2.97 3.14 2.89 8 2.38 2.19 2.52 2.32 2.38 2.19 Note 1: Supplier is allowed to deviate from Maximum r

31、esistance for 0.35 mm2 wire to meet the tensile requirement. 5 Resistance to Fuels For long term fuel exposure applications, the cable shall be tested as follows. Note: The cable shall already pass the standard fluid requirements (Media Group one (1) and two (2) as stated in GMW15626. The fuel compa

32、tibility is determined via a measurement of the outside cable diameter, winding around a mandrel, and withstands voltage tests. The cable shall be tested to Group three (3) Media, Table 6, for long term fuel immersion compatibility. A list of approved suppliers for the test fuels is shown in Appendi

33、x C, Table C1. 5.1 Test Samples. Prepare individual test samples, each 600 mm long with 25 mm of insulation removed from each end, for each fluid to be tested. 5.2 Test Method. Fill the enclosed vessels with the fuels at the temperatures according to Table 6. Determine the outside cable diameter of

34、each test sample by taking three (3) measurements distributed 120 degrees around the circumference of the cable in the middle of the test sample. Calculate an average of the three (3) measurements. Immerse the area of each test sample which shall be needed for the winding test for the specified time

35、 in the fuel shown in Table 6 with the test sample ends emerging above the surface of the fluid. Perform fuel change every 160 h. Once the specified aging time is reached, remove the test sample from the fluid and wipe the surface to remove any remaining liquid. Allow it to dry at room temperature (

36、RT) for 30 minutes, and then perform the outside diameter change measurements and withstand voltage tests. Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEE

37、RING STANDARDS GMW16848 Copyright 2013 General Motors Company All Rights Reserved February 2013 Page 6 of 12 Table 6: Group 3 Media for Fuel Resistance Test Media Description/Specification Test Samples Storage Time in Oven at Class Temperature (hours) Group Fluid 3 E25 GMPT-4-008 General Purpose 4 9

38、60 h at 60 C Oxidized Gasoline GMPT-6-019 Oxidized Gasoline 4 960 h at 60 C E85 GMPT-4-002 General Purpose Summer 4 960 h at 60 C M15 GMPT-6-030 Testing Fluid with 15% Methanol 4 960 h at 60 C Oxidized B20 Diesel GMPT-5-029 4 960 h at 90 C ULSD, B20 GMPT-5-020 Ultra-low Sulfur B20 Biodiesel 80/20 Un

39、additized 4 960 h at 90 C 5.3 Requirements. Compliance to the Fuel Resistance section shall be demonstrated by individual samples and not just lot averages. 5.3.1 Outside Diameter. 5.3.1.1 Measure the cable outer diameter (OD) change at the same place as before the immersion, with respect to the ori

40、ginal cable OD. Calculate the percentage of change in outside cable diameter. The cable must pass the requirement as shown in Table 7. 5.3.1.2 Dry-out fuel immersion tested samples by conditioning in a circulating air oven for 72 h at an air temperature of 60 C 2 C and then re-measure the cable OD,

41、with respect to the original cable O.D. Calculate the percentage of change in outside cable diameter. The cable must pass the requirement as shown in Table 7. Table 7: Media Group 3 Requirements Fuel Type Cable Outer Diameter Change after Fuel Immersion Maximum Change (%) Cable Outer Diameter Change

42、 after Fuel Immersion and Conditioning in Circulating Air Oven for 72 h at 60 C Maximum Change (%) E25 +10% -6% Oxidized Gasoline +10% -6% E85 +10% -6% M15 +10% -6% Oxidized B20 Diesel +10% -6% ULSD, B20 +10% -6% Copyright General Motors Company Provided by IHS under license with General Motors Comp

43、anyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW16848 Copyright 2013 General Motors Company All Rights Reserved February 2013 Page 7 of 12 5.3.2 Withstand Voltage and Mandrel Wrap. Upon the completion of the 72 h conditionin

44、g, remove the test samples from the oven and maintain them at room temperature 23 C for 30 minutes. After winding on a mandrel ( 4X of the cable OD), make a visual examination of the insulation. If no exposed conductor is visible, perform the Withstand Voltage test (ISO 6722-1) on the samples with t

45、he following conditions: Immerse the test samples in the salt water bath for a minimum of 10 minutes prior to the application of the voltage. Apply the 1 kV alternating current (ac) for one (1) minute. During the withstand voltage test, breakdown shall not occur. 6 Provisions for Shipping Not applic

46、able. 7 Notes 7.1 Glossary. Not applicable. 7.2 Acronyms, Abbreviations, and Symbols. Ohm (electrical resistance) AC Alternating Current ASTM ASTM International DC Direct Current GMPT General Motors Powertrain IMDS ID International Material Data System Identification IVED Integrated Vehicle Electric

47、al Design OD Outer Diameter RT Room Temperature ULSD Ultra-Low Sulfur BioDiesel 8 Additional Paragraphs 8.1 All parts or systems supplied to this standard must comply with the requirements of GMW3059, Restricted and Reportable Substances for Parts. 9 Coding System This standard shall be referenced i

48、n other documents, drawings, etc., as follows: GMW16848 10 Release and Revisions This standard was originated in August 2012. It was first approved by the Fuel Storage and Handling Global Subsystem Leadership Team in February 2013. It was first published in February 2013. Issue Publication Date Description (Organization) 1 FEB 2013 Initial publication. Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING