GMKOREA EDS-T-5505-2008 RELAY CONNECTOR TEST (VERSION 3 Replaced by GMW15267).pdf

1、GM DAEWOO Auto & Technology EDS Engineering, GM DAEWOO Auto & Technology Standards RELAY CONNECTOR TEST Do Not Use on New Programs. Being Replaced by GMW15267 EDS-T-5505 ISSUED DATE: 1990. 04. 24 REVISED DATE: 2008. 10. 21 VERSION: 3 (Superceded) EDS-T-5505RELAY CONNECTOR TEST PAGE: 1/15 ISSUED DATE

2、: 1990. 04. 24 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 It is Superceded for all future projects and replaced by GMW15267. 1. PURPOSE This standard aims at specifying the requirements, test con

3、ditions and test method of the relay used for automobiles manufactured by GMDAT to perform the test in a correct manner and obtain the accurate results. 2. DEFINITION OF TERMS 2.1. Relay The relay here refers to the electrically operated relay for automobiles used in GMDAT which contains the electro

4、mechanical and electronic circuit with one or more contacts. 2.2. Test load The test load is the load used for the performance and durability test of the relay and refers to the rated load, which is applied and installed in the vehicle, and the equivalent inductance and resistor load. 2.3. Test volt

5、age The test voltage refers to the voltage used for the relay performance and durability test which is specified in drawings or test standard. 3. TEST CONDITIONS 3.1. Standard test conditions Unless specified otherwise, test shall be performed at the normal temperature and normal humidity specified

6、in KS A 0006 (Standard Conditions of Test Place). 4. TEST EQUIPMENT 4.1. General Measuring instruments used for test shall basically be calibrated by the national calibration institute and within the effective calibration period. 4.2. Constant power supply The constant power supply shall have been c

7、alibrated and the maximum load current shall meet the requirements in the drawings or test standard. In preparation against the possible over current at the test, it shall have a +50 % effective capacity. 4.3. Voltmeter Class 0.5 or higher specified in KS C 1303 (Electric Indicating Instrument). EDS

8、-T-5505RELAY CONNECTOR TEST PAGE: 2/15 ISSUED DATE: 1990. 04. 24 REVISED DATE: 2008. 10. 21 VERSION: 3 GM DAEWOO Auto & Technology 4.4. Ammeter Class 0.5 or higher specified in KS C 1303 (Electric Indicating Instrument). 4.5. Insulation resistance meter DC 500 insulation resistance meter specified i

9、n KS C 1301 (Generator Type Insulation Resistance Meter) and KS C 1302 (Battery Type Insulation Resistance Meter). 4.6. Voltage withstand tester A tester capable of generating the high voltage specified in the drawings or test standard, adjusting the test time, memorizing the instantaneous high volt

10、age rate and automatically interrupting the high voltage at a time of dielectric breakdown. 4.7. Temperature chamber A chamber capable of maintaining the temperature from 40 to +90, it shall have a minimum capacity of 15 liter and accuracy of 2.5 for each temperature level. 4.8. Water spray tester A

11、 tester capable of performing the test according to KS R 0051(Humidity and Water Resistance Test Method for Automobile Parts) or QT 126502 (Relays) 4.9. Salt water spray A spray capable of performing the test according to KS D 9052 (Salt Spray Test Method for Automobile Parts) and GME 60206 4.10. Vi

12、bration tester A tester capable of performing the test according to KS R 1034(Vibration Test Method for Automobile Parts) and QT 126502 4.11. Drop tester A tester capable of performing the test according to QT 126502 4.12. Control panel & box for durability test It shall be capable of automatically

13、supplying and cutting off the voltage for precise operation and stop of the relay, displaying the number of tests in the digital mode, automatically interrupting the voltage applied to the relay when the test is over, detecting any defects during the test and recording the no. of cycles of durabilit

14、y test. 5. APPEARANCE TEST 5.1. The appearance inspection shall be performed visually. 5.2. When observed visually, the relay shall show no sign of harmful flaws, cracks, or other defects that may EDS-T-5505RELAY CONNECTOR TEST PAGE: 3/15 ISSUED DATE: 1990. 04. 24 REVISED DATE: 2008. 10. 21 VERSION:

15、 3 GM DAEWOO Auto & Technology adversely affect the performance. 6. ELECTRIC PERFORMANCE TEST 6.1. Operating voltage test 6.1.1. Operating voltage test under normal temperature (1) Construct the electric circuit as shown in Appendix1. (2) Increase the voltage of the DC power supply to apply the mini

16、mum operating voltage specified in the drawings or test standard to the relay coil terminal. (3) Check if the contacts of the relay touch with each other. (4) With the voltage kept applied, increase the voltage to the maximum operating voltage range to check if the contacts of the relay remain touch

17、ing with each other. (5) The brake and make of the contacts shall be observed with the ohmmeter installed at both ends of the relay load terminals. (6) The relay that includes the electronic circuit shall not be tested. However, tests may be performed in this case if the loads are connected as speci

18、fied on the drawings or test standard. In this case, the brake and make of the contacts shall be determined by the operation of the test load with the rated load connected to the relay and test voltage applied. 6.1.2. Operating voltage test under high temperature (1) Adjust the temperature of the te

19、mperature chamber to the test temperature specified in the drawings or test standard. (2) After the temperature of the chamber reaches the test temperature, store the relay inside the chamber. The starting point of storage may either when the surface temperature of the relay becomes identical to the

20、 test temperature or after 5 minutes from storage of the relay. (3) Immediately after storing the relay inside the temperature chamber for 1 hour, take it out and repeatedly perform the test in clause 6.1.1 with the electric circuit shown in Appendix 1. (4) The test time after taking the relay out o

21、f the temperature chamber shall not last longer than 30 seconds. 6.2. Minimum operating voltage test 6.2.1. Minimum operating voltage test under normal temperature (1) Construct the electric circuit as shown in Appendix1. (2) After applying voltage with the DC power supply, increase the voltage leve

22、l. (3) The voltage at the moment the contacts of the relay touch for the first time is the minimum operating voltage. (4) Read the voltage at this moment with a voltmeter. (5) The moment of contact is judged with an ohmmeter installed between the load terminals. (6) The relay that includes the elect

23、ronic circuit shall not be tested. EDS-T-5505RELAY CONNECTOR TEST PAGE: 4/15 ISSUED DATE: 1990. 04. 24 REVISED DATE: 2008. 10. 21 VERSION: 3 GM DAEWOO Auto & Technology 6.2.2. Low temperature return voltage test (1) Adjust the temperature of the temperature chamber to the test temperature specified

24、in the drawings or test standard. (2) After the temperature of the chamber reaches the test temperature, store the relay inside the chamber. The starting point of storage may either when the surface temperature of the relay becomes identical to the test temperature or after 5 minutes from storage of

25、 the relay. (3) Immediately after storing the relay inside the temperature chamber for 1 hour, take it out and repeatedly perform the test in clause 6.3.1 with the electric circuit shown in Appendix 1. (4) The test time shall not last longer than 30 seconds. 6.3. Exciting current test 6.3.1. Constru

26、ct the electric circuit as shown in Appendix 2. 6.3.2. Apply the test voltage specified in the drawings or test standard to the to the relay coil terminal. 6.3.3. Read the current flowing through the relay coil with an ammeter. 6.3.4. The test time shall not last longer than 30 seconds. 6.4. Voltage

27、 drop test 6.4.1. Construct the electric circuit as shown in Appendix 3. 6.4.2. In constructing the electric circuit, the test load shall meet the requirements of the rated load and rated capacity specified in the drawings or test standard. 6.4.3. Operate the relay with the test voltage. 6.4.4. With

28、 an ammeter, check if the current capacity of the test load meets the test conditions. 6.4.5. Measure the voltage drop between the relay load terminals with a voltmeter. 6.4.6. Get the mean value of 3 measurements to make it the voltage drop. 6.4.7. The test time shall not last longer than 10 second

29、s. 6.5. Operating temperature range test 6.5.1. High temperature operating test (1) Adjust the temperature of the temperature chamber to the test temperature specified in the drawings or test standard. (2) After the temperature of the chamber reaches the test temperature, store the relay inside the

30、chamber. The starting point of storage may either when the surface temperature of the relay becomes identical to the test temperature or after 5 minutes from storage of the relay. (3) Immediately after storing the relay inside the temperature chamber for 1 hour, take it out and repeatedly perform th

31、e test in clause 6.1.1. EDS-T-5505RELAY CONNECTOR TEST PAGE: 5/15 ISSUED DATE: 1990. 04. 24 REVISED DATE: 2008. 10. 21 VERSION: 3 GM DAEWOO Auto & Technology (4) The test time shall not last longer than 30 seconds. 6.5.2. Low temperature operating test Same as clause 6.5.1. 6.6. Insulation resistanc

32、e test 6.6.1. Have the lead line of the insulation ohmmeter connected to the relay surface. 6.6.2. Measure the insulation resistance between the insulated parts of the relay, or between the terminals, and between the terminal and other conducting parts. 6.7. Voltage withstand test 6.7.1. Install the

33、 relay inside the voltage withstand tester. 6.7.2. The lead wires of the high voltage generator shall be installed at some distance between them. (This is to avoid interference between the lead wires at a time of high voltage generation.) 6.7.3. With the controller of the high voltage generator, app

34、ly the voltage specified in the test standard between the insulated terminal of the relay and the conducting part under the specified test conditions. 6.7.4. In case of presence of dielectric breakdown, continuous discharge or other defects on the relay surface during the test, read the voltage at t

35、he moment and interrupt the power source of the high voltage generator. 6.8. Overload current test 6.8.1. Construct the electric circuit as shown in Appendix 4. 6.8.2. Apply the test voltage specified in the drawings or test standard to the relay. 6.8.3. The overload current test result varies depen

36、ding on the accuracy of the load capacity, which thus shall be precisely adjusted with an ammeter. 6.8.4. The test time starts from the moment the test voltage is applied to the relay under the adjusted load conditions. 6.8.5. After this test, repeat the test in clause 6.1.1. 7. TEMPERATURE EXPOSURE

37、 TEST 7.1. Adjust the temperature of the temperature chamber to the test temperature specified in the drawings or test standard. 7.2. After the temperature of the chamber reaches the test temperature, store the relay inside the chamber. The starting point of storage may either when the surface tempe

38、rature of the relay becomes identical to the test temperature or after 5 minutes from storage of the relay. EDS-T-5505RELAY CONNECTOR TEST PAGE: 6/15 ISSUED DATE: 1990. 04. 24 REVISED DATE: 2008. 10. 21 VERSION: 3 GM DAEWOO Auto & Technology 7.3. After elapse of a certain time, take the relay out of

39、 the temperature chamber and expose it to normal temperature for an hour. 7.4. In the same method, proceed with test in other temperature ranges. 7.5. After the temperature storage test, conduct the appearance test in clause 5 and electric performance test in clause 6 to check for the presence of ex

40、ternal defects in the relay and faulty functions. 8. DURABILITY TEST 8.1. Unless specified otherwise, test shall be performed at the normal temperature and normal humidity specified in KS A 0006 (Standard conditions of test place). Special requirements in the test standard and drawings shall be met

41、if any. 8.2. Construct the electric circuit as shown in Appendix 5 and mount the relay in the vehicle conditions. The electric wire used for the durability test shall meet the requirements for the rated load capacity in Appendix 6 8.3. After adjusting the test voltage with a voltmeter check with an

42、ammeter if the current of the test load meets the test requirements. Interrupt the power supply for a moment 8.4. Apply voltage to the control box for durability test and set the “operation” and “stop “, “test duration” and “total number of test cycles conducted” to correspond to the test conditions

43、. 8.5. On completing setting, apply the test voltage to the relay and operate the control box. 8.6. Thus all is ready for durability test. 8.7. While proceeding with durability test, conduct routine checks according to Appendix 7. 8.8. If faults are found during the test, record the phenomenon of fa

44、ults and the total number of operation in Appendix 7 and keep it. 8.9. After the durability test, conduct the electric performance test in clause 6. When thus specified in the drawings or test standard, only needed items may be performed selectively. Unless specified otherwise, however, the electric

45、 performance test specified in clause 6 shall be repeated. 9. WATER SPRAY TEST 9.1. Mount the relay onto the water spray tester to the vehicle mounting angle. 9.2. Each test shall be performed with a test sample. EDS-T-5505RELAY CONNECTOR TEST PAGE: 7/15 ISSUED DATE: 1990. 04. 24 REVISED DATE: 2008.

46、 10. 21 VERSION: 3 GM DAEWOO Auto & Technology 9.3. After adjusting the water spray tester to meet the test standard, perform test for a specified time. 9.4. After the test, remove moisture on the relay surface, expose the relay to the normal temperature for 1 hour and conduct the test for each test

47、 item as specified in the test standard. 9.5. Unless specific test items are specified, perform the test in clause 6.1.1. 9.6. The relay installed not in the engine room but in other parts of the vehicle are not tested. 10. SALT SPRAY TEST 10.1. Install the relay, which is combined with a normal hou

48、sing, inside the salt spray tester to the vehicle mounting angle. 10.2. After adjusting the salt spray tester to meet the test standard, perform test for a specified time. 10.3. Conduct test for the duration specified in the drawings or test standard. After elapse of a certain time, wash the relay w

49、ith flowing water without having its surface damaged. Check if the metal surface shows signs of rust formation and other abnormalities according to the test method in clause 5. 10.4. Conduct the electric performance test in clause 6 according to the test standard and drawings to check for normal operation. 10.5. The relay installed not in the engine room but in other parts of the vehicle are not tested. 11. VIBRATION TEST 11.1. Install the relay to the vibrating stand of the vibration tester. 11.2. After adjusting the vibration tester to meet the test standard, perform test for a specif