1、GM DAEWOO Auto & Technology EDS Engineering, GM DAEWOO Auto & Technology Standards UNSCREENED HIGH-TENSION IGNITION CABLES Do Not Use on New Programs. Being Replaced by GMW3172 EDS-T-5208 ISSUED DATE: 1992. 03. 04 REVISED DATE: 2008. 10. 27 VERSION: 3 (Superceded) EDS-T-5208UNSCREENED HIGH-TENSION I
2、GNITION CABLES PAGE: 1/13 ISSUED DATE: 1992. 03. 04 REVISED DATE: 2009. 10. 27 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 It is Superceded for all future projects and replaced by GMW3172 1. PURPOSE This test specification
3、specifies the dimensions, general and special requirements and the test method for unscreened high-tension ignition cables. 2. NUMBER OF TEST SAMPLES A conduct composed of at least twenty 5m high-tension ignition cables. 3. APPARATUS 3.1. Test instruments shall correspond to the specified DIN-standa
4、rd. 3.2. Ohmmeter(accuracy class 1.5), for measuring the resistance to conduction 3.3. Micrometer, for measuring diameters and wall thicknesses. 3.4. Trigger mechanism or machine, with which to pull plugs from instruments or from cables at a speed of 100 mm/min. Measuring range of force: up to 200N
5、3.5. Wire coiled filament, of +1mm in inner diameter like that of the cable, approx. 3mm in slope, and 1.5mm in wire diameter. It is used to examine defective portions. 3.6. High voltage source: 12KV40KV (50Hz60Hz) 3.7. High-voltage measuring instrument (accuracy class 2.0): 0KV40KV 3.8. Glass test
6、tube, for carrying out tests in salt water, tap water, oil and fuel. 3.9. Chamber (for low and high temperature), for temperature tests. 3.9.1. Height of interior: min. 500mm 3.9.2. Range of temperature: -50+250 3.9.3. Permissible temperature deviation: 2.5K at a temperature over 0, 3K at a temperat
7、ure under 0 3.10. Microscope, for measuring depth of indentation. EDS-T-5208UNSCREENED HIGH-TENSION IGNITION CABLES PAGE: 2/13 ISSUED DATE: 1992. 03. 04 REVISED DATE: 2009. 10. 27 VERSION: 3 GM DAEWOO Auto & Technology 3.11. Rotary spindle ( 35 mm), for ozon resistance test. 3.12. Tank, capable of c
8、ontaining bearing lead balls of 3mm in diameter( ) fully. 3.12.1. Length: 220 mm 3.12.2. Width: 110 mm 3.12.3. Depth: 80 mm 4. DIMENSIONS OF IGNITION CABLES 4.1. Finished cables shall have outside diameters as follows. 4.1.1. 80.3 mm 4.1.2. 70.3 mm 4.1.3. 50.3 mm 4.2. As for required diameters, sele
9、ct from clause 4.1 appropriately. 5. TEST PROCEDURE 5.1. Insulation failure test 5.1.1. Principle Grounded dry ignition cables (or, cladding that covering corresponds to cathode) shall not show dielectric breakdown when voltage is applied to the coil wire(anode). 5.1.2. Apparatus Coil wire, of +1 mm
10、 in inside diameter equal to that of the cable, approx. 3mm in coiled width, and 1.5 mm in wire diameter. 5.1.3. Test voltage For 8 mm ignition cable: 30KV (50Hz60Hz) For 7 mm ignition cable: 25KV (50Hz60Hz) For 5 mm ignition cable: 20KV (50Hz60Hz) 5.1.4. Test period Application for at least 1 secon
11、d is required for each portion of the cable. 5.2. Thirty-minute-test voltage and dielectric breakdown test (see Fig 1, Appendix Table #2) 5.2.1. Length of test sample EDS-T-5208UNSCREENED HIGH-TENSION IGNITION CABLES PAGE: 3/13 ISSUED DATE: 1992. 03. 04 REVISED DATE: 2009. 10. 27 VERSION: 3 GM DAEWO
12、O Auto & Technology Ignition cable of approx. 1200 mm 5.2.2. Test procedure Immerse the ignition cable into the salt water of 3% for 4h with both ends exposed to the air of 235 When applying voltage according to clause 5.2.3 for 30 min between the solution and the ignition cable, dielectric breakdow
13、n shall not occur. While the voltage is raised at the rate of 500V/sec until reaching the specified values(5.2.4), dielectric breakdown shall not occurs, either. 5.2.3. Test voltage (applied for 30 minute) For 8 mm ignition cable: 20KV (50Hz60Hz) For 7 mm ignition cable: 20KV (50Hz60Hz) For 5 mm ign
14、ition cable: 15KV (50Hz60Hz) 5.2.4. Test voltage (for dielectric breakdown) For 8 mm ignition cable: Approx. 40KV (50Hz60Hz) For 7 mm ignition cable: Approx. 35KV (50Hz60Hz) For 5 mm ignition cable: Approx. 25KV (50Hz60Hz) 5.3. Capacity test 5.3.1. Length of test sample Ignition cable of approx. 120
15、0 mm 5.3.2. Test procedure Immerse the ignition cable into 3% salt water of +702 for 24h. Here, the both ends shall be projected from the water by approx. 100 mm. Measure the capacity between the conductor and the tank of salt water. Then immerse the ignition cable into the tap water of 232 for 1h w
16、ith the both ends exposed to the air by approx. 100mm. Measure capacity between the conductor and the tank of tap water. (Capacity shall not exceed the values specified in Appendix Table #1) 5.3.3. Measuring frequency 1000 Hz 5.4. Resistance test under corona discharge (see Fig 2, Appendix Table #2)
17、 5.4.1. Length of test sample Ignition cable of approx. 1200 mm 5.4.2. Test procedure Fasten one of the sample ends to the rotary spindle of 25 mm and apply load of 2.5 kg to the other end. Wind the sample 5 turns around the spindle and fasten it so that the both ends of the cable stands off freely
18、19 mm. Cover the top with a metal sleeve and apply voltage according to clause 5.4.3. After 8 hours of test, any change or defective like ruptures and cracks shall not appear on the sample. EDS-T-5208UNSCREENED HIGH-TENSION IGNITION CABLES PAGE: 4/13 ISSUED DATE: 1992. 03. 04 REVISED DATE: 2009. 10.
19、 27 VERSION: 3 GM DAEWOO Auto & Technology 5.4.3. Test voltage For 8 mm ignition cable: 20KV (50Hz60Hz) For 7 mm ignition cable: 20KV (50Hz60Hz) For 5 mm ignition cable: 15KV (50Hz60Hz) 5.5. Pressure test at high temperature (see Fig 3. Appendix Table #2) 5.5.1. Length of test sample Ignition cable
20、of approx. 100 mm 5.5.2. Test procedure Mount the sample on the apparatus and put it into the naturally-ventilated hot oven at a temperature specified in Appendix Table #1 for 4h and at a load specified in clause 5.5.3. Then dismantle the sample from the apparatus and cool it in the cooling water wi
21、thin 10 sec. Inspect the dented point in the horizontal or vertical section with a microscope. This dented point shall not occupy more than 50%. It is related to the mean value of the covering thicknesses of test samples at a point that is apart from the pressurized area to some degree when dividing
22、 the sample into 6 parts. 5.5.3. Test load For 8 mm ignition cable: 510g (including the weight of assembly table) For 7 mm ignition cable: 450g (including the weight of assembly table) For 5 mm ignition cable: 312g (including the weight of assembly table) 5.6. Thermic overload test 5.6.1. Length of
23、test sample Ignition cable of approx. 500 mm 5.6.2. Test procedure Suspend the sample vertically in a naturally-ventilated hot oven and leave it at the temperature specified in Appendix Table #1 for 48h. After then cool the sample at 235 and wind the sample both clockwise and counterclockwise 4 turn
24、s each around the cylindrical spindle of 12.5 mm in diameter while applying a load of 4.5Kg. Here, cracks shall not occur. 5.7. Thermal contraction test 5.7.1. Length of test sample Ignition cable of approx. 200 mm 5.7.2. Test procedure Measure the length of the sample precisely at 235 prior to the
25、test. Locate the sample horizontally in the naturally ventilated hot oven which is circulated in all directions, and leave it at the temperature specified in Appendix Table #1 for 15 minute. Cool the sample at 235 and measure the length again. The difference EDS-T-5208UNSCREENED HIGH-TENSION IGNITIO
26、N CABLES PAGE: 5/13 ISSUED DATE: 1992. 03. 04 REVISED DATE: 2009. 10. 27 VERSION: 3 GM DAEWOO Auto & Technology between the two measured values shall be within 2% and there shall be no ruptures. 5.8. Combustion resistance test (see Fig 5. Appendix Table #2) 5.8.1. Length of test sample Ignition cabl
27、e of approx. 500 mm 5.8.2. Apparatus Inside diameter of combustion tube: 9 mm Height of flame: 100 mm Height of blue flame: 50 mm Temperature of flame: The one at which copper wire of 100 mm(0.70.03 mm in diameter) can be melted within 4 to 6 sec. 5.8.3. Test procedure Suspend the sample in a labora
28、tory that is not ventilated. Here, adjust the height of bule flame to Fig. 5, Appendix Table #2. Apply flame only for the time specified in Appendix Table #1. Combustion flame of the insulator shall be extinguished after removing the flame of the burner within the time specified in Appendix Table #1
29、. 5.9. Flexibility test at low temperature 5.9.1. Length of test sample Ignition cable of approx. 400 mm 5.9.2. Test procedure Fasten the sample to the rotary spindle of 25 mm and apply a load of 4.5 kg to one of the sample ends. Suspend the assembly vertically a cold oven at the temperature specifi
30、ed in Appendix Table #1 for 4 hr. Keep the winding speed 1 winding/sec. Wind the sample at least 3 turns around the spindle. During the test, any cracks or slits shall not occur and the coil of the cable shall not protrude from the insulator. 5.10. Mechanical tensile test (see Fig 4. Appendix Table
31、#2) 5.10.1. Length of test sample Ignition cable of approx. 1200 mm 5.10.2. Test procedure Suspend the sample cable with the test apparatus as shown in Fig. 4, Appendix Table #2 for 5 minutes with the load (without removement) specified in Appendix Table #1. Wind the sample of 1200 mm at least each
32、3 turns around each of both spindles so that the length of sample becomes 250 mm. Then pressurize it with the load specified in Appendix Table #1, and apply a voltage of approx. DC 12V. Here, power failure shall not occur. Conduct the test and measurement at the room temperature of 235 5.11. Insulat
33、ion removal test EDS-T-5208UNSCREENED HIGH-TENSION IGNITION CABLES PAGE: 6/13 ISSUED DATE: 1992. 03. 04 REVISED DATE: 2009. 10. 27 VERSION: 3 GM DAEWOO Auto & Technology 5.11.1. Test procedure If it is needed to remove the insulation from the cable, at least 20mm shall be cleaned to be easily remove
34、d without difficulty. 5.12. Oil resistance test 5.12.1. Length of test sample Ignition cable of approx. 400 mm 5.12.2. Test procedure Immerse the sample into the No. 1 oil according to ISO 1817 at 902 for 48h. Here, the ends of the conductor shall be projected from the oil surface approx. 50 mm. Dur
35、ing test, removement of oil shall be observed. Take the sample out of the oil and clean the surface. Cool the sample at the room temperature of 235 One of the cable ends shall be fastened to a torsion plug of 12.5 mm in diameter, and the other end shall be loaded with 4.5kg. Rotate the sample clockw
36、ise and then counterclockwise uniformly to the same distance at least 4 cycles. (on the spindle) Here, the revolution shall be 1 cycle/sec. During the test, any ruptures shall not be shown on the insulation covering. Change rate (percent) of the initial diameter shall be permissible only within the
37、range specified in Appendix Table #1. 5.13. Fuel resistance test 5.13.1. Length of test sample Ignition cable of approx. 400 mm 5.13.2. Test procedure Immerse the sample into the solution C at 235 for 30 min according to ISO 1817. Here, the ends of the sample shall be projected from the solution sur
38、face approx. 100 mm. Take the sample out and dry it at room temperature for approx. 30 minutes. Fasten one of the two ends to a torsion plug of 12.5 mm in diameter, and apply a load of 4.5 kg to the other end. Rotate the sample clockwise and then counterclockwise uniformly to the same distance at le
39、ast 4 cycles.(on the spindle) The revolution shall be 1 cycle/sec. During the test, any ruptures shall not be shown on the insulation covering. Change rate(percent) of the initial diameter shall be permissible only within the range specified in Appendix Table #1. 5.14. Ozone resistance test 5.14.1.
40、Length of test sample Ignition cable of approx. 600 mm 5.14.2. Test procedure Fasten one end to the cylindrical spindle and apply a load of 4.5 kg to the other end. Then wind the sample clockwise at least 3 turns and remove the load. Bury the sample into the tank filled with lead bearings of approx.
41、 3 mm in diameter and apply 12KV(50Hz) of alternating current for 24h to the ends. Here damages like cracks etc. shall not occur. EDS-T-5208UNSCREENED HIGH-TENSION IGNITION CABLES PAGE: 7/13 ISSUED DATE: 1992. 03. 04 REVISED DATE: 2009. 10. 27 VERSION: 3 GM DAEWOO Auto & Technology 6. REFERENCES QT
42、063504 DIN-ISO 3808/1 DIN-ISO 3808/2 DIN-ISO 1817 DIN 72535 B SAE J 577 EDS-T-5208UNSCREENED HIGH-TENSION IGNITION CABLES PAGE: 8/13 ISSUED DATE: 1992. 03. 04 REVISED DATE: 2009. 10. 27 VERSION: 3 GM DAEWOO Auto & Technology Class A B Test item Type 1 2 3 4 1 2 3 4 5.1 Insulation failure test Applic
43、able Inapplicable Applicable Inapplicable5.2 Thirty-minute-test voltage and dielec-tric breakdown test Applicable Applicable 5 mm cable (232) (702) 7 mm cable (232) (702) 5.3 Capacity test 8 mm cable (232) (702) Capacity control shall be done after consultation between cable manufacturers and users.
44、 5 mm cable AC 12KV (50 or 60 Hz) 7 mm cable AC 15KV (50 or 60 Hz) 5.4 Resistance test under corona discharge 8 mm cable AC 18KV (50 or 60 Hz) 5.5 Pressure test at high temperature (702) (1052) Temperature (1052) (1202) 5.6 Thermic overload test Tolerance (unit: %) - - +50-30- - - +50 -30 - Temperat
45、ure (1552) (1552) 5.7 Thermal contraction test Contraction max. 2% 2% Ignition time 30 sec 30 sec 5.8 Combustion resistance test Extinguishment time 30 sec 30 sec 5.9 Flexibility test at low temperature (temperature) (-203) (-203) 5 mm cable 180N 180N 7 mm cable 250N 250N Load 8 mm cable 250N 250N T
46、olerance 0+30%Inap-plic-able 0+ 30% Inap-plic-able 5 mm cable - - - - 7 mm cable - 250N - 250N5.10 Mechanical tensile test Load for contact braking test 8 mm cableInapplicable- 250NInapplicable - 250N5.11 Insulation removal test see ISO 3808/1 5.12 Oil resistance test (Max tolerance) -1% +4% -1%+4%
47、5.13 Fuel resistance test (Max tolerance) 6% 6% Appendix Table #1. Application test and requirements according to the class and type of ignition cables EDS-T-5208UNSCREENED HIGH-TENSION IGNITION CABLES PAGE: 9/13 ISSUED DATE: 1992. 03. 04 REVISED DATE: 2009. 10. 27 VERSION: 3 GM DAEWOO Auto & Techno
48、logy Class C D Test item Type 1 2 3 4 1 2 3 4 5.1 Insulation failure test Applicable Inapplicable Applicable Inapplicable5.2 Thirty-minute-test voltage and dielec-tric breakdown test Applicable Applicable 5 mm cable (232) (702) 7 mm cable (232) (702) 5.3 Capacity test 8 mm cable (232) (702) Capacity
49、 control shall be done after consultation between cable manufacturers and users. 5 mm cable AC 12KV (50 or 60 Hz) 7 mm cable AC 15KV (50 or 60 Hz) 5.4 Resistance test under corona discharge 8 mm cable AC 18KV (50 or 60 Hz) 5.5 Pressure test at high temperature (1202) - Temperature (1552) (1802) 5.6 Thermic overload test Tolerance (unit: %) - - +50-30- - - +50 -30 - Temperature - - 5.
