WORLDWIDE eer sacl General Specification Gmw3i91 Sau NAP) Connector Test and Validation Specification 1 Introduction 1.4 Scope. 1.2 Mission/Theme. 1.3 Classification, 2 References.. 2.1 Extemal Standards/Specitications.. 2.2 GM Standards/Specifications... 2.3 Additional References, 3 Test Preparation and Evaluation. 3.1 Resources. 3.1.1 Calibration, 3.1.2 Alternatives. 3.4.8 Facilities. 3.44 Equipment. 3.48 Test VehiclelTest Piece. 3.4.6 Test Time. 7 3.1.7 Test Required information. 3.4.8 Personnels 3.2 Preparation, 8.2.4 Conditioning... Figure 1: Terminal Conditioning 3.3 Conditions... 3.3.1 Environmental Conditions. 3.9.2 Test Conditions. 3.4 Instructions... 3.4.1 Visual Examination, 3.5 Data, 3.6 Safety. 3.7 Documentation 3.7 Test RESUS. rennin 8.7.2 Deviations from Test Procedure... 3.8 Test Tolerances. © Copyight 2012 Genera Motors Company Al Fighs Reserved ‘June 2012 ‘Originaing Deparment: Noth Amatican Enginearing Sanaarde Page 10179GM WORLDWIDE ENGINEERING STANDARDS. GMw3191 3.8.1 Default Tolerances. 9 Table 1: Parameters and Tolerances. 9 ‘4 Requirements and Procedure . 9 4.1 Classification. o 9 4.4.4 Temperature Class... stn 9 Table 2: Temperature Class (T). ea 10 4.1.2 Vibration Class. 7 10 Table 3: Vibration Class (V) 10 4.1.3 Sealing Class, 10 Table 4: Sealing Class (8)... 10 4.4.4 Connector Mating Force Class. . sn ane 10 ‘Table 5: Connector Mating Force Class (M) renee 4.4.5 Test Procedures and Sequences. 4 4.2 Mechanical Tests... 4.2.1 Crack Corrosion 4.2.2 Crimp Weld Integrity. . 4.23 Terminalto-Terminl Engegement Force 4.2.4 Terminalto-Conneclor Engagement Force. 4.2.5 Terminal-from-Connector Extraction Force. ‘Table 6: Minimum Extraction Force - Terminal from Connector Cavity. 14 4.266 Terminal Cavity Polarization. 14 4.2.7 Terminal Bend Resistance... ‘ 15 Figure 2: Terminal Design Style 16 Figure 3: Terminal Bend Test . se 16 ‘Table 7: Terminal Size and Applied Bending Force. : 16 4.28 Connector-to-Connector Engagement Force. 16 4.2.9 Terminal Position Assurance (TPA). 7 Table 8: TPA Removal Force Table... : 18 4.2.10 Lever and Slide Open Position Retention... 18 Figure 4: Retention of Slide in the Open Position 19 4.2.11 Mechanical Assist integrity . 19 Figure 5: Side Force Strength... 20 4.2.12 Connector Mounting Feature Mechanical Strength. a 20 Figure 6: Connector Mounting Fixture Strength Example.n. : 21 Figure 7: Connector Mounting Fixture Strength Test Setup, 3-Dimensional View. se A Figure 8: Connector Mounting Fixture Strength Test Setup, End View. 22 Figure 9: Connector Mounting Fixture Strength Test Setup, Side View 22 4.2.13 Connector Audible Feedback... tne 22 4.2.14 Connector Lock Mechanical Overstress.. 23, ‘©.Copytght 2012 General Mors Company All Rights Reserved June 2012 Page 2 of 78GM WORLDWIDE ENGINEERING STANDARDS _ GMW3191 4.2.15 Connector Position Assurance (CPA)... 4.2.16 Connector Seal Retention - Mated Connector. 4.2.17 Connector Seal Retention - Unmated Connecter... Figure 10: Unmated Connector Seal Test 4.2.18 Locked Connector Disengagement Force. Table 9: Locked Connector Disengage Force 4.2.19 Unlocked Connector Disengagement For62. nnn 4.2.20 Connector Polarization (Coding) Feature Effectiveness... 4.2.21 Mechanical Shock. Figure 11: Series Circuit Montoring Figure 12: Vibration Mounting Fixture Table 10; Mechanical Shock. Figure 13: Continuity Loss wn Figure 14: Continuity Loss for SIR Connectors. 4.3 Electrical Tests. 4.3.4 Maximum Current Rating Figure 15: Draft-Free Enclosure. Figure 16: Base Curve. Figure 17: Derating CUnv@ nnn 4.32 Dry Circuit Resistancs, Figure 18: In-Line Circuit Lead Location... Table 11: Maximum Resistance Values. 4.33 Vokage Drop. Figure 19 - Terminal Inser8on wun Figure 20: Current Resistance Test Setup, a a 36 Figure 21: Typical Connection Resistance Milivelt Lead Locations 4.3.4 1008-Hour Current Cycling... a7 4.35 Isolation Resistance. sono 38 4.36 Dielectric Strength 38 4.4 Environmental Tests. 39 8ssssRes 4.44 Thermal AgINg. 0 39 4.4.2 Thermal Shock... 40 4.4.3 Humid Heat Cyclic (HHO)... A Table 12: Cyelic Humiity Requirements. “1 Figure 22: Cyclic Humidity Profile seven A Table 13: Cyclic Humisity Profile 4.4.4 Humid Heat Constant (HHCO), Toble 14: Constant Humidity Requitements «nu 4.4.5 Heavy Duty Test... {© Copyight 2012 Ganaral Motors Company All ight Reserved ‘June 2012 Page 3 of 79GM WORLDWIDE ENGINEERING STANDARDS GMW3191 4.46 Flammability. . 45 : 45 48 47 AT 4.47 Corrosion. 444.8 Vibration wth Thermal Cyeling Figure 28: Thermal Gye... Table 16; Thetral Cycle Renutements Figure 24: Body (Sprung Masses) Random Vibration Schedule ee 47 ‘Table 16: Body (Sprung Masses) Random Vibration Schedule 48 48 48 Figure 25: Engine Mounted Sinusoidal Vibration Cycle (based on ISO 16750-3) Table 17; Engine Mounted Sinusoidal Vibration Cycle (based on ISO 16750-3).... Figure 26: Engine Mounted Random Vibration Cycle (based on 'SO 16750-2)... 49 Table 18; Engine Mounted Random Vibration Cycle (based on ISO 1670-3) nse Figure 27: Whee! Random Vibration Cycle. 0 Table 19: Whee! Random Vibration Cycle 50 Figure 28: Severe Applications Sinusoidal Vibration (based on ISO 16750-3) 51 Table 20: Severe Sinusoidal Vibration (based on !SO 16750-3) ann 51 Figure 20: Severe Random Vibration Cycle (based on ISO 18750-2). 82 62 Table 21; Severe Random Vibration Cycle (Severe Appcations; based on ISO 1750-8 xn Table 22: Generic Vibration Profiles for Transmissions (12 to 20 000) Hz. 63 4.4.9 Water Submersion. 53 Figure 30: Water Submersion Setup. . 7 : 54 4.4.10 Pressure/Vacuum Leak. 54 4.4.11 High Pressure Spray... 7 56 Figure 31: Nozzle and Jet Dimensions .. eam oat asiH67s Table 23: Spray Pattern 87 Figure 32: High Pressure Spray Test Arangement : 58 4.4.12 Fluid Resistance. 58 Table 24: Fluids. 60 4.5 Miscellaneous T8818, neu 60 4.8.4 Resistance of Short Circuit Devices. 60 Figure 33: Electical Resistance of Shorting Bars. sn 61 4.82 Terminal Push-out Foros... et Table 25: Push-0ut Force urn 62 4.6 Further Requirements, 62 4.6.1 Test Sequences... i 62 Table 26: Terminal Mechanical Tests. 3 Table 27: Terminal Electrical Test. 64 Table 27: Terminal Electical Tests (continued). 65 Table 28: Connector Mechanical Tests... oo 66 Table 28: Connector Mechanical Tests (continued) er © Copyight 2012 Genera Motors Comgany A Rights Reserved ‘June 2012 Page 4 of 79GM WORLDWIDE ENGINEERING STANDARDS GMW3191 Table 28: Connector Mechanical Tests (continued) 63 Table 28: Connector Mechanical Tests (continued) 69 Table 29: Sealed Connector Environmental Tests. 170 Table 28 Sealed Connector Environmental Tests (corteued) Table 30: Unsealed Connector Environmental Tests Table 31: Connector Validation Test Matrix 6 Provisions for Shipping 6 Notes 61 Glossary. Not applicable 62 Acronyms, Abbreviations, and Symbols. 7 Additional Paragraphs. 7.1 Allparts or systems supplied to this standard 8 Coding System nur 9 Release and Revisions Appendix A. : Data Sheet At Elecial Connection System ~ Test Summary © Conyght 2012 General Mets Company Al Rights Reserved ‘June 2012 Page 50f79.‘GM WORLDWIDE ENGINEERING STANDARDS GMw3191 1 Introduction Note: Nothing in this standard supercedes applicable laws and regulations. Note: In the event of conflct between the English and domestic language, the English language shall take precedence. 1.1 Scope. This standard defines the requirements, functional tests, and durabilty tests for low voltage ‘auiomotive single and muliple-pole electrical connectors, terminals, and related components. Procedures Included within this specification are intended to cover performance testing al all phases of development, production, and field analysis of electrical terminals, connectors, and components that constitute the electrical ‘connection systems. 1.2 Mission/Theme. Define test and validation requirements including test sequences for electrical connection systems. 1.3 Classification. Not applicable. 2 References Note: Only the latest approved standards are applicable unless otherwise specified. 2.4 External Standards!Specifications. ASTM IRM-902 EN 590 IsorTs16949 USCAR23 ‘ASTM IRM-903 EN 60068-2-6 SAE S127 USCAR25 ASTM Reference Fuel CEN 60068-2-64 SAE J1128 USCAR3B ASTM Service Fluid 104 IEC 60068-2-38 SAE RM68-04 Citgo #33123 1EC 60088-2-78 uscar21 2.2 GM Standards/Specifications. B 040 0900 B040 2012 omw3t72 040 1065 ooo 102 omw3232, B 040 1073, Ghaw3059 omwi4914 2.3 Additional References, 1SO/TS16948 Certification 3 Test Preparation and Evaluation 34 Resources. 3.1.1 Calibration. The test facilities and equipment shall be in good working order and shall have a vali calibration label. (Ae required by ISO/TS16949.) 3.1.2 Alternatives. Alternative test facilties and equipment may also be used. However, all measuring ‘atlabies as specified in this standard shall be determined correcty with respect to their physical definition, 3.1.3 Facilities. Al facities and test equipment shall be ISO/TS 16949 certfied. 3.1.4 Equipment. Test equipment shall be capable of measuring the physical and electrical parameters as specified All meters and gauges used in measurements of the test sample shall be capable of measuring to one significant digit less than the specified value. 3.1.5 Test Vehicle/Test Piece. Electrical connectors used for testing shall be manufactured according to the values and the tolerances that are shown on the drawings or the releases. Materials shall conform to ail pectcations shown on the respective crawings. Specific sample quantity requirements are detalled in each tost procaduro, Sea test sequences in Section 4.6 to determine which tests are required. Should a lost failure ‘occur, consult with the responsible GM engineer to determine ifthe testis to be continued to gain additional product experience or if testing shall be terminated. 3.1.5. Terminal Attachment. Terminals shall be affixed to the cable using production intent processes per USCAR21 mechanical crimp or USCAR38 ultrasonic weld specifications. © Copyight 2012 General Motors Company Al Fighs Resorved ‘June 2012, Page 6 of 79GM WORLDWIDE ENGINEERING STANDARDS GMW3191 3.1.8.2 Disposition of Samples. Test samples shall be retained for examination and further analysis and shall ‘ot be disposed of without permission of the responsible GM connector and validation engineers. 3.1.6 Test Time. Not applicable. 3.1.7 Test Required Information. Not applicable. 3.4.8 Personnol/Skills. Not applicabie. 3.2 Preparation. 3.2.4 Conditioning. The following conditioning shall be performed as defined on connectors and terminals prior to the test procedures specified in this specification: 1. Attach wires of appropriate gauge size to terminals. b. Insert terminated leads into the specific connector housings undergoing testing, if required, . For tests that do not require connector housings, mate and unmate the fomalo terminal with the corresponding male terminal 10 times being careful not to cause overstress to the contact spring, 4, For tests on connectionvterminal assembles, male and unmate the connectors with terminals 10 times with the corresponding connector or header interface, except when performing Section 4.2.8, which requires unmaled virgin test samples. . For tests on connection'terminal assemblies with terminals sizes 2.8 mm and smaller, stress terminals by ingerting a male terminal or equivalent test pin into the female terminal. The male terminal or test pin shall ‘corrospond in size to the female terminal being tested. Insert the test pin and apply a force of 0.5 N in each direction as shown in Figure 1 for 10 seconds. Note: A terminal shall be stressed in only one direction, thus for another axis stress another terminal. Thus it takes four separate terminals to stress in each of the four directions, 4 terminals, each in one direction only Figure 1: Terminal Conditioning f. Connector housings without terminals shall be aged for 2 minimum of 24 hours at (+403)°C and a relative humidity of 95% to 98% prior to performing any connector mechanical testing, 1g. Store test samples at an ambient temperature of (+23 + 8) °C for at least 24 hours prior to performing any ‘electrical testing regardless of connector housing material 3.3 Conditions. (© Copyright 2012 General Moors Company Al Fighs Reserved June 2012, Page 7 of 79GM WORLDWIDE ENGINEERING STANDARDS: GMw3191 3.3.1 Environmental Conditions. Not applicable. 3.3.2 Test Conditions. Deviations from the requirements ofthis standard shall have been agreed upon. Such requirements shall be specified on component drawings, test certificates, reports, etc. 3.4 Instructions. 3.4.4 Visual Examination, 3.4.1.4 Purpose. Assure parts used for testing are free of damage and obvious defects. 3.4.1.2 Equipment. Normal lighting, photographic equipment, a device with at least 10x magnification 3s required. 3.4.4.8 Sample Preparation. All test samples shall be conditioned per 3.2.4 3.4.1.4 Procedure. Not applicable. 3.41.5 Pre-Test Visual Examination. Visually examine each test specimen before testing andior Conditioning. The test specimens shall not exhibit any evidence of deterioration, cracks andlor other deformities that could affect performance, function andior appearance. A control sample shall be retained Photographs andlor video recordings of the samples being tested shall be taken. 3.4.1.6 Post-Test Visual Examination. After testing, re-examine each test sample and note in detail any ‘observable changes, such as swoling, corrosion, discoloration, physical distortions, cracks, etc. Compare the tested samples to the folowing items, noting any differences: ‘© Controt sampies = Videos © Photographs 3.4.1.7 Acceptance Criteria. There shall be no corrosion, discoloration, cracks, etc., which could affect the functionality of the part. Swelling or physical distortion shall not exceed the tolerances specified on the part drawing. 3.5 Data. Not applicable. 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. itis the responsibilty ofthe user of this, standard to establish appropriate safety and healtn practices and determine the applicabilly 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 ofthis standard and approved by the responsible GM department prior to the start of delivery of production level components or materials, ‘Any change to the component or material, ©.g., design, function, properties, manufacturing process andlor location of manufacture requires @ new release of the product. itis the sole responsibilty of the supplier to provide the customer, unsolicited, with documentation of any change oF modification to the productiprocess, ‘and to apply for a naw release. 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 to between the responsiole GM department and the supplier. ‘The supplier shall maintain adequate records ofall tests performed and their resulls as specified by TS16949, Documentation shall include a copy ofthe test facility certification, ‘Arminimum of 5 fully assembled samples from the same batch as the tested sample shall accompany the initial test report. The sample connectors shall be fully assembled with terminals, cables, and seals. Terminals with crimped on wire seals shall be fully sssembled with cables and seals The supplier shall inform the GM Connector Design Release Engineer (DRE) of al adjustments, modifications. of parts and/or processes required to comply with Production Part Approval Process (PPAP). 3.7.4 Test Results. Test results shall be reported in a detailed format as defined in Appendix A, with one ‘summary per test sequence. Each sequence and its specific results shall be reported. Any failures shall be documented and include the requirement that was not met. Additional documentation may be attached (0.9., © Conyeght 2012 General Motors Company Al Rights Reserved ‘June 2012, Page 8 of 79GM WORLDWIDE ENGINEERING STANDARDS GMw3191 pletures, charts of measurements), The summary test form is contained in Appendix A. Raw test data shall be provided when requested. 3.7.2 Deviations from Test Procedure, Deviations from this test procedure shall be approved by the GM Connector DRE and documented before beginning any testing. Such deviations shall be specified on component drawings, test certificates, reports, etc. 3.8 Test Tolerances. 3.8.1 Default Tolerances. Unless stated otherwise, Table 1 shall define the test environment parameters and tolerances to be used forall validation testing. Table 4: Parameters and Tolerances ““*? Requirement Tolerance ‘Ambient Temperature AAs Speaified, #3 °C Room Temperature eeaittt (923 £5)°0 Room Ambient Relative Humidity 30% t0 70% ‘Chamber Humicity| AS Specified, = 5% Voltage ‘As Specified, «0.1% Current ‘As Specified, # 1% Resistance ‘As Specified, + 1% Random Acceleration (Gru) ‘As Specified, + 20% *"* ‘Acceleration (Mechanical Shock. 6) ‘As Speatied, + 20% Length ‘As Specified, 21% Test Time He ‘As Specified, # 0.5% Force ‘As Specified, # 5% Frequency As Specified, = 1% Distance (Excluding Dimensional Check) if AAs Specified, # 1% Flow Rate __As Specified, # 5% Relative Velocity AAS Speoiied, 50 # 10 mmminute (ote 1: Netto be used for partomance-dependont variables. Hoe P30 dans om apni a ae reid wt QM roa San = Reo Mean Sauce 4 Requirements and Procedure 4.1 Classification. Electrical connectors are classified by temperature class, vibration class, seating class and mating force cass. 4.1.1 Temperature Class. Table 2 defines the general temperature classes for electrical connection systems within the vehicle. © Conyight 2012 General Nolors Company All Rights Reserved ‘June 2012 Page 8 of 79GM WORLDWIDE ENGINEERING STANDARDS. GMW3191 Table 2: Temperature Class (T) Class ‘Ambient Operating Temperature ‘Typical Installation Position 1 (£4010 +88) °C Passenger compartment or trunk 2 (4010 H105)°6 Underhoed, chassis 3 (oto +428)°C (On engine, transmission 4 (4010 +150) °C ‘On engine (hot locations) 5 Per connector CTS. Per CTS Ge ‘Component Techni! Speatestion 4.1.2 Vibration Class, Table 3 defines the general vibration classes for electrical connection systems within the vehicle. Table 3: Vibration Class (V) ‘Typical installation Position ‘On body or chassis ‘On engine ‘On wheel, Unsprung Mass ‘Severe applications (6.9., ECU, Throttle Body, EGR) “Transmission (intemal and external) ec gine Conte Unk EGR» Exhaust Gas Reckulaton Note: As defined in GMW3172, the traditional target life of 160 000 km (100.000 mi) shall be classified as Target Life 1. When Target Life is expected to exceed this, the classification shall be labeled as the multiple of this tracitional target life, Le., 240.000 km (180 000 mi) shall be labeled as Target Life 1.5 and 320 000 km (200 000 mi) as Target Life 2. Uniess otherwise specified, connectors will be validated to Target Life. 4.1.3 Sealing Class. Table 4 defines the general sealing classes for electrical connections systems within the vehicle. Table 4: Sealing Class (8) Description ‘Typical Installation Position Unsealed Passenger compartment or trunk 2 ‘Submersion Sealed Underhood or exposed areas, including door Exposed areas where high pressure spray is 3 High Pressure Spray Protected isqauedl 44.4 Connector Mating Force Class. Table § defines the general connector mating force classes for electrical connections systems within the vehicle. Refer to USCAR25 for specific design and performance requirements. © Copyright 2012 Ganera Motors Commany Al Rights Reserved June 2012, Page 10 of 79GM WORLDWIDE ENGINEERING STANDARDS _GMw3191 Table 5: Connector Mating Force Class (M) Class ‘Maximum Allowable Mating Force 1 22N 2 45N 3 T5N 4,15 Test Procedures and Sequences. The supplier shall follow all of the procedures defined under each test section. The supplier shall folow the test sequences defined in Section 4.6. 4.2 Mechanical Tests. 4.2.4 Crack Corrosion. 4.2.4.4 Purpose. This test is used to determine the susceptibility to stress-corrosion of any portion of terminals made from un-plated copper-zine alloys. ‘This test Is carried out by exposing test sample components to suitable corrosive media under controlled conditions for specified time periods and then examining for induced cracking. This test shall be run on any terminal that has any unplated copper/zinc (copper content less than or equal to 70%) based section 42.4.2 Equipment. ‘© Glass test vessel of suitable size (= 150 mm high) to contain test samples and requisite volume of test medium. The test vessel shall be fitted with 2 gas tight glass lid and suitable glass grid or frame to allow suspension of the test plece above the test medium, ‘+ Magnification equipment to provide at least 10* magnification 4.2.4.3 Sample Preparation. 42.1.3.1 Test Samples. Finished terminals crimped to wires. 4.2.1.3.2 Numbor of Tost Samples. Three (3) minimum. 42.1.4 Procedure. 1. Clean contacts or material to be tested by degreasing in @ suitable alkaline cleaner or organic solvent. I necessary, immerse parts for approximately 30 seconds in either sulfuric acid (10% by mass) or ritric acid (30% by mass) and then rinse in clean running water to remove any surface oxides. Dry the paris thoroughly. 2. Prepare the test media using commercial grade reagen’s and disiiled or de-ionized water Composition of test medium: Ammonia solution (25% by mass) diluted with water to a ratio of 1 to 1 (Gensity at #20 °C: 0.946 glam to 0.950 giom. Unless otherwise specified, the test shall be performed at an ambient tamperature of (#23 # 6) °C. 4. Fill the test vessel with the ammonia solution to a depth of = 30 mm. Suspend the cleaned test samples at a height of 80 mm above the surface of the ammonia solution and seal the test vessel Expose the samples for (24 # 1) hours. Note: Deviations from the continuous time requirement shall be noted on the test report. If itis necessary to interrupt the test, test samples may be removed from the vessel and stored in de-lonized water for up to 16 hours, dried and then re-exposed to the ammonia medium for the remainder of the time required 5. Following the 24 hour ammonia exposure, submerge the samples in either sulfuric acid (10% by mass) ‘oF nitric acid (30% by mass) at (+23 + 5) °C for 30 seconds to 60 seconds. 6. Examine the parts using at least 10* magnification. Observe and note any cracks, 42.4.5 Acceptance Criterla. The surface shall be free of cracks. 4.2.2 CrimpiWeld Integrity. 4.2.2.1 Purpose. The purpose of this procedure is to verily cable attachment integrity and conformance to performance requirements. All cable to terminal attachment configurations shall be verified © Copyight 2072 Genera Motors Company Al Righs Reserved June 2012, Page 11 of 78GM WORLDWIDE ENGINEERING STANDARDS ~__ GMW3191 4.2.2.2 Sample Preparation. Crimp terminals used for testing connectors shall be crimped to the requirements defined in USGAR 21, "Performance Specification for Cable to Terminal Electrical Crimps”. Ultrasonically welded terminale used for testing connectors shall be welded to the requirements defined in USCAR38, “Performance Specification for Ultrasonically Welded Wire/Cable Termination’. Use the appropriate cable seal as applicable. 4.2.2.3 Procedure. 4.22.3:1 Cable to Terminal Crimps. Cable to terminal crimps shall be validated per USCAR21. Refer to USCAR2I for test procedure. Terminal crimps forall wire sizes specified for the terminal shall be completed, 42.2.3.2 Cable to Terminal Welds and Welded Splices. Cable to Terminal Welds and Welded Splices shall be validated per USCAR38. Refer to USCAR38 for test procedure. Cable Terminals Welds and Welded Splices for all wire sizes specified for the terminal shall be completed. 4.2.2.4 Acceptance Criteria, The terminals shall meet the acceptance criteria defined in USCAR21 and USCAR3B specifications. 4.2.3 Terminal-to-Terminal Engagement Forc 4.2.3.1 Purpose. Quantify the force required to insert @ male terminal into a female terminal 4.2.3.2 Equipment. insertion/Extraction tester with peak force reading feature. 4.2.3.3 Sample Preparation. 42.3.3.1 Test Samples. Male and female torminals with attached wire leads. 4.2.3.3.2 Number of Test Samples. Ten (10) terminal pairs, minimum, 42.3.4 Procedure. 1. Secure terminals to bs tested onto fixtures. 2. Mate terminals at a uniform rate of (50 + 10) mm/minute unt fully engaged. 3. Record peak force and graph force versus distance from initial terminal to terminal contact to the fully engaged position. 4.2.3.8 Acceptance Criteria, Documentation purposes only. 42.4 Terminal-to-Connector Engagement Force. 4.2.4.1 Purpose. The purpose of this testis to quantify the force required to insert a terminal with an attached wire lead into an appropriate connector body. 4.2.4.2 Equipment. Insertion/Extraction tester with a peak force reading feature 4.2.4.3 Sample Preparation. 42.4.3. Test Samples. Terminated leads, including appropriate wire seals (if applicable) and suitable ‘connector bodies. 42.4.3.2 Number of Test Samples. Minimum of 10 terminals and an appropriate number of connector bodies. Note: Terminated leads shall be constructed from the smallest and largest wire size specified for the respective terminals as listed below. 4.2.8.4 Procedur 42.4.4 Terminal Position Assurance (TPA) in Open Position. ‘1. Mount the connector with the TPA in the Open position into a fixture. 2. Secure a terminated lead into a sultable fixture approximately 20 mm from the back of the terminal or ‘seal, Take special care when securing he terminated lead so that the lead fixture does not interfere ‘with full terminal insertion during the test. 3. Insert terminal into connector at a uniform rate of (50 + 10) mmiminute until fully seated and locked. 4. Record peak force and graph force versus distance from intial contact of terminal to connector body to final engaged positon. 4.2.4.4.2 TPA in Fully Seated Position. 4. Mount a connector with a fully seated TPA into a fixture. © Conynght 2012 General Motors Company Al Rights Reserved June 2012 Page 12 0f 79‘GM WORLDWIDE ENGINEERING STANDARDS GMw3191 2. Secure a terminated lead into @ suitable fhture approximately 20 mm from the back of the terminal or ‘seal. Take spacial care when securing the terminated lead so that the lead fixture does not interfere with fil terminal insertion during the test 3. Insert the terminal into the connector at a uniform rate of (50 + 10) mm/minute until itis either fully ‘seated and locked into the cavity or all forward motion of the terminal ceases due to interference between the terminal and the TPA or the maximum test insertion force reaches 75 N. 4. Record peak force and graph force versus distance from initial contact of terminal to connector body to final engaged position. 4.2.4.5 Acceptance Criteria. 4.2.4.5. TPA in Open Position. 1. For terminals with less than 1.0 mm? wire, the maximum engagement force to fuly seat and lock the terminal shall be less than 15 N, For terminals with 1.0 mm? or larger wire, the maximum engagement force to fully seat and lock the terminal shall be less than 20 N. 3, The forward stop shall withstand a push-through force of 25 N or the column strength of the largest applicable conductor size, whichever is smallest 4.2.4.5.2 TPA in Fully Seated Position. 1. For terminals with less than 1.0 mm? wire, the minimum engagement force to fully seat and lock the terminal shall be 30N of the terminal shall not be capable of being seated and locked due to Interference between the TPA and the terminal. 2. For terminals with 1.0 mm? wire, the minimum engagement force to fully seat and lock the terminal shall be 40 N or the terminal shall not be capable of being seated and locked due to interference between the TPA and the terminal. 3. For terminals with greater than 1.0 mm? wire, the minimum engagement force to fully seat andl jock the terminal shall be 60N or the terminal shall not be capable of being seated and locked due to Interference between the TPA and the terminal 42.5 Terminal-from-Connector Extraction Force. 42.5.1 Purpose. Quantiy the force required to remove a terminated lead from the connector body. 42.5.2 Equipment. + Pull tester with peak force reading feature. + Climatic chamber capable of 95% to 98% Relative Humiity at +40 4.2.5.3 Sample Preparation, 4.2.5.3.1 Test Samples. Terminals crimped to the maximum wire size specified for the respective terminal and compatible connectors. 4.2.5.3.2 Number of Test Samples. Fifty (60) terminated leads and a sutficient number of connectors to support the 50 terminals. Note: All cavities of a connector shall be tested, 425.4 Procedure. 1, Assemble connectors and 10 of the terminals including ali seals and other necessary components but ‘without the TPAs. Designs using pre-staged TPAs shall have the TPA in the pre-staged position. 2. Secure the connector into a fature 3, Attach the lead to the pull tester at a point less than 100 mm behind the rear ofthe terminal, 4, Pull the lead at a uniform rate of (60 + 10} mm/minute until pull-out occurs. Note the pull-out value and fallure mode. 5. Record peak force required to pull the terminal out of the connector cavity. If the conductor breaks or pulls out ofthe terminal before the terminal pulls out ofthe cavity, record this force and note the failure mode. 6. Using new test samples repeat Stops 1 thru Step 5, but with all TPAs fully seated. (© Copytight 2012 General Metars Company All Rights Reserved ‘June 2012 Page 13 0f 79GM WORLDWIDE ENGINEERING STANDARDS. _GMW3191 7. Using new teat semples and fully seated TPAs, repeat Steps 1 thru Step § using connectors that are moisture conditioned by being exposing to 95% to 98% Relative Humidity at +40 °C for 6 hours. The pull test shall be performed immediately following removal of the connectors from the temperaturelhumidity chamber. 8. Using new test samples and fully seated TPAs, repeat Steps 1 thru Step & immediately after 4.4.1 9. Using new test samples and fully seated TPAs, repeat Steps 1 thru Step 5 immediately after 4.4.3. 4.2.5.5 Acceptance Criteria. The terminal extraction force shall meet the requirements specified in Table 6. Table 6: Minimum Extraction Force - Terminal from Connector Cavity Primary Lock and TPAIPLR and | Post Thermal Aging Section 4.4.4 Post-Moisture Conditioning per Heat Cyclic (HHC) Terminat | Primary Lock ae omy Section 4.2.5.4, tem 8 Section 4.43 0.50 mm 20N eon SON 0.84 mm 30N oN SON 7 1.5mm ‘SON 80N 70N 26mm | 60N 100N ON 563mm oon 120N +10N 95mm 100 : 150N 140N >95mm 100N 200N 190N fl PLR = Premary Leck Fetetion 4.2.6 Terminal Cavity Polarization. 42.6.1 Purpose. This test Is conducted to ensure that the design of the cavity and the terminal polarization features will prevent insertion of a terminal in an improper orientation Note: This procedure is not required for terminal designe that are designed to plug and lock in any orientation. Note: If surrogate data is used to full the requirements of this test, the design of the cavity, terminal, cable, ‘cavity wall thicknesses and all materials (except terminal plating) shal be identical. The responsible Connector Engineer shall datermine the need for individual testing in cases where all terminal and cavity criteria are not identical 4.2.6.2 Equipment. ‘+ Insertion Force Tester with peak reading feature and all necessary fixtures or jigs. ‘+ Sufficient number of connectors to test each incorrect terminal orientation ten (10) times, using a new cavity for each trial 42.6.3 Procedure, 11. By analyzing the cavity and terminal design, choose the incorrect terminal orientations to be tested. At ‘@ minimum, each incorrect orientation in increments of 90” shail be tested, Rectangular designs where Improper insertion at 20° from horizontal is clearly not possible do not need to be tested. It is ppermissiole to test these designs in 180” increments. The responsible GM Connector Engineer is the final authority for determining the positions to be tested. 2. Prepare leads using the largest size conductor and insulation thickness applicable to the design. 3, Secure the connector housing in an appropriate fiture that will not distort the natural state, shape, or ‘geometry of the connector or the terminal cavities. 4, Secure the terminal sample inthe force tester by gripping the conductor a minimum of 20 mm behind the insulation grip. © Copyight 2012 General Motors Compaay Ad Rights Reser ‘June 2012 Page 14 0f 79GM WORLDWIDE ENGINEERING STANDARDS omw3191 | ‘8. Adjust the connector holder and force tester to insert the terminal in one of the “incorra ‘chosen in Stop 1 6. Push the terminal into the connector at a uniform rate of 50 mm/minute until the test force is 1.5 times the maximum force recorded in Section 4.3.1, Terminal to Connector Engagement Force, or 15 N. whichever is greater. 7. Record results:, Le, terminal seated in cavity, terminal insarted but did not seat and to what approximate depth, terminal did not enter cavity, cable buckled, etc. 8. Repeat Steps 4 thru Step using new terminals, cavities or connectors until all orientations determined in Step 1 have been tested. 9. Complete the visual examination of the terminals and connectors per Section 3.4.1.7 4.2.6.4 Acceptance Criteria. Terminals inserted in any incorrect orientation shall not fit or lock into @ connector cavity at @ force 1.5 times the normal insertion force, 15 N, or the column strength of the largest applicable wire size, whichever Is greater. There shall be no visible damage to either the terminal or connector that would prevent subsequent correct Insertion and function following any attempt at incorrect insertion per this procedure. 4.2.7 Terminal Bend Resistance. 42.7.4 Purpose. This test checks for a minimum level of terminal strength to resist bending or breakage during crimping, assembly, or service. Actual bending force values in each of three directions are recorded, 42.7.2 Equipment. ‘+ Special steel mounting fixture(s) appropriate to the terminal's) under test. + Linear Force Tester with peak reading feature or weights per Table 7 4.2.7.3 Procedure. 1, Using Figure 2, determine which design style most closely resembles the terminal under test. 2. Prepare terminal samples per Section 3.2, Tast Samples using the smallest size conductor with the thinnest insulation specified for the terminal to be tested. 3, Repeat Stop 2 except use the largest conductor size with the thickest insulation specified for the terminal to be tested 4, Number each terminal 5, Mount the terminal in a fixture taking care that location "1" is positioned as shown in Figure 3. 6. Apply the force specitiad in Table 7 on the insulation crimp wing to the sample as showin in Figure 3 for 15 seconds and reloase. 7. Inspect the area around the bend using at least 10% magnification. Note in the test report any signs of ‘meatal cracking or tearing, 8 Straighten the terminal to its original position and re-inspect the terminal for signs of metal cracking or tearing, Note in the test report any signs of metal cracking or tearing, 9. Select a new batch of at least § samples and mount them in a test fixture with the terminal rotated 180" from the postion shown in Figure 3, Repeat Steps 4 thru Step 8 40. Select 2 new batch of at least § samples and mount them in the test fixture with the terminal rotated 0° from the position shown in Figure 3. Repeat Steps 4 thru Step 8, Note: Since terminals are typically symmetrical in this "side to side" direction, itis not necessary to test oth directions. If the terminal is not symmetrical both directions shall be tested. Consult the GM Connector DRE for guidance in this regard 11, For terminal style "B designs in Figure 2, repeat Steps 4 thru Step 10 with each terminal mounted ‘such that location "2" is firmly retained at the edge of the fixture. 42.7.4 Acceptance Criteria, The terminal shall not tear or crack when subjected to the applied force for 15 seconds. If the terminal bends from its original position during the test, it shall not tear or crack when straightened to its original postion, orientations (© Copyright 2012 General Motors Company Al Rights Reserved ‘June 2072 Page 15 of 79‘GM WORLDWIDE ENGINEERING STANDARDS GMw3191 Location 1" Location on ] a 4 ) STYLE “A STYLE “8° Figure 2: Terminal Design Style Location “1” _Center Line Fixture TUT = Terminal Under Test Figure 3: ‘Table 7: Terminal Size and Applied Bending Force Terminal Size ‘Applied Force ee osmm ee 30N (0,64 mm to 1.5 mm 40N 1.5mm to28 mm 7ON 2.8mm (06.3 mm 0.0N 63mm (095mm 160N { 295mm 20.0N 42.8 Connector-to-Connector Engagement Force. 4.2.8.1 Purpose. This test quantifies the force required to engage fully populated fernale and male connectors. to each other, Note that this test shall also be used for connectors with manually operated mating assist devices such as slides, levers or cam locks. In this case, the force required to manually operate the (© Copysght 2012 Genaral Moors Company All Fights Reserved ‘June 2012 Page 16 of 79GM WORLDWIDE ENGINEERING STANDARDS: ‘GMW3191 mechanigal assist in mating and unmating the fully populated connector is measured. This also applies to pre-staging of connectors having bolts, side locks, or other locking assist devices. 42.8.2 Acceptance Criteria. Refer to USCAR25 for Procedure and Acceptance Criteria of Connector to Connector Engagement Requirements. 4.2.9 Terminal Position Assurance (TPA). 4.2.9.1 Purpose. This testis used to determine the mechanical function of the TPA. The purpose of ths testis to prevent intermittent electrical function caused by an incom pletely/improperly inserted terminal 42.9.2 Equipment. ‘+ Insertion/Extraction tester with peak reading feature. 4.2.9.3 Sample Preparation. Obtain 3 minimum of ten (10) samples of connectors and components to be tested. No special semple preparation is required. 4.2.9.4 Procedure, 4.2.9.4. TPA Retention Capability (Pre-lock Position to TAP Removal from Connector Force and Pre- lock Position to TPA Lock Position Force) without Terminals. Note: This applies to connectors with pre-assembled TPAs only. 1. Using a suitable fixture, oriant the connector with orientations specified by the design engineer as most likely to defeat the retaining feature. 2. Pull the TPA from the connector at a uniform rate (SO #10) mmiminute. Record peak force and graph force versus distance from intial position of TPA to connector body to final d'sengaged position. 3. Push the TPA into the connector at a uniform rate (50 + 10) mmlminute. Record peak force and graph force versus distance from intial pasion of TPA to connector body to final locked postion 4,2.9.4.2 TPA Preslock to Lock Closing Force with Properly Assembled Terminals, 41. Insert terminals into all cavities of the connector. 2. Secure connector body and TPA into a holding fixture, 3 Insort TPA into connector body at a uniform rate of (60 + 10) mmiminute.. 4, Record peak force and graph force versus distance from initial position of TPA to connector body to final engaged postion, 4.2.9.4,3 TPA Pre-lock to Lock Closing Force with One improperly Assembled Terminal. 1. Study the design of the terminal and TPA and determine the position of the terminal where itis most likely that the TPA is possible to close with the lowest force and stil provide terminal electrical contact Rendomiy select one cavity of each terminal sizeltype. ‘Secure connector body to fixture. Partially insert the terminal Into that position so that it i just short of locking into position. Secure/hold the terminal in that position 5. Insert TPA into connector body at a uniform rate of (50 + 10) mmiminute. 6 Record the peak force and whether or not the TPA seated and locked. 7 8. Properly assemble/insert the out of position terminal into the connector body. Extract the terminal from the connector per the procedure specified in Section 4.3.2 Note: Additional Moisture Conditioning is not required, 9. Remove terminal and inspect for physical damage. 4.2.9.4.4 Retention Force of Seated TPA. ‘1. Seal the TPA in its fully seated position in a fully populated connector. 2. Pull TPA at a uniform rate of (50 £ 10) mm/minute from the fully seated position to the pre-steged position. Record the force. (© Copyright 2012 Ganarat Motors Compsny Al Righs Resored June 2072 Page 17 of 79GM WORLDWIDE ENGINEERING STANDARDS GMw3191 4.2.8.5 Acceptance Criteria, Refer to Table 8. Table 8: TPA Removal Force Table Row Procedure Unprotected TPA"? Protected TPA 4_| TPA Removal from Connector "#? 20.N minimum 20.N minimum 2 | Pre-lock to Lock Position 30.N minim 20.N minimum | without Terminals 45 N maximum 45N maximum 3. | Pre-iock to Lock Position 30.N minimam 20N minimum with Properly Seated Terminals 45.N maximum 45.N maximum 4 | Presiock to Lock Position 0 Nor @0Nor with One Incorrectly Seated Terminal “*"* | 2 the measured value of | 2 x the measured value of RoW 3, Row 3, whichever i larger whichever is larger | TPA Locked to Pre-ocked Position 25 N minimum 20/N minimum 45.N maximum 45.N maximum ‘an ungrtected TPA is one that shows proud ofthe connector body. ‘litoutdamage't the TPA, connecter or terial 4.2.10 Lever and Slide Open Position Retention. 4.2.10. Purpose. This test is used to verify that the retention force of the slide or lever is high enough to prevent it from separating from the connector body and remaining in the pre-lock position. 4.2.10.2 Equipment. + Insertion/Extraction tester with peak force reading feature. 4.2,10.3 Sample Preparation. 4.2.10.3.1 Minimum sample size is five (5) 4,2.10.3.2 No spacial sample preparation is required. 4.2.40.4 Procedure. 4, Make a fixture that will secure the connectors to be tested without distorting any of the parts. ‘Mount the samples in the fixture with the slide or lever in the open position, Apply a 50 N force in direction *F", as shown in Figure 4, atthe rate of (60 + 10) mm/minute, ‘Mount new connectors in the fixture maintaining the slide or lever in the as-delivered pre-lock position. Apply a 150 N force to close the slide or lever at the rate of (50 + 10) mm/minute, Mount new connactors in the fixture maintaining the slide or lever in the as-delivered pre-lock position. ‘Apply an increasing force to the slide or lever at the rate of (50 + 10) mmy/minute until the pre-lock position is defeated. Record the force. © Copyight 2012 General Mtors Company Al Rights Reserved June 2072, Page 18 of 79GM WORLDWIDE ENGINEERING STANDARDS mws191| Figure 4: Retention of Slide in the Open Position 4.2.10.5 Acceptance Criter 4, The slide or lever shall withstand a 0 N force without separation or damage, 2, The slide or lever pre-lock postion shall withstand a 150 N force without inadvertent closure. 3. The slide/iever and the connector body shall withstand the force to defeat the pre-lock position without permanent damage or deformation. 4.2.11 Mechanical Assist Integrity. 4.2.41. Purpose. This testis used to enaure that a lever or side will withstand the handling of the connector ‘and wire harness. 4.2.11.2 Equipment. ‘+ Insertion/Extraction tester, with peak force reading feature 42.11.3 Sample Preparation. 4.2.11.3.1 Minimum sample size is five (5), 4.2.11.3.2 No special sample preparation is required. 42.11.4 Procedure, 1. Make a fixture that will secure the connectors to be tested without distorting any of the parts. 2. Mount the samples in the fixture. 3. Apply a 100 N force in direction “F", as shown in Figure 2, atthe rate of (60 # 10) mmfminute with the lover or side in both the open and closed positions, 4, Apply a 100 N force in the direction opposite to direction *F* at the rate of (50 + 10) mna/minute with the lever or slide in the open and closed positions. 5. Position the slide or lever in @ position approximately half way between the open and closed positions, Aaply a 60 N force in direction “F”, as shown in Figure 4, atthe rate of (60 + 10) mmyminute, 6. Position the slide or lever in @ position approximately half way between the open and closed positions, Apply a 60 N force in the direction opposite to direction "F", as shown in Figure 5, at the rate of (60 = 10) mmiminute. © Copyight 2012 General Motors Company Al Rights Reserved ‘June 2012 Page 19 0f79GM WORLDWIDE ENGINEERING STANDARDS. GMW3191 Figure 5: Side Force Strength 4.2.11.5 Acceptance Criteria. 1. The leverislide shall withstand a 100 N force in the open and closed positions without separation or damage. 2, The loverislide shall withstand a 60 N force in the midpoint position without separation or damage. 4.2.12 Connector Mounting Feature Mechanical Strength. 4.2.12.4 Purpose. This test is designed to test the mechanical strength of clip slots and other designed-in mounting features for electrical connectors. Such features shall withstand mechanical stresses (pulling, pushing, etc.) expected in the vehicle including vehicle assembly, service and repair without functional damage tothe housing 4.2.42.2 Equipment, ‘+ Insertion/&xtraction tester with peak force reading feature. 4.2.12.3 Sample Preparation. Obtain a minimum of thirty (30) samples of connectors to be tested. No special sample preparation is required, Manufacture a mounting feature with the correct dimensions to fit the Connectors on test. 4.2.12.4 Procedure. Note: The same samples may be used for testing various force directions if not damaged. 4, Test a minimum of thirty (30) connectors; five (5) in each direction. 2. One non-mounting (mating) connector may be used to test all connectors. 3, Secure a new connector with the designed-in mounting feature to a bracket with a fixture simulating the coordinating mounting feature. See Figure 6. Note: No additional reinforcement of the connector slot is permitted 4. With the connector assembly attached to the bracket, apply a downward force at a rate of (60 10) mmiminute to the non-mounted mating connector in direction F1 until breakage of the mounting feature or until the force specified in the Acceptance Criteria of Section 4.2.12.5 is reached Tne force shall be applied § mm from the rear and side of the connector to affect the greatest moment arm, See Figure 7, Figure 8, and Figure 9. 6, Remove the connector from the fixture, Repeat Steps 2 thru Step 5 with four additional connectors. 7. Repeat Steps 2 thru Step 6 in the othor three directions (F2, #3, and F4, 90° apart, and each Perpendicular to the direction of mating of the mounting feature), 8. Secure a new connector with the designed-in mounting feature to a bracket with @ fixture simulating the coordinating mounting feature. See Figure 6. 9. With the connector assembly attached to the bracket, apply a push force connector with a probe (at a rate of (50 # 10) mm/minute) at the centerline of the connector in direction FS unil breakage of the ‘mounting feature or until the force specified in the Acceptance Criteria of Section 4.2.12.6 is reached, ‘Soo Figure 7, © Conyight 2012 Goceral Motors Company Al Righs Reserved June 2012, Page 20 of 79GM WORLDWIDE ENGINEERING STANDARDS Gmws1ot | 40. Remove the connector from the fixture 41. Repest Steps 8 thru Step 10 with four additional connectors, 12, Repeat Steps 8 thru Step 11 in the other direction (F6), Figure 6: Connector Mounting Fixture Strength Example Mounti aN Fars V 6 FS Mounting Connect i Non: Hountina A ed Note: Arrows inate decton of apoed force, nt ccaton of probe Figure 7: Connector Mounting Fixture Strength Test Setup, 3-Dimensional View {© Capyight 2012 Genera Motors Company All Rights Reservod ‘June 2012 Page 21 of 79emw3191 | Mounting Clip Bracket i — — 5s Latch t F2 Figure 8: Connector Mounting Fixture Strength Test Setup, End View Mounting Feature oe am Non- Mounting (mating) Connector Figure 9: Connector Mounting Fixture Strength Test Setup, Side View 42.425 Acceptance Criteria. 4.2.12.5.4 The minimum force required to break the mounting feature or separate the clip from the mounting feature in directions F1 fo FS shall be > 50 N. 42.12.52 The minimum force required to break the mounting feature or separate the clip from the mounting feature in direction F6 shall be > 110 N. 4.2.13 Connector Audible Feedback. 4.2.13.1 Purpose. This test measures the level of noise generated when two connectors are mated. Connectors shall be mated by hand for this test rather than being clamped into a fixture which could dampen ‘or amplify the sound, 4.2.13.2 Equipment. ‘Sound Pressure (decibel (dB) Meter 4.2.13.3 Procedure. Eight (8) cample pairs are required. Samples are to be production intent. All connector ‘cavities shall be filed with wires and terminals of any size appropriate to the connector under test (CUT). Include all TPAs, seals, stuffers, and auxiliary pieces as applicable, © Copyright 2042 General Motrs Company Al Rights Reserved June 2072, Page 22 of 79‘GM WORLDWIDE ENGINEERING STANDARDS. Gmwa3191 1. Measure and record the sound pressure level in decibels C-weighted scale (dB (C)), of the ambient sound within the test environment. The ambient noise level shall be 60 dB (C) minimum. 2. Locate the sound measuring device or microphone (600 + 60) mm from the connector. 3. Mate the connectors by htand and measure the dB (C) level of the sound generated 2s the lock engages, De rot bias the connectors toward or away from the latch as they are engaged. 4. Repeat Steps 1 thru Step 3 using moisture conditioned parts. Parts are brought to their practical limit Cf moisture content by exposing "dry as molded parts" to 95% to 98% Relative Humidity at 40 °C for 6 hours (minimum), then compieting the test within 30 minutes. 5. The minimum sound level required shell be as specified on the part drawing. If no value Is specified, the requirement is 7 dB above the recorded ambient for un-conditloned parts and 5 dB for conditioned parts, 4.2.13.4 Acceptance Criteria, Data from this test is for engineering evaluation purposes ony 4.2.14 Connector Lock Mechanical Overstress. 4.2.14. Purpose. This test is to determine that the connector lock mechanism can withstand oversiress applied to the lock. 4.2.14.2 Equipment. + Pull tester with peak force reading feature. 4.2.14.3 Sample Preparation. 4.2.14.3.4 Minimum sample size = Ten (10). 4.2.14.3.2 No special sample preparation is needed. 4.2.14.4 Procedure. Wrap a 0.33 mm? (22 ga) wire around the connector lock assembly. Pull with 150 Non the wire against the lock in both horizontal and vertical directions. 42.145 Acceptance Criteria, There shell be no damage to the connector lock assembly after the force is applied. 4.2.15 Connector Position Assurance (CPA). 4.2.18. Purpose. This test is used to ensure that the CPA will function properly and verily the robustness to inadvertent closure and separation. 4.2.18.2 Equipment. ‘+ Insertion"@xtraction tester with peak force reading feature 4.2.18.3 Sample Preparation. 4.2.18.3.4 Minimum sample size = Ten (10). 42.18.3.2 No special sample preparation is needed. 42.15.4 Procedure. 4.2.18.4.1 CPA Lock and Unlock Fore 1, Using a mated connector pair, close the CPA at 2 uniform rate of (50 + 10) mmfminute until fully seatad and locked. Racord the peak force. 2. Open the CPA at a uniform rate of (50 + 10) mmiminute until fuly opened. Record the peak force, 4.2.18.4.2 CPA Closing Force at Connectors. Using an unmated connector, close the CPA at a uniform rate (of (60 + 10) mm/minute until fully seated and locked. Record the peak force, 42.18.43 CPA Extraction Force. Using an unmated connector, apply a force to the CPA in the opposite Girecton Yo the normal closing dection et a uniform rate of (6010) mmininute unl fly detached, Record the peak force. 4.2.18.5 Acceptance Criteria. +The CPA pre-stage to lock force shall be 22 N maximum, +The CPA lock to pre stage force shall be between 10 N and 30 N without the use of special too's 4.2:18.5.1 CPA Closing Force on Unmated Connectors. The closing force for non-mated connector shall be E 8 © Figure 18: In-Line Circuit Lead Location ‘The Initial Rrora: connection and Post-Test Rrors: conection Shall be less than or ‘equal to the values listed in Table 11. Note: Velues for terminal sizes not shown in Table 41 may be calculated by linear interpolation Table 11: Maximum Resistance Values ‘Total Connection Resistance Nominal Male Terminal Size"°** Maxienum "2-422 0.5 mm per CTS <0.64mm 16.0 ma = 1.5mm 8.oma =28mm 50mO 26.36 mm 15ma Note {As defined by te male bade porton (wah) ofthe TUT Note 2:4ma=1mvia Note 5: anim aowabe mVO = 50 © Conyright 2012 Genera Motore Comsany Al Rights Reserved June 2012, Page 34 of 73GM WORLDWIDE ENGINEERING STANDARDS GMW3191 Note: Values for other terminal sizes between 0.64 mm and 6.36 mm are calculated by interpolation. Terminal sizes outside of this range are usually for specialized use. The requirements for these terminals shall be set by the Responsible Engineer. In no case may the Total Connection Resistance exceed 20 m0 433.3 Voltage Drop. 43.3.1 Purpose. This test determines the voltage drop associated with the electrical resistance of the conductor crimp(s) and contact interface regions at nominal current conditions. This voltage drop is then used to calculate the Total Connection Resistance. 43.3.2 Equipment. + Digital Multimeter (DMM) + DC Power Suppiy (0 to 20) VDC at (0 to 150 A} © Current shunts 433.3 Procedure, 41. Prepare twenty (20) (at least ten (10) male and ten (10) female) terminal samples per section 3.3, using the largest gage size conductor and insulation thickness applicable to the design of the terminal tobe tested 2. For purposes of this test, the male terminal shall be inserted to a precise depth into the female. Standard practice Is that, in the worst case, there shal be at least 1 mm of excess insertion between the rearmost contact point with the Female Terminal and the start of any lead-in taper on the Male Terminal, as illustrated in Figure 19. This dimension is to be calculated from the GM Approved terminal drawings, taking into account the worst case tolerances. Each male terminal is to be suitably marked 0 test personne! can make the final mating of the test terminal pairs to the correct depth. Score marks fr any other marking that might introduce contaminants or alter the strength or conductivity of either terminal or the interface are not permitted. Do not use the connector housings, even unsealed, to control terminal insertion since the housings wil alter heat dissipation during testing. This wall Compromise test repeatability and will invalidate comparisons of data collected for various terminals. SINGLE SPRING MEMBER EXAMPLE J Ferale Tasrina 4 Malo Torminat entry End 1.ueren- Minimum | Point of contact Noarest anmry end L start of Tapor MULTIPLE SPRING MEMBER EXAMPLE Female Terminal Ay beat Springs Male Terminal —--»3 Entry Ené 4.0mm Point ot contact ranma Noareat ontry ond Start of Fapar Figure 19: Terminal Insertion {© Copytght 2012 Genaal Motors Company At Riahs Reserved June 2012 Page 35 of 72 Som. SEES erence,[ GM WORLDWIDE ENGINEERING STANDARDS ‘GMW3191 3. Prior to mating the test terminal pairs, provision shall be made for mounting them on an electrically non-conductive surface in such a manner that the mechanical stabilly of the male to female interface ‘can be maintained. 4. Carefully mate the test lerminal pair fo the appropriate depth, as specified in Step 3. Use caution to ‘ensure that mating is done along terminal centerlines to prevent side pressure that may distort either terminal, Secure the TUT to the mounting surface so that the correct insertion depth is maintained throughout the test 5, Assemblo the test circuit shown in Figure 20. Adjust the power supply to provide the required test current of 5Almm’ of conductor cross section for the conductor selected in Step 1. Refer to SAE J1127 and SAE J1128 or USCAR23 for the cross sectional area of the conductor selected. More than one terminal pair may be tested in series. Refer lo Figure 21, for placement of the milvlt test leads, Record the test current used. Curent Shunt De Powar Supply + ee 9.22 mm* aes aE — | ——> 7523 mm ‘7623 mm Figure 20: Current Resistance Test Setup i Lille. { it it3mm 19+ 3mm J Figure 21: Typical Connection Resistance Millivolt Lead Locations {© Copyight 2012 General Metore Company Al igh Reser ‘June 2012, Page 36 of 78GM WORLDWIDE ENGINEERING STANDARDS GMWw3191 6. Measure and record the milivolt drop across 150 mm of the conductor size and insulation type to be Used during the test, using the test current determined in Step 5. For testing Header type connectors, ‘and measure the milivolt drop across only 75 mm of the conductor used. Note: For attachmant points excseding (75+3)mm per side, the extra wire resistance shall be measured and subtracted per Step 9. 7. Choose the preferred method of taking measuremonts (soldered sense lead or probe) and document the method chosen. In elther case, the sense point T1 (Figure 20) shall be soldered for all stranded cable. For Header type connectors, T2's attached to the Header terminal, All mlivolt leads shall be no iarger than 0.22 mm’ (24 AWG), 8. Set the power supply for the current determined in Step 6 and wait 30 minutes (minimum) to ensure that the test current stabilizes at the appropriate value. Allow suificient time for all other test equipment ‘to warm and stablize per the manufacturer's recommendations. 9. Using the test currant determined in Step 6, measure and record the milivolt drop (mVD) readings between test polnts T1 and T2. Use these values in the equation below to calculate the voltage drop ‘across the entire connection, including the erimp(s) and terminal interface. In the case of Header type connectors, T2 Is altached to the “tal” of the Header Connector. ‘mVD Entire Connectior MVD (Ty Ta) = (mVD Conductor) (See Step 7) Total Connection Resistance = (mVD Entire Connection)(Test Current) Use these resulls to verify conformance to the Acceptance Criteria of Section 4.3.3.4, Note: These values apply to both before and after environmental conditioning such as Thermal Shock, Humic Heat Cyclic (HH), etc. or on field samples, 43.3.4 Acceptance Criteria, The maximum allowable resistance is defined in Table 11 Note: The ‘After Test” values are for “crimp-to-crimp" measurements (T; to Ty in Figure 20, tess the ‘appropriate conductor resistanca). For headers, the values are the “orimp-to-al" (T to T, in Figure 21), less the appropriate conductor resistonce. Note: Values for other terminal sizes between 0.64 mm and 6.35 mm are calculated by interpolation. Terminal sizes outside of this range are usually for specialized use. The requirements for these terminals shall be set by the Responsible Engineer. In no case may the Total Connection Resistance exceed 20 m0. 43.4 1008-Hour Current Cycling, 4.3.4.1 Purpose. This test is used to ensure that the elactical connection system can carry various current loads for an extended period of time, 43.4.2 Equipment. + DMM + DG Power Supply (timer controlled) + Current shunts Thermocouples + Data Logger 4.3.4.3 Sample Preparation. Attach thermocouples to the terminals hottest spot as close as possible to the hottest spot on the surface of the terminal. f the hottest spot is unknown, perform an independent test ‘Thermal Imaging is an acceptable technique. 4.3.4,3.1 Test Samples. Mated lerminal pair altached to 300 mm ofthe largest wire size to be validated. 43.4,3.2 Number of Test Samples. Ton (10) terminal pairs for every wire size to be validated, 43.4.4 Procodure. Note: Perform the mate/unmate conditioning on a mated pair only once ifthe pair is used in muitiple tess. {© Copytight 2072 General Mtore Company All Fights Reserved ‘June 2012 Page 37 of 79GM WORLDWIDE ENGINEERING STANDARDS omw3191 | Note: Throughout this ontre procedure, when using DC current fer testing of samples, thermocouple readings aha be taken wh pola onthe ot Samples in Boh rections and thn verge fo ena err custo thermocouple 1. Constuct a dafetree enclosure as show in Figure 15. Mount the thermocouple used to measure ambient temperature in the middle of the test chamber ay a height of (50 =5)mm from the lower surface of the chamber i 2, Attach testaads at points A, 8, and C to samples as shown in Figure 18 3. Set the power supply to provide a duty cycle of &6 minutes ON and 15 minutes OFF at the Base Curve Current ofthe terminal fom Figure 17 4. Connect a data logger tothe voltage droo and thermocouple loads. 5. After 30 minutes int the fist ON cycle record the following readings for each terminal pai: + Rrora.comeonny thermocouple readings 68. Cycle tho current with a duty cycle of 45 minutes ON and 15 minutes OFF for 1008 hours taking reatkngs at least once daly, or 28 spectied by the test requester, 20 minutes ino the ON cycle, and at the conclsion of hotest. 43.45 Acceptance Criteria. The measured temperature of any mated terminal psi shall not exceed the temperature lt ofthe terminal and cable size combination unde test. The Teal Connection Resistance called per Secton 432 shal not exceed the valine spose in able 1. 43.5 Isolation Resistance. 43.5.1 Purpose. This test is to ensure proper electrical isolation between adjacent terminals in connection systems. 43.5.2 Equipment. ‘+ Precision Mega-Ohmmeter, capable of measuring at 500 VDC. 43.5.3 Sample Preparation. 43.5.3.1 Test Samples. Mated connector pair filed with terminals attached to 300 mm ofthe largest wire size tobe validated. 4.3.5,3.2 Sample Size. Four (4) pairs. 43.5.4 Procedure. Note: For soaled connector pairs, complete all measurements in this test procedure within one hour after any previous environmental test. Note: For unsealed connector pairs, test samples shall rest al ambient temperature and hur 3 hours prior to measuring isolation resistance after any previous environmental test 1. Mate connector pairs. 2, Remove a minimal amount of insulation from the ends of the wires. 3, Seperate wires under test with sufficient distance as to have no influence on isolation resistance between any two wire pairs. 4, Measure the isolation resistance by applying 600 VDC between all adjacent pairs of terminals. 5, Record the resistance after 15 seconds of stabilized readings. 6. For connectors with Shorting Bars, measure the isolation resistance between the two terminals designed to be shorted together by the Shorting Bars, Note: Conduct this measurement with the Shorting Bar in the Open/Unshorted postion. 7. Record the resistance after 15 seconds of stabilized readings. 4.3.5.5 Acceptance Criteria, All measured isolation resistances shall be greater than 100 MO. 4.3.6 Diolectric Strength. 4.3.6.1 Purpose. Verily the electrical insulation capability of a connector body. idity for at least (© Copyright 2012 General Moors Company Al Rights Reserved ‘June 2012 Page 38 of 79GM WORLDWIDE ENGINEERING STANDARDS omw3191 | 43.6.2 Equipment. + High potential tester with toad meter. 4.3.6.3 Sample Preparation. 43.6.3.1 Test Samples. Mated connector pair filed with terminals attached to 300 mm of the fargast wire size to be validated, 4.6.3.2 Number of Test Samples. Three (3) pairs. 43.6.4 Procedure. Note: For sealed connector pairs, all measurements in this test procedure shall be completed within one hour after any prior environmental test. Note: For unseeled connector pairs, test samples shall rest at ambient temperature and humidity for at least ‘3 hours prior to measuring dielectric strength after any previous environmental test. 1. Mate connector pairs. 2. Wrap metal fll around the exterior ofthe connector without contacting any terminals or wires. 3, Remove a minimal amount of insulation from the ends of the wires, 4. Separate wires under test with sufficient distance as to have no influence on isolation resistance between any two wire pairs Using the high potential (hi-pot) tester, apply an alternating current (AC) voltage of 1000 Vays at 50 Hz ‘9F 60 Hz, oF a DC voltage of 1600 V across each adjacent cavity for at least 60 seconds. Record any current leakage. ‘Attach all the terminated wire leads to the positive lead of the hi-pot tester. Attach the negative lead of the hi-got tester to the metal foi. 8. Apply an AC voltage of 1000 Vera at 50 Hz or 60 Hz, or a DC voltage of 1600 V between the terminals ‘and the metal foil for at least 60 seconds. 9. Record any current leakage. 43.6.5 Acceptance Criteria. 1. No dielectric breakdown or flash-over shall occur between cavities at any time during the test. 2. No dielectric breakdawn ar flash-over shall occur between the cavities and the outside of a connector at any time during the test 4.4 Environmental Tests. 4.4.4 Thermal Aging, 44.1.1 Purpose. This conditioning procedure evaluates the effects of long term exposure to elevated temperatures on connector assemblies. Changes in metal and plastic materials including stress relaxation and warping are evaluated. Note: This full 1008-hour test duration is required for all naw materials and hygroscopic materials. Nor-hygroscopic materials may be tested to shorter time periods if the supplier provides test data that illustrates that further degradation does not occur with continued thermal aging. The supplier may then test to the shorter time period with approval of the GM connector engineer. The absolute minimum thermal aging shall be 240 hours. 4.4.1.2 Equipment. + Temperature chamber{s) capable of -40 °C to +180 °C, or as required by the components under test 4.4.1.3 Sample Preparation. 4.4.1.3.1 Test Samples. Complete mated connector pair test samples with all terminals and wires connected. 4,4.1.3.2 Numbor of Tost Samples. Ten (10) pais. 444.8 Procedure, The test procedure used shell be elther the default General Thermal Aging or ‘Transmission Thermal Aging as defined in the connector CTS. 4.4.1.4.1 Thermal Aging - General Applications. (© Copypght 2912 General Motors Company ll Fights Reserved ‘June 2012 Page 39 of 78‘GM WORLDWIDE ENGINEERING STANDARDS GMw3191 1. Set the temperature chamber to the maximum ambient temperature specified in Table 2, for the class rating of the connector under test. 2. Place the samples in the chamber and heat age for 1008 hours. 3, Remove the samples from the chamber and let rest at ambient temperature and humidity for at least 24 hours. 4.4.1.4.2 Thermal Aging - Transmission Applications. 1. Place the samples in the chember and heat age for 1008 hours using the following profile: = 963 hours at 125 °C + 41 hours at 132°C + Shours at 140°C 2. Remove the samples from the chamber and let rest at ambient temperature and humidity for atleast 24 hours. 44.4.5 Acceptance Criteria, All test samples shall mest the visual requirements of Section 3.4.1.7. All mechanical assists andlor other elements required to separate connectors for service shall function without breakage. 4.42 Thermal Shock. 44.2.1 Purpose. This test subjects the connector assembly to extreme temperature cycles which cause expansion and Contraction of the materisls used in the connector system. This is intended to produce accelerated wear at the terminal contact surfaces. 44.2.2 Equipment. + DC Power Supply (0 to 20) V + Continuity monitoring equipment + Temperature chamber(s) capable of -40 °C to +180 °C, or as required by the components under test 4.42.3 Sample Preparation. 4.4.2.3.4 Test Samples. Complete mated connector pair test samples with al terminals and wires connected. 4,4.2.3.2 Numbor of Test Samples. Ten (10) pais. 1. Divide the test samples into two groups of five (5) 2. The first group of five (6) shall be set up and monitored continuously 2s follows: ‘a. On connectors with up to ten (10) cavities, all cavities shall be monitored. b. On connectors with more than ten (10) cavities, the test requester shall determine the exact umber and location of the cavities to be monitored, The chosen cavities shall be evenly distributed across the connector. 3, The second group of five (6) shall not be monitored continuously. 4.4.2.4 Procedure. 1. Solder the ends of the conductors to each other in the test sample set being monitored, to form a single series circuit with only two free ends. 2. Solder one ofthe free conductor ends to a 2 W (120 + 1.2) 0 resistor. ‘Solder the power supply negative lead to the free end of the resistor and the power supply positive Jead to the remaining free conductor end of the test sample, Preset the power supply to provide 100 mA to the circut. Connect the continuity monitoring equipment across the resistor, making sure that the negative lead of the continuity monitoring equipment is connected to the negative side of the resistor. Set the continuity monitoring equipment to moritor the current through the resistor. As an option, the continuity ‘monitoring equipment may be used to monitor one or more terminal pairs instead of the resistor. Measure the dry circu resistance per Section 4.3.2 for both sample sets, Place the test samples in the chamber so that there Is no substantial air flow obstruction around the test samples. {© Copytight 2012 Ganeral Motors Company Al Flghs Reservas “lune 2012 Page 40 of 78GM WORLDWIDE ENGINEERING STANDARDS: GMw3191 8. Determine the minimum and maxirnur temperatures per the temperature class of the component set being tested, Set the temperature chamber to the minimum ambient temperature for that class. 9. Place the samples in the chamber and allow the Chamber temperature to stabilize, Soak the samples an additional 20 minutes, 10, Transfer the samples to the high temperature chamber set to the maximum ambient temperature for the class selected. Allow the test samples to soak for 30 minutes. Note: Chamber to chamber transfer time shall be less than 10 seconds, 11, For Temperature Glass 1: Transfer test samples between temperature extremes 100 total times while ‘continuously monitoring for any loss of electrical current level per the setup described above. 12. For Temperature Classes 2, 3, and 4: Transfer test samples between temperature extremes 300 total times while continuously monitoring for any loss of electrical current level per the setup described above. 18, At the end of the cycling schedule remove the test samples from the chamber and measure the dry Circult resistance per Section 4.3.2 for both sample sets, 4.4.2.5 Acceptance Criteria, There shall be no loss of electrical continuity as defined in Figure 13 during this test for any connector except SIR connectors, SIR connectors shall not lose continuity as defined in Figure 14, ‘Test samples shall mest the dry circuit requirements of Section 4.3.2.6, Table 11, both before and after thermal shock testing paragraph. All test samples shall meet the visual requirements of Section 3.4.1.7. All mechanical assists andlor other elements required to separate connectors for service shall function without breakage. 4.4.3 Humid Heat Cyclic (HHC), 4,4.3-1 Purpose. This conditioning procedure simulates the effects of combined temperature and humidity on the connector assembly. Wear and fretting of terminals and breakdown of plastic and silicone components are ‘evaluated. 4.4.3.2 Equipment. ‘+ DC Power Supply (0 V to 20) V ‘+ Continuity monitoring equipment + Temperature chamber(s) capable of -40 °C to +150°C and humidity, or as required by the components under test 4.4.3.3 Sample Preparation. 44.3.3.1 Test Samples, Complete mated connector pair test samples with al terminals and wires connected. 44.3.3.2 Number of Test Samples. Ten (10) pairs. 44.3.4 Procedure. 41. Measure the dry circuit resistance per Section 4.3.2 2, Place the test samples in the chamber ensuring that there is no substantial er flow obstruction around the test samples. 3. Use test equipment according to 1EC 60068-2-38, Test Z/AD, Composite tamperatura/humiotty cyclic test, and then perform the test as stated in Table 36 of IEC 60068-2-38. Table 12: Cyclic Humidity Requirements Description Value High Temperature +65°C Middle Temperature +25°C Low Temperature Duration 10 days {© Copyigh 2012 General Motors Company Al ight Reserved June 2012 Page 41 of 79‘GM WORLDWIDE ENGINEERING STANDARDS _GMW3101 Figure 22 end Table 13 show a two-day cycle that isto be repeated a total of five times (2 ¥ 5 = 10 days). The humicity during high temperature is (93 2)% and drops to 80% during the transition from #65 °C to +25 °C. ‘At #25 °C, the humidity shall increase to (93 # 3)%. The humidity Is uncontrolled when the temperature is less than #25°C, Perform The Following Five Timea mr tf_Si 26 126 255 POE 385 376 Taro anen"C) hs sot DoD 4 6 8 1012 2 95 0 20 2 2a 2e 2a BO aD HE Bee aD aD a 28 Tan 5 fOver Twa Baye Figure 22: Cyelic Humidity Profile Note: Pay attention to anomalies resulting from condensation of moisture. © Copytigh 2012 General Motors Company Al Rights Reserved June 2012 Page 42 of 79‘GM WORLDWIDE ENGINEERING STANDARDS GMW3191 Table 13: Cyclic Humidity Profile Temperature Ohours 25°C 1S hours 65°C 8.5 hours cere 65°C a hours 25°C @ hours 25°C ‘9.5 hours 65°C 13.5 hours 65°C 15 hours 25°C 24 hours 25°C 25.5 hours z 86°C 29.5 hours °C 31 hours 35°C ‘32 hours 25°C 33.5 hours 05°C 37.5 hours 65°C 38 hours 25°C #15 hours { 25°C 42 hours “10°C 45 hours “10°C 46.5 hours 25°C 48 hours 25°C 4.4.3.5 Acceptance Criteria. Test samples shall meet the dry circuit requirements of Section 4.3.2, Table 11 both before and after the Humid Heat Cyclic (HHC) test All test samples shall meet the visual requirements of Section 3.4.1.6. All mechanical assists andlor other ‘elements required to separate connectors for service shall function without breakage. There shall be no loss of seal integrity for sealed connectors, 4.4.4 Humid Heat Constant (HHCO). 4.4.41 Purpose. This conditioning procedure simulates the effects of high humidity on the connector assembly. Wear and fretting of terminals and breakdown of plastic and silicone components are evaluated. 4.4.4.2 Equipment. + DC Power Supply (0 to 20) V ‘+ Continuity monitoring equipment ‘© Temperature chamber(s) capable of -40 °C to +180°C and humidity, or a8 required by the components under test 4.4.4.3 Sample Preparation. 4.4.4.3.1 Test Samples. Complete mated connector pair test samples with all terminals and wires connected {© Copyight 2012 General Moors Company Al Rights Reserved ‘June 2012, Page 43 of 79GM WORLDWIDE ENGINEERING STANDARDS. GMW3191 44.4.3.2 Number of Test Samples. Thiteen (13) pairs, the same samples that were used in Power Temperature Cycling. 4.4.4.4 Procoduro, 1. Measure the dry circuit resistance per Section 4.3.2 2. Place the test samples in the chamber ensuring that there is no substantial air flow obstruction around the test samples, 3. Use test equipment according to EC 60068-2-78, Damp heat, steady state, and then perform the test as stated in Table 14. Table 14: Constant Humidity Requirements, Ei Deseription Value Temperature 85 £3)°C Duration 10 days, Relative Humidity (045% 4. Continuously monitoring the current level inthe test circuit 5. Atthe completion of test, measure tho dry circuit resistance per Section 4.3.2. 44,45 Acceptance Criteria, Test samples shall mest the dry circult requirements of Table 11 in Section 4.3.2.5 before and after the Humid Heat Constant (HHCO) test. All test samples shall meet the visual requirements of paregraph 3.4.7.7. All mechanical assists andlor other ‘elements required to separate connectors for service shall function without breakage. ‘There shall be no loss of seal integrity as applicable for sealed samples. 4.4.5 Heavy Duty Test. 4.4.5.1 Purpose. This test is used to evaluate terminal sensitivity to high current load at high temperature, 4.4.5.2 Equipment = DMM + DC Power Supply (timer controlled) © Current shunts ‘+ Thermocouples + Data Logger ‘+ Temperature chamber(s) capable of -40 °C to 150°C, or as required by the Temperature Class of the ‘component to be tested. 4.4.5.3 Sample Preparation. Obtain at least six (6) mating terminal pairs attached to wires ofthe largest wire size to be validated. Attach thermocouples to the female terminals as close to the hottest spot as possible without compromising the possiblity to insert the terminal inio the connector. Insert the terminals into the ‘connectors in six (6) adjacent cavities. If the number of cavities is lower, perform the test at the maximum ‘configuration. Connect all terminals in series. 44.5.4 Procedure. ‘1. Complete the dry circuit test per Section 4.3.2 and record the results for each terminal pai. 2. Sot the power supply to provide the maximum de-rated current forthe terminal and cable taken from the border of Area 2 in Figure 17 for the largest wire size at the specified test temperature, Le., 80 °C F100 °C, 3. Connect the thermocouple leads a data logger. 4, Set the Temperature Chamber to 80 °C for Temperature Classes 1, 2, or 3 in Table 2, and 100 °C for Temperature Class 4 in Table 2. {© Copytght 2012 Genaral Motors Company All Fighs Resorvad June 2012 Page 44 of 79GM WORLDWIDE ENGINEERING STANDARDS. GMW3191 5, Run the maximum de-rated current through the test samples at the respective test temperature for S hours, Transfer the samples to -40 °C and coo! for 2 hours at 0A. Repeat the above test procedure fora total of § cycles, Aller 5 cycles, store the samples at room temperature for at least 24 hours. 9. Perform a dry circuit test per Section 4.3.2 and record the results for each terminal pai. Note: It ie important that no mechanical disturbance of the terminal-to-terminal interface occurs prior to, or during the last test. Relative movement of the metal terminals could rupture any insulating film that may have formed. 4.4.5 Acceptance Criteria, Maximum allowed temperature rise on the torminal at the end of each cycle is 50 °C. Rrorat coneecnow measured shall be in accordance with Table 11 in Section 4.3.2.8. The temperature on Any terminal shall not exceed the terminal's maximum temperature rating at any time during the test 4.4.6 Flammability. 4.4.6.1 Purpose. The purpose of this test is to determine the burning behavior of materials used in connector bodies. 4.4.6.2 Equipment. As roquired per GMW3232, 4.4.6.3 Sample Preparation. 446.3.1 Test Samples. Material test amples of plastic used in connector bodies in sizes and dimensions ‘specified in GMW3232. 4.46.4 Procedure, Perform the flammability test per GMWV3232. 4.4.6.5 Acceptance Criteria. The burn rate of the material test samples when tested according to GMW3232 shall be less than 100 mmiminute. 4.4.7 Corrosion. 4.4.7.1 Purpose. The purpose of this test is to determine the corrosion resistance of the materials used in the torrinal and the electrical connection system to salt during vehicle operation. Note: This test applies to Sealed Connectors with Exposed Metalic Components and unsealed connectors, Note: Corrosion testing is not necessary on existing terminal andlor connection systems provided that the terminal has previously passed corrosion testing in an unsealed connector or if similar sealed connection systems have previously passed corrosion testing. The Supplier may submit test data from the previous test report to full this requirement. 44.7.2 Equipment. + Appropriate salt chambers and elt solutions as described the respective test procedures + Temperature Chamber + Power Supply/Supplies 4.4.7.3 Sample Preparation. 44,7.3.1 Unsealed Connection Systems. Fully populated connector mating pairs with the ends of the wire leads sealed. 4.4,7.3.1.1 Sample Size, Ten (10) mated connector pairs in total 447.3.2 Sealed Connection Systems with Exposed Metal Components. Fully populated connector pairs with all seals, shrouds, ete. The connectors shall be populated with terminated leads using the largest and ‘smallest wire sizes specified forthe respective terminals, 44,7.3.2.1 Sample Size. Tan (10) mated connector pairs in total 44.7.4 Procedure. 447.41 Unsealed Connection Systems, Test the connectors per GMW3172 Salt Mist Test with the folowing conditions: 1. Mount connector pairs in both a vertical and horizontal orientation within the test chamber. {© Copytight 2012 Genera Motors Company Al Rights Reservas ‘June 2012 Page 45 of 79 Ce Reeeunen cae, SEOTED YE ama wminisey nnamgocsone[GM WORLDWIDE ENGINEERING STANDARDS GMWw3191 2. Test per GMW3172 Salt Mist, Material Degradation Test, according to the instructions for Non-sealed components without vent openings (IP Water Code 3 or 4K). 3. Perform the Dry Circuit Resistance Test per Section 4.3.2. 4, Perform the After Test Visual Inspection per Section 3.4.1.7 5. Perform the Terminal-from-Connector Extraction Force Test per Section 4.2.5 4.47.42 Sealed Connection Systems. Test the connectors per GMW3172 Salt Spray Test with the following ‘conditions: 1. Mount connector pairs in both a vertical and horizontal orientation within the test chamber. 2. To power the connector set the power supply to deliver the Base Curve Current of the termine! end wire size combination from Figure 11 3, Test per GMW3172 Salt Spray Test with a test duration of 40 days (960 hours). Note: Connectors shall be powered even during 15-hour soak time, even if not required by GMW3172. 4, Perform the After Test Visual Inspection per Section 3.4.1.7. 4.4.1.5 Acceptance Criteria. 447.51 Unsealed Connectors Only. 41. roma connecron Shall meet the requirements specified in Table 11 in Section 4.3.2.5. 2. After aging, the terminal retention force shall mest the requirements specified in Table 6 in Section 4.2.5.5. 4.4.5.2 Sealed and Unsealed Connectors. 1. There shall be no deformation, cracks, or breaking evident on the connector body. Any swelling or physical distortion shall not exceed the tolerances specified on the part drawing. 2, There shall not be any corrosion on exposed metalic components of the connection system. 4,48 Vibration with Thermal Cycling. 44.8.1 Purpose. This tast subjects @ connector system to variable vibration simulating accelerated exposure 10 potential vehicle conditions. 4.4.8.2 Equipment, + DC Power Supply (0 to 20) V ‘+ Vibration’Shock Table + Vibration/Shock Controller + Continuity monitoring equipment + Accelerometers: + Temperature Chamber 44.8.3 Sample Preparation. See Section 4.2.21.3 for sample preparation guidelines. 448.4 Procedure. The supplier shall use the same test samples and mounting fixtures lized in the Section 4.2.21, Vibration profiles and temperature settings are chosen based on the intended vehicie application ‘The test samples undergoing the appropriate vibration profile shall be simultaneously subjected to the thermal oycle as defined in Figure 23 and Table 15. Refer to the appropriate vibration profile for specific test procedures, test duration, amplitude and frequency requirements. [At the completion of the required vibration cycles, measure the dry circuit resistance per Section 4.3.2. Record the results. © Copyright 2012 General Moors Company AR Fights Reserved ‘June 2012 Page 46 of 79 Sema eee cr, SERRE Eo weary. commonersGM WORLDWIDE ENGINEERING STANDARDS. GMWw3191 —+— Temperature Class 4 —4— TemperatureClass2 —+— Temperature Class 3 a Temperature Class 4 timing Figure 23: Thermal Cycle Table 15: Thermal Cycle Requirements. Temperature | Temperature Temperature Temperature Glass 1 Class 2 Class 3 Class 4 E 420°C. 420°C 20°C E 40°0 40°C “40°C. 40°C 150 minutes “40°C. 40°C 40°C 40°C 210 minutes 420°C, 420°C 720°C 20°C 300 minutes: 485°C +100°C 125°C. 160°C "410 minutes 420°C, ¥100°C. +125 °C +150°C. 480 minutes 420°C #20°C 420°C. 20°C 4.4.8.4.1 Mounting Location: Body (Sprung Masses). See Figure 24 and Table 16. 100 =-3 PSD |(m/s*)/Hz)] 2 0,01 10 100 1000 10000 f [Hz] Notes: PSD. = Power Spectra! Donety in (fz (2 Frequency Herts (2) Test accor to EN 60086.284: RUS Aeceleraton = 200 mist ‘est Ouration = 22 hows to 24houts foreach X,Y, Zeoowinae ax ofthe ps Figure 24: Body (Sprung Masses) Random Vibration Schedule {© Copyright 2012 General Metors Company Al Rights Reserved ‘June 2012 Page 47 of 79GM WORLDWIDE ENGINEERING STANDARDS GMw3191 Table 16: Body (Sprung Masses) Random Vibration Schedule Frequency Power Spectral Density ‘Acceleration Power Density 10Hz 7 (mis! (0.073 (G'H2) 50 Hz “35 (mis'ViKe. (0.036 (GHz) OH 1.75 (mis fine 0.018 (GHz) 71000 Hz 0.08 (mis?) Hz 0.0006 (G*iH2) 448.414 Random Vibration - Mounting Location Engine Sinusoidal Vibration. See Figure 25 and Table 17. Notes: 1 Ampeute of scceoratonin st {= Frequency in ere (He) “ect according to EN 60088-28 Frequency sweep: ontaveiminio ‘Teel duration = 22 hours to 24 hour foreach XY, Z coordinate xs of he pat “he spendad test pote apples bon galing ad dese engines. Ths ets ffowed by the Random Vibration Testin Figure 22 Figure 25: Engine Mounted Sinusoidal Vibration Cycle (based on 1SO 16750-3) Table 17: Engine Mounted Sinusoidal Vibration Cycle (based on ISO 16750-3) Frequency ( “Amplitude of Acceleration (8) 100 He 00 (mis?) | 150He 3 150 (ls?) 200 He 200 (nls*) 240 Hz 200 (mnls*) 20 Hz 700 (ms") 7 +50 (rds? © Copytight 2012 General Motors Company Al Rights Reterved ‘June 2012 Page 48 of 79 SEER Sapna pera snrGM WORLDWIDE ENGINEERING STANDARDS emw3101 | 4.4.8.4.1.2 Random Vibration Cycle. See Figure 26 and Table 18. 100 10 1 04 PSD [(m/s*}/H2)] 10 100 1000 10000 Notes PSD. = Power Spectral Dees in iste f= Frequency in Hara (42) Testaceorang to £N 6000-26 FS celeron value= 181 mis® Frequency Sebep: 1 celabininse for aach X,Y, Zco-tdnate axis ofthe part Figure 26: Engine Mounted Random Vibration Cycle {based on ISO 16750-3) ‘Table 18: Engine Mounted Random Vibration Cycle (based on ISO 16750-3) Frequency (f) Power Spectral Density (PSD) OH 10 (mis? 400 Hz 40 (mis*yz 300 Hz 0.51 (mis IH ___500Hz. 20 (mnis*)tz 2000 Hz 20 (mis Hz {© Gooytght 2012 General Motors Company Al ight Resend June 2012 Page 49 of 79GMW3191 GM WORLDWIDE ENGINEERING STANDARDS 4.4.8.4.2 Mounting Location: Wheel. See Figure 27 and Table 19. g PSD [(m/s**/Hz)} Notes PSD = Poner Social Density in mie 12 Frequency Hart (H2) Tost eccorang io EN 600682-64 FMS Aeceleaton = 107-3 mist Test Ouran = 2 hours 1o 28 Nowe foreach lane Figure 27: Wheel Random Vibration Cycle Table 19: Wheel Random Vibration Cycle Frequency ( Power Spectral Density ‘Acceleration Power Density 20 Hz 200 (m/s*)'/Hz 208G%Hz - 40 Hz 200 (emis) 2.08 GHz, 300 Hz 0.5 (mis"//Hz (0.005 GHz 200 He 0:50 (mis 0.008 Giz 1000 Hz 3 (mis*¥/Hz_ 0.031 GHz 2000 Hz fae: (mis*fMz 0.031 GHz 4.4.8.4.3 Mounting Location: Severe Locations. 448.4.3.1 Sinusoidal Vibration. See Figure 28 and Table 20. © Conyight 2012 Guneral Motors Company Al Rights Reserved ‘June 2012 Page 50 of 79‘(GM WORLDWIDE ENGINEERING STANDARDS Gmwa3191 350 300 250 200 180 100 a [wey Notes plus of acaleraton ia mist rosuaney in Herts) “eat accoring o EN S0059-26 Frequency Sweap:#octavelminute, "Test Duration = 2 hours to 24 nurs foreach X.Y. Z econ ax ef he part ‘The speed let profile apples Boh gacolne snd cosa ergioa. Ths tats olonad bythe Random Vitaton Tetin Figur 28, Figure 28: Severe Applications Sinusoidal Vibration (based on ISO 1670-3) Table 20: Severe Sinusoidal Vibration (based on ISO 16750-3) Frequency (f) ‘Amplitude of Acceleration (a) 400 Hz 100 mis 160 Hz 150 mis" 200 Hz all 300 mis 240 Hz 300 mis? 270 Hz it 100 mis? a 400 Hz 160 mis* © Conyight 2042 Generel Metre Company Al Rights Reserved ‘June 2012, Page 51 of 78[6M WORLDWIDE ENGINEERING STANDARDS GMW3191 4.48.4.3.2 Random Vibration, See Figure 29 and Table 21 100 PSD [(m/s*}/Hz)] 2 a: 3 3 3 8 3 8 Notes: PSD. = Power Spectal Dene in (nisi Fo = Frequensy n Het (2) Teat accordna o EN 60058.2.64 dS seceleraton vate = 181 ist Test Durston = 22 hows lo 25 ours foreach XY, Z esenate ais ofthe pat Figure 29: Severe Random Vibration Cycle (based on ISO 16750-3) Table 21: Severe Random Vibration Cycle (Severe Applications; based on ISO 16750-3) Frequency () Power Spectral Density toe 10 (mis Fine 400 Hz 10 (mis*¥/Hz_ 300 Hz 10.51 (mis'}Hz 500 Hz 20 (mist 2000 Hz 20 (mis"}Hz © Conysigh: 2012 General Moors Company Al Fights Resend June 2012 Page 52 of 79GM WORLDWIDE ENGINEERING STANDARDS. ‘GMW3191 ssion. See Table 22, 4,4.8.4.4 Mounting Location: Transt ‘Table 22: Generic Vibration Profiles for Transmissions (12 to 20 000) Hz ForelAft Lateral Vertical ForelAtt Breakpoints Breakpoints Breakpoints Breakpoints 33 hours/Axis 33 hoursiAxis 33 hours/Axis 33 hours/Axis He | Giz He Gil fe [Gite He [Gime 12_| 1486-02 72_| 3676-08 12 | 147E-02 12 | 1486-02 36 | 1435-03 56 | 316-04 32 [311603 a2_|_311e03 52_| 750-03 264 | 1.696-02 60 | 7.38603 2 | 7506-03 92 | 354-03 306_| 4526-03 128 | 1276-02 | | 128 | 127-02 300 | 1.54E-02 528 |_1.726-02 160 | 2386-03, 180__| _5:80E-03 23 | 3.406-03 776 | 5696-03, 280 | aa7eo2 | | 280 | 347602 aaa | 1016-02 | | 4a | 1526.02 44g | 2.71603 448__| 8006-03 1228 | 1.196-03 1936 | 1.286-04 508 | 1,076.02 526 | 1726-02 1616 | 1.008-02 | | 2000 | 7266-05 96 | 2626-03, 776_|_5.69E-03, 1748 | 1.626-03 3AGaus 4396 | 1.208-02 ae | 1526-02 1944 | 3.296-08, kurtosis=9| | 2000 | 1516-03 1068 | 6206-03, 2000 | 2.736-03 on 1396 | 1286-02 326,05 kurtosis = 1616 | 1006-02 kurtosis = 1676 | 4806-03 | 1864 | 2506-03, 1044 | 3236-03 [2000 2736-03 | 44Gans kurtosis =9 4.4.8.5 Acceptance Criteria. There shall be no loss of electrical continuity as defined in Figure 13 during this test for any connector except SIR connectors. SIR connectors shall not lose continuity as defined in Figure 14. Test samples shall meet the dry circuit requirements of Table 11 in Section 4.3.2.5 before and after the test. ‘Tast samples shall not have any base metal apparent at the contact surlace, or evidence of fretting corrosion, when viewed under 10* to 40x magnification, 4.4.9 Water Submersion. 4.4.9.1 Purpose, Determine the abiliy of sealed connection systems fo withstand submersion in water. 4.49.2 Equipment. + Water Tank + De-lonized Water containing 5% NaC, 0.1 g/L wetting agent and a florescent dye ‘+ Megs-ohm Meter + Temperature Chamber {© Copstight 2012 General Motors Grapary Al Rights Reserved ‘June 2012 Page 53 of 79GM WORLDWIDE ENGINEERING STANDARDS. GMW3191 44.8.3 Sample Preparation. For block seals, insert and remove the terminal from its cavity twice. 4.4.9.3. Test Samples. Fully populated mated sealed connector pairs with terminals terminated to the smallest and largest wires size, Terminated leads shall be a minimum of 800 mm. + Three (3) pairs withthe largest wire size + Four(4) pairs with the smallest wire size + Three (3) pairs mixed with the smallest and the largest wire size. Some cavities shall remain unplugged and the cavities sesled with appropriate design intent cavity plugs, flashed-over cavities, et. 4,493.2 Number of Test Samples. Ten (10) pai. 4.4.9.4 Procedure. 1, Prepare a water submersion test device per Figure 30, 2, Place mated connector samples into a thermal chamber and heat soak the samples for a minimum of 30 minutes at the maximum Ambient Operating Temperature for the appropriate temperature class. 3, Remove the heated test samples from the thermal chamber and immediately immerse the heated test sample into (+23 + 5) °C de-ionized water to a depth of 100 mm for at least 1 hour. 4, With the test samples immersed in the quid, record any leakage current measurements between each terminal pair and the electrode at 14 VDC. Also, record the leakage current measurements between every two adjacent terminals pairs. 5. At the completion of the test, visually inspect each mated sample pair for any physical degradation, cracking, ete., per Section 3.4 taking special care not to allow any surface moisture to enter the interior of either connector. Disconnect the mated connectors and carefully inspect the interior of the connectors for any evidence of moisture ingress as evidenced by residue of the florescent dye. fea @ " ‘ ’ { , = (am 10 Legene! 4,231 = Test Points 4 Fterose 5 STenSamp Figure 30: Water Submersion Setup 4.49.5 Acceptance Criteria, 1, The leakage current shall be less than 5 yA. 2, No evidence of water or florescent dye shall be present in the interior of either mated connector. 4.4.10 Prossure/Vacuum Leak. 4.4.40 Purpose. This test evaluates the sealing capability of a sealed connector system when subjected to @ specified prassure differential between the interior and exterior of a sealed connection system. 4.4.10.2 Equipment. + Regulated Pressure/Vacuum Source ‘+ Container for sample immersion + Temperature Chamber capable of -40.°C to 125 °C, or as required by the appropriate temperature class in Table 2 © Copytaht 2012 General Metors Company Al Rights Reberved ‘June 2012 Page 54 of 79GM WORLDWIDE ENGINEERING STANDARDS ‘GMW3191 4.4.10.3 Procedure. 1 10. 1" 42, 18. 14, 16. 16 7, Prepare terminated leads using the smallest conductor size and insulation type appropriate to the terminal and connector under test. Prepare enough samples of male and female terminals to assemble, {8 minimum of ten (10) pairs of connector assemblies leaving one cavity open for each connector pair. ‘Assembly shall include all applicable TPAS, seals, etc. Number each mated connector pat. Note: For convenionce, and to minimize loose conductor ends, conductor lengths may be terminated ‘on both ends and looped between samples. Insert a loase wire seal into the open cavities of the connector pair. For block type seals only, select ten (10) cavities at random among the sample set and record the ‘connector and cavity numbers. Remove and re-insert the terminals in the selected cavities. The purpose ofthis step is to ensure the terminal does not damage the seal during service operations. Insert a tube of sufficient diameter and wall strength (to prevent leakage between the tube and the conductor seal into the seal in the open cavity in each connector pair paying special attention that the lube is inserted far enough to engage the full sealing capability of the wire seal, Verity conformance of each mated sample connector assembly to the Isolation Resistance Test specified in Section 4.3.5 This establishes a reference for the concluding Isolation Resistance test. Connect the free end of the tube to a regulated pressure source. Prepare enough salt water solution to completely submerse all samples to a depth of 300 mm to 400 mm below the surface. Use tap water at (+23 C + 6) °C and 15 g to 16 9 of NaCl (table salt) per liter. Add an appropriate ultraviolet (florescent) dye to aid in the visual inspection for any ingress of solution into the test samples. Ten milliiters (10 mL) of liquid dish washing soap per iter of water may also be added. Mic well before adding to lest apparatus. Bend all conductors in the same direction, 90° to the back of each sample connector half and secure: them in this postion, using actual conductor dress shialds if available. This Is to simulate dressing of the conductors as they exit the connector and is intended to stress the conductor seals(s) as in actual applications. If actual production dress shields are not available, simulate production application intent {a closely 28 possible. Ensure that the tube Is not kinked, squeezed shut or otherwise obstructed, The tube should be left out of the 90" bend if feasible, Seal al loose conductor ends to eliminate possible leakage through the conductor strands. Completely submerse all samples into the container of salt water solution prepared in Step 7 above. Use care to avoid submersing any wire ends or the open end of any tube. Slowly increase the air pressure of the regulated pressure source supplying the tube in each sample tuntl the gauge reads 48 kPa (7 psig). Observe samplas for 18 seconds and verify that there are no air bubbies. ‘Switch the regulated source from pressure to vacuurn and slowly apply 48 kPa (7 psig) of vacuum to the sampies for 15 seconds. Remove the samples from the salt water solution, shake off excess fluid and then carefully dry all ‘exterior surfaces of the sample. ‘Strip 10 mm of insulation from the conductor ends of each terminal in one connector half and repeat the Isolation Resistance test specified in Section 4.2.6, ‘At the completion of the test, visually inspect each mated sample pair for any physical degradation, ‘cracking, etc., per Section 3.4.1.7 taking special care not to allow any surface moisture to enter the interior of either connector. Disconnect the mated connectors and carefully inspect the interior of the connectors for any evidence of moisture ingress as evidenced by residue of the florescent dye. Re-connect each sample to its original mate and re-seal all conductor ends. Place the samples in a temperature chamber stabilized at the maximum ambient tomperature for the appropriate Temperature Class from Table 2. Heat Soak all samples for 70 hours. ‘After the Heat Soak, remove the samples from the chamber and allow the samples to cool to room temperature. Repeat Steps 9 thru Step 15, except limit the pressure in Step 11 and the vacuum in Stops 13 to 28 kPa (4 psig), © Capyight 2012 Generat Motors Company All Rights Reserved ‘June 2072 Page 55 of 79GM WORLDWIDE ENGINEERING STANDARDS. GMW3191 18, Verly conformance ofall test samples to the Acceptance Criteria in Section 4.4.105. 4.4.40.4 Pressure!Vacuum Test for Connectors with Block Type Conductor Seals. Note: This test is not applicable to single cavity connector designs. This is an additional test and requires use of new samples. its purpose is to check for seal distortion from extremes of conductor size that may produce a leak. 1. Repeat Step 1 from Section 4.4.10.3, except prepare one (1) male and one (1) female terminated lead using the emallest conductor size for each connector pair to be tested, 2. Repeat Step 1 from Section 4.4.10.3, except using the largest conductor size and insulation type for the terminals to be used in the intended application. Prepare only enough terminal samples to fully populate all connector pairs, less one cavity for each connector half and less the one cavity left open for the pressure/vacuum tube. 3, Prepare a minimum of ten (10) connector pairs co that all but one randomly selected cavity in each ‘connecter half is populated with a terminal crimped to the largest conductor size, prepared in Step 2 above, Leave one cavity in each connector pair open for the pressureivacuum tube, as directed in ‘Step 1. Then fil the remaining cavity In each connector half with appropriate terminal crimped to the. ‘smallest conductor size, prepared in Slep 1 above. Unless the size of the connector makes it impossible, do not place the smallest conductor in a cavity adjacent to the pressure/vacuum tube, Number each connector pai. 4, Repeat Steps 4 thru Step 19 from Section 4.4.10.3 using the samples prepared in Step 3 above. 4,410.5 Acceptance Criteria, When samples are subjected to positive pressure, there shall be no foss in the applied pressure and no bubbles visible exiting any test sample, After samples are subjected to negative pressure (vacuum), all shall meet the Acceptance Criteria of the Isolation Resistance test in Section 4.3.5. {At the conclusion of the test, all samples shall meet the Acceptance Criteria of the Visual Inspection test, Section 3.4.1.7. No evidence of water or florescent dye shall be present in the interior of either mated ‘connector. 4.4.11 High Pressure Spray. AA,11.4 Purpose, This tost shall only be run if the connector CTS defines the connector requirement of Sealing Class 3, This tost shall be run in addition to the Submersion Test specified in Section 4.4.9. The purpose of this test Is to determine the abiily of sealed connection systems to withstand high pressure spray. Such conditions may be encountered where there Is direct road splash or in cases where high pressure washing may be expected, 4.4.11.2 Equipmont. 1. Nozzle and jet dimensions as shown in Figure 31 and Table 23 2, Water spray per the following conditions: 3, Temperature: (+80 + 6) °C 4, Flow rate: 14 Liminute to 16 Liminute 5. Pressure: 8000 kPa to 10 000 kPa (1160 psi to 1450 pel) measured as near as possible to the nozzle aperture, © Conyight 2012 Genera Motoes Company Al Rights Reserved June 2012 Page 56 of 79 SRSA esac, SENSED oo weve aenergereounGM WORLDWIDE ENGINEERING STANDARDS. GMw3191 5 Measuring ree Nowe’ 14,3, = Spray Potten Dimensions (Seo Table 23) Figure 31: Nozzle and Jet Dimensions Table 23: Spray Pattern @ a b (305)* 100 mm (22)mm (305) 160mm (10=2)mm 4.4,11.3 Sample Preparation. Prepare complete connector samples with all terminals, seals, TPAs and ‘grommets or shields intended for the production application. For block type cable seals, insert and remove the {erminal from its cavity twice. 4.4.11.3:1 Test Samples. Fully populated mated connector pairs fitted with the following: 4.4.11.3.2 Number of Test Samples. Ten (10) pairs, ‘+ Three (2) paits with largest wire size + Four(4) pairs with smallest wire size + Three (3) pairs mixed with the smallest and the largest wire size. ‘Some cavities shall remain unplugged and the cavities sealed with appropriate design intent cavity plugs, flashed-over cavities, otc © Copytght 2012 Gener! Moire Compary Al Fights Reserved June 2012 Page 87 of 79‘GM WORLDWIDE ENGINEERING STANDARDS GMW3191 4.4.11.4 Procedure. Mount the test samples on a tumntable with a rotation rate of (5 & 1) rpm. Subject the connector samples to the high pressure water spray for in Positions 1 thru Position 4 as ilustrated in Figure 32 for 30 seconds each. ‘Let connectors dry through evaporation instil air at room temperature. Perform the Isolation Resistance Test specified in Section 4.3.6. Position 1 Legon es Nozzle 8: = Testsample : = Turtle Rotating one Foferance pins (0, $0", 60" and 90") Figure 32: High Pressure Spray Test Arrangement 4.4.1.5 Acceptance Criteri 4. All parts shall meet the Isolation Resistance Test Acceptance Criteria specified in Section 4.3.5, 2. There shall be no traces of water visible inside the connector upon examination of the interior of the connection system at the end of test. 3. All parts shall meet the visual examination acceptance criteria specified in Section 3.4.1.7. 4.4.12 Fluid Resistance. 4.4.12.1 Purpose. To determine ability of sealed connection systems to withstand exposure to various fluids commonly found in and eround road vehicies. Note: This test shall only be run If the connector CTS defines the connection system as Sealing Class 2 of Sealing Class 3. © Copyraht 2012 Genera Motors Gorapany All Rigs Reserved ‘June 2012 Page 88 of 79‘GM WORLDWIDE ENGINEERING STANDARDS GMw3191 4.4.42.2 Equipment. + Laboratory fume hood. + Stainless steel lanks or glass beakers. + Explosion-proof heat chamber. 4.4.2.3 Sample Preparation. Prepare complete test samples with all torminals terminated to the smallest Wire size specified for the respective terminal. For block type seals, insert and remove the terminal from its cavity twice. 4.4.12.3.1 Test Samples. Mated connector pair. 4.4.12.3.2 Number of Test Samples. Twenty (20) pairs minimum. 44.124 Procedure. Caution: Follow all federal, state, and local safety regulations, standards, and procedures when performing this test 1. Prepare a sufficient number of male and female terminal leads using the smallest size wire specified for the respective terminals to fully essemblo at least twenty (20) mated connector pairs. These terminated leads shall be built on design intent production crimp machines. Note: For header-type connectors, prepare samples only for the mating connector. 2. Assemble a minimum of twenty (20) pairs of fully populated mating connector pairs using the terminals prepared in Step 1, Assembly shall include all applicable TPAs, seals, etc. Number each mated ‘connector pair. 3. Condition test samples per Section 3.3. Verify conformance of each mated connector assembly pair to Section 3.4, . Perform the Isolation Resistance test, per Section 4.3.6. This establishes a reference for the ‘concluding Isolation Resistance test. 6. Completely submerse at least two (2) test samples in each fluid listed in Table 24 for 30 minutes, Fluids are to be stabilized at the temperatures indicated in Table 24. Note: A fresh test sample is to be used for each fluid and each test sample is to be submersed in one {lid only, unless otherwise requested by the GM Connector Engineer. 7. Atthe conclusion of the submersion period, remove the sample from the fluid and store the wet test ‘samples in suitable containers for one week. Do not allow test samples submersed in different fluids to touch each other and do not allow any dissimilar fuid drippings to intermingle. Caution: Do not shake off any excess fluid. Use care not to splash any fluid on unintended surfaces. 8. Porform Pressure(Vacuum Leak, Section 4.4.10. © Copysght 2072 General Motors Company Al Righs Reserved ‘June 2012 Pago 59 of 79GM WORLDWIDE ENGINEERING STANDARDS, Gomw3191 Table 24: Fluids Fluid é aes ‘Specification Number Temperature Brake Fluid {L000 0102 or SAE RMEE-04 50°C oil 'B 040 0800 or ASTM IRM-002 85°C Gasoline ‘GMW14914 oF ASTM Reference Fuel C 25°C Engine Coolant 8 040 1085 or ASTM Service Fluid 104 100°C ‘Automatic Transmission Fluid 18040 1073 or Citgo #33123 85°C Windshield Washor Solvent ‘Commercial 25° Power Steering Fluid “B 040 2012 or ASTM IRM-903 50°C Diesel Fluid EN’ 690 or 90% ASTIN IRM 903 + 10% T-Xylone 25°C E85 Ethanol Fuel {85% Ethanol + 15% GMW14914 or 25°C 85% Ethanol + 15% ASTM Reference Fuel | Note: Depending on the specific application, addtional fluids may be required. Refer to GMW 3172. 4412.5 Acceptance Criteria. There shall be no visible degradation, ewelling, cracking, of loss of mechanical function evident on any test sample when examined under 10% to 40x magnification Note: Swelling of cable and cable seals is permissible if the function is not affected, Connectors shall pass all sealing performance requirements. 4.5 Miscellaneous Tests. 4.8.4 Resistance of Short Circult Devices. 4.5.4.4 Purpose. This test is used to determine the electrical resistance of a short circuit device or shorting bar. This testis performed each time a test sequence specifies the Dry Circuit Test defined in Section 4.3.2 if the connector under test utiizes any number of shorting clips in its design and construction. This testis run in addition o the Ory Circuit Test. Care must be taken not to interfere with the reliable collection of data from the Dry Circuit Test. This test may 'be run at the end of the tast sequence if performance of ths test In its normal occurrence in the test sequence would result in the corruption of data in the Dry Circuit Test 4.5.4.2 Equipment. ‘A micro-ohmmeter that limits the following: «The open circuit voltage to 20 mV. The applied current to @ maximum of 100 mA. ‘The micco-ohmmeter shall also use either the offset compeneation or current reversal mothods to measure resistance. 4.5.1.3 Sample Preparation. A minimum of ten (10) samples shall be measured. 4.5.1.4 Procedure. Refer to Figure 33. Measure the resistance across A to B and B to C using instruments which determine resistance by either the ‘offset compensation or current reversal methods. Calculate the resistance across points D and E per the following formula: Rrotat comnecrion = R(DE) = R(AB) — R(BC) © Conynght 2012 Genel Motors Company Al Rghis Reserva ‘June 2012 Page 60 of 79GM WORLDWIDE ENGINEERING STANDARDS GMW3191 c B E 460mm23mn 75mm:3mm Short circuit spring = eo v mt 75mm23mm A D Figure 33: Electrical Resistance of Shorting Bars 5.1.5 Acceptance Criteria. Rrorat cowecrion shall be less than 40 mQ. 4.5.2 Terminal Push-out Force, 4.5.2.1 Purpose. The Terminal Push-out Force testis used to determine the retention of the male terminal in certain stitched or insert molded header connectors. It may also be used to test the attachment of male pins ‘when staked or soldered directly to circuit boards. Proper pin retention ensures that the terminal will not be displaced by forces associated with normal engagement and disengagement of the mating connector. 4.5.2.2 Equipment. + Insertionfextraction force tester with peak force reading feature + Appropriate fixtures to hold the connactors + Collets, mandrels, or jaws to grip the terminal or pin in a longitudinal direction, as needed. 4.5.2.3 Sample Preparation. All test samples shall be production intent. For designs where pins are closely spaced, pins or terminals may need to be selectively removed or cut to allow space for attachment of jaws, collets or mandrels. All pin locations for a given header design shall be tested. In no case shall less than ten (10) pins be tested, 45.2.4 Procedure. 1, Measurements shall be taken in the following directions, if possible: fa, Forward pushing force to dislodge the pin into the header (as if mating a female connector). b. A rearward puling force to dislodge the terminal out of the header (as when removing a female connector from the header) Note: Depending on individual design, "pushing” or “pulling” may be reversed in order to get the proper reading. I may also be appropriate to apply the loads from the back of the connector on certain designs, 2. Secure the header body to an appropriate fixture. 3. Using the force tester, epply pressure to the male terminal pin at rate of (50 + 10) mm/minute. Record the peak force required to displace the terminal a distance of 0.20 mm. Repeat for each pin location. Note: Where resultant damage to the connector housing would affect readings on adjacent cavities, ‘move fo an undamaged pin oF use a fresh connector. 4. Using new test samples as needed, reverse force direction and repeat Step 2 and Step 3. 5. Repeat Stops 1 thru 4 using headers that are moisture conditioned by being exposed to 95% to 98% Relative Humidity at +40 °C for 6 hours. The push/pull tests shall be performed immediately following ‘removal of the headers from the temperaturefhumidity chamber. Note: Step 5 is not required for designs where soldering, welding, or metal-to-metal mechanicat ‘crimping isthe primary terminal retention method, © Conyght 2012 General Motors Compa June 2012 Page 61 of 79GM WORLDWIDE ENGINEERING STANDARDS GMW3194 be at least the values specified in Table 25. Table 25: Push-out Force 4.5.2.5 Acceptance Criteria, The force required to displace a male terminal 0.20 mm in either direction shall ‘Terminal Width Push Force (Engage) Pull Force (Disengage) £0.80 mm z Pee ag NSEC 16N s15mm SON SON 528mm ON eON 228mm 7ON 70N a 4.6 Further Requirements. 4.6.1 Test Sequences. The respective test sequences are defined in Tables 26 thru Table 30, and ‘summarized in Table 31 (© Copyright 2012 General Metre Company Al Rights Reservas ‘June 2012 Page 62 of 79‘GM WORLDWIDE ENGINEERING STANDARDS ‘GMW3191 Table 26: Terminal Mechanical Tests Crack Corrosion teat Section 4.2.4 CrimpWeld Integri Seq, 298 Secion 423 Terminal-to-Terminal Seq, 26C Engagement Force r Section 4.2.3 Visual Vieval Examination [7] Examination Section 3.4 Section 3.4 Terminal Cavity Polarization Seq, 26D Section 4.26 ‘Terminal Send Resistance eae Section 4.2.7 Terminal Push-Out Force Seq. 26F Section 4.52 Male Terminals (if needed) Nota: Seq, = Sequence © Copyright 2012 General Netra Company Al ighis Reserved ‘June 2012 Page 63 of 79GM WORLDWIDE ENGINEERING STANDARDS: GMw3191 Table 27: Terminal Electrical Tests Seq. 274 Seq. 278 10 Samples of each [10 Sampies of the largest wire size wite size Conditioning Section 33 Conditioning Section 3.3 ‘Visual Examination Visual Examination Section Visual Examination Section Section 3.4 34 zeta: Maximum Current Maximum Current Rating Table 11: Maximum Rating Section 4.3.4 Section 4.3.1 Resistance Values ‘Visual Examination Section 34 Note: Sea, «Sequence {© Copyright 2012 Goneral Motors Compary Al Rights Reserved June 2072 Page 64 of 79GM WORLDWIDE ENGINEERING STANDARDS. GMW3194 Table 27: Terminal Electrical Tests (continued) Visual Examination’ Section 3.4 Dry Circuit Resistance Section 43.2 Resistance of Short Circuit Devices ‘Section 4.5.1 (Gf required) Seq. 276 i a Seq, 270 ~~ 1008-Hour Current Cyeing Heavy Duty Test Section 4.3.4 Section 4.4.5 Dry Circuit Resistance Section 4.3.2 Visual Examination Section 3.4 Note: Seq, =Sequence © Copyright 2012 General Motors Company Al Fights Reserved ‘June 2012, Page 65 of 79‘GM WORLDWIDE ENGINEERING STANDARDS GMw3191 Table 28; Connector Mechanical Tests Teyminalo-Conedor Seq Engogemert Force a ‘Section 4.2.4 Conditioning | Terminal-from-Connector i Gecion33 cea Parson ace 7 8 i (See Breakout Flow {next page) coed vege) ; [ Connocorto Comes | sea Crsavemat Farce | Sttion tz Vaval Vat cxonation cxomiation Souler at Gaston se Terminal Postion Assurance 33 Pes sedin 29 Teyaiand Si “Opor sea ton Retenon | PSoeton 0 sea Mechanical Assit teanity a Socton att = Conpacor Wout Fate sea Mechanical Strenath | we seon a2 = Connecter Aube oa = Comet Look eshaical ssi Grete seater 4 Note: Seq. = Sequence: ote cepts cru ic age teg used Tone 2072 Pose 86 of 78‘GM WORLDWIDE ENGINEERING STANDARDS GMw3191 Table 28: Connector Mechanical Tests (continued) Ge res poe) A Seq. 288 Temalar Stionrace Section 4.2.5 ee Tose Pinar ond su Torna uni ot Primary Lock a Conataning rome Cami Heat row Smet, | foocint25| | seatQeay | | Stora rent, ron a Tonlew ron uae yoke Tomi oe Binary rd one ene) Visual earttien Somees ee assole cee ec Tre 2 Pata‘GM WORLDWIDE ENGINEERING STANDARDS Gemw3i91 Table 28: Connector Mechanical Tests (continued) Connector Poston er ‘Assurance (CPA) "Section 218 ‘Conditioning es ‘Connector Seal Retention - Section 33 Sen ated Connector Section 42.18 ‘Connector Seal Retention - Sea. Uae Conector Section 42.417 Viewai Viewal Examination Examination Section 34 Section 3.4 = ‘locked Connector | 2N Disengagement Force LN Section 4.2.18 pe Uniocked Connector —) S68 Disengagement Force | ——} Section 42.18 Connector Poiarzaton Soa. (Coding) Feature 280 etfectvanccs Section 4.2.20 Sec, Flammability 2aR Section 44.6 Note: Sag.» Sequence © Conyight 2012 General Motors Company At Rights Reserved June 2072, Page 68 of 79GM WORLDWIDE ENGINEERING STANDARDS. Gmw3191 Table 28: Connector Mechanical Tests (continued) Visual Examination Section 3.4 Seq. 285, Dry Circuit Resistance Section 4.3.2 Resistance of Short Circuit Devices Section 4.5.4 (required) ‘Mechanical Shock Section 4.2.21 Dry Circuit Resistance Section 4.3.2 [ Resistance of Short Circuit Devices Section 4.5.1 (if required) Vibration with Thermal Cycling Section 4.4.8 Diy Gircut Resistance Section 43.2 Resistance of Short Circuit Devices Section 4.5.1 (if required) Visual Examination Section 3.4 Note: S0q, = Sequence (© Copyright 2012 General Motors Company All Fights Resonisd ‘June 2012 Page 69 of 79emw3191 | GM WORLDWIDE ENGINEERING STANDARDS. ‘Table 29: Sealed Connector Environmental Tests Conditioning Section 3.3 Visual Examination Section 3.4 Teolation Resistance Section 4.3.5 Dry Cireult Resistance Section 4.3.2 Resistance of Short Circuit Devices Section 4.5.1 (if required) S09. 298 Seq. T Fluid Resistance Section 4.4.12 Pressure/Vacuum Leak Corrosion B Section 4.4.10 Section 4.4.7 (next page) Isolation Resistance Section 4.3.5 Dielectric Strength Section 4.3.6 Dry Circuit Resistance Section 4.3.2 Resistance of Short Circuit Devices Section 4.5.1 (if required) Visual Examination Section 3.4 Note: Sag. = Sequance {© Copyight 2012 Ganaral Motors Company Al Rights Reserved June 2012 Page 70 of 78Table 29: Sealed Connector Environmental Tests (continued) GM WORLDWIDE ENGINEERING STANDARDS (from previous page) B Pressure/Vacuum Leak (Sealing Class 2 and Class 3) ~ Gmwsi91 Seclon a ee Seq. 296 Seq.200__| Seq. 29 Seq. 20F I — I Farid Host Ther Agog ‘Themal Shock dul eat Gonsant Secon Seon 2 yee HC) tates) ; senion ee eer reese Note: Sag. = Sequence ‘June 2012 PressurelVacuum Leak (Sealing Class 2 and Class 3) ‘Section 4.4.10 ‘Water Submersion (Sealing Class 2 and Class 3) Section 4.49 T Visual Examination Section 3.4 eee] High Pressure Spray (Sealing Class 3) Section 4.4.11 Cts cee eee Isolation Resistance Section 4.3.6 Dielectric Strenath Section 4.3.6 : Dry Circuit Resistance Section 4.3.2 Resistance of Short Circuit Devices Section 4.5.4 (ifrequired) fisual Examination Section 3.4 {© Copyight 2012 General Moore Compary Al Rghs Reasred Page 71 of 79‘GM WORLDWIDE ENGINEERING STANDARDS ‘Tabla 30: Unsealed Connactor Environmental Tests ‘Conditioning Section 3.3 Visual Examination Section 3.4 Isolation Resistance Section 4.3.5 Dry Gireuit Resistance Section 4.3.2 I Resistance of Short Circut Devices ‘Section 4.5.1 (if required) GMws191 ‘Seq. 308 Seq. 308 Seq. 306 Seq, 30D Seq. 30E T Thermal Aging Section 4.4.1 I Humid Heat Termat Humid Heat juin ‘Shock Cyalic (HC) (HHCO) Section 4.4.2 Section 4.4.3 ares Corrosion Section 4.4.7 Note: Seq. = Sequence ‘June 2072, Isolation Resistance Section 4.3.5 Dielectric Strength Section 4.3.6 Dry Circuit Resistance Section 4.3.2 Resistance of Short Circuit Devices ‘Section 4.5.4 {if required) T Visual Examination Section 3.4 (© Copypght 2012 General Motors Comany Al Rights Reserved Page 72 of 79 SENTASE Bayes wromnon. enemaGM WORLDWIDE ENGINEERING STANDARDS. GMW3194 Table 31: Connector Validation Test Matrix } eeii | , 4 5 ge/3 | 2 4 Hn GLIB rca sh) aa| ee] ae] 42 8 SPURL EET ail a iz]. ge | ga|s2| 32) 8s ia) ¢ ab |e) 23) 22] oe as & gE —| $2] se | sé |@2| 4 Name of Test fh 88) 42/95] 23 Terminal - Mechanical Tests 2A | 424 _| Grack Conosion x x 268 422 _| CrimpiWeld Integrity x x x acc | 429 | TeminstiocTemine| Erosoement | i i 260 | 426 _| Terminal Cavity Polarization x x x 26 | 42.7 _| Terminal Bend Resistance x x Terminal Push-out Force call ona {male terminals only} * a a Terminal - Electrical Tests 27 | 434 _ | Maximum Current Rating x x x 278 | 433 _ | Votage Drop x x x 27e | 434 | 1008-Hour Curent Gyeing x x x 270 | 445 | Heavy Duty Test x x x Connector System Mechanical Tests “Terminal to-Connector Engagement zea | 424 | Tomi x | x x x TTerminal-rom-Connector Extraction | zee | 428 | Fermi x | x x x Cannectort-Connector 28C | 428 | Engagement Force eee | seen ee fe 220 | 42.9 _ | Terminal Postion Assurance (TPA) Level and Slide “Open? Postion 2a | 42.0 | Loveland x |x | x 2aF | 42.17 | Mechanical Assist integrity Mae anes ae Connector Mounting Feature 286 | 42.12 | Mechanical Strength z i 20H | 42.13 _| Connector Audible Feedback x px Lx px Connector Lock Mechanical ras | 42.14 | Connector x | x |x | x {© Covi 2012 General Motors Company A Rats Reserved “June 2012 Page 73 of 79 es ee eeGM WORLDWIDE ENGINEERING STANDARDS. Gmw3191 [eat | corre tone eis FEATHER a ee ie awa | camo [Soompamenr ome [x [x | x x 298 | 4.4.12 | Fluid Resistance eee a 290 444 Thermal Aging x x x [290 | 442 _| Thermal Shock x x x 296 4.4.3 Humid Heat Cyclic (HHC) Se x x x 290 a y ae a Unsealed Connector Environmental Tests 308 | 4.4.1 | Thermal Aging x 308 | 4.42 | Thermal Shock x 30c | 443 | Humid Heat Cyclic (HHO) x x x 300 | 4.4.4 | Humid Heat Constant (HHCO) | x |x| «|x 306 | 4.47 | Corrosion (© Copyright 2012 Genera Motors Cmany Al Fights Reserved June 2012, Page 74 of 79‘GM WORLDWIDE ENGINEERING STANDARDS Gmw3191 5 Provisions for Shipping ‘Not applicable. 6 Notes 6.1 Glossary. Not applicable, 6.2 Acronyms, Abbreviations, and Symbols. a ‘Amplitude of Acceleration ac Alternating Current Avg ‘Average of Values CPA Connector Position Assurance crs ‘Component Technical Specification cur Conductor Under Test cur Connector Under Test pe Direct Current omm Digital Multimeter DRE Design Release Engineer DRE Design Responsible Engineer ECU Engine Control Unit EGR Exhaust Gas Recirculation f Frequency HH Humid Heat Cyclic HHCO Humid Heat Constant Hipot High Potential 4 Cutrent Load hr Test Current w Connector Mating Force Class Max Maximum Value Min Minimum Value ‘mvD ‘Miltivott Drop Nacl Sodium Chloride (Table Salt) PIF PassiFall Result PLR Primary Lock Retention PPAP Production Part Approval Process sD Power Spectral Density RMS. Root Mean Square 8 Sealing Class Seq. ‘Sequence SIR Supplemental inflatable Restraint sqrt Square Root sto ‘Standard Deviation of Values T Temperature Class Ts Ambient Temperature qh Temperature Limit TPA Terminal Position Assurance Tur Terminal Under Test v Vibration Class, {© Copysght 2012 General Motors Company ll Fights Reserved ‘June 2012 Page 75 of 79GM WORLDWIDE ENGINEERING STANDARDS. GMw3191 7 Additional Paragraphs 7.4 All parts or systems supplied to this standard must comply with the requirements of GMW3059, Rest and Reportable Substances for Parts. 8 Coding System This standard shal be referenced in other documents, drawings, etc, as flows: cmwatat 9 Release and Revisions This standard was originated in January 1999. It was first approved by the Global Electrical Team in October 2007. It was frst published in December 2007. Issue | Publication Date Description (Organization) 1 DEC 2007 | initial publication 2 JUN 2012 | General updates, 5 year refresh. (Electrical - PSDS) © Copyight 2012 General Moore Company Al Fights Reserved ‘June 2012 Page 76 0f 79‘GM WORLDWIDE ENGINEERING STANDARDS GMw3191 Appendix A Data Sheet At: Electrical Connection System ~ Test Summary Date: Tost Report Number: Preliminary Final Signatures: Tested By Approved: Seq. : Results nite, | Section | Name of Test oF tar [Avg [S10 Terminal Mechanical Tests 2A 42.1 _ | Crack Corrosion 268 42.2 _ | CrimpiWeld Integrity | | 200 42.3 _ | Terminalto-Terminel Engagement Force 260 42.6 _ | Terminal Gavity Polarization 20, 42:7 _| Terminal Bend Resistance Terminal Push-out Force fa 482 | (male terminals only) ‘Terminal - Electrical Tests 27”, 43.1 _ | Maximum Current Rating 278 433 _ | Voltage Drop 270, 43.4 _ | 1008-Hour Current Cycling 270) 445 | Heavy Duty Test Connector System - Mechanical Tests 288 42.4 _ | Terminal-to-Connector Engagement Force 288 425 _ | Terminal-from-Connector Extraction Force Dae 429 | Comeetorto-Connecor Engagement 280) 42.9 _ | Terminal Position Assurance (TPA) I 28E 42.10 | Lever and Slide "Open Position Retention 28F 4.2.11 | Mechanical Assist integrity ae ara. | Conneclor Mounting Feature Macon 28H 42.13 | Connector Audible Feedback NIA. 28) 4.2.14 | Connector Lock Mechanical Overstress 28K 42.48 _ | Connactor Position Assurance (CPA) I (© Copyright 2012 Ganecal Motors Company Al Righs Resorved ‘June 2012 Page 77 of 78‘STANDARDS GMw3191 Results Number | Seton | Name of Text iF | Min | wax [Avg [ S10 I or antion = aa | azae | SrmacarbosiRaerin-tees i ; zen | 427 | Sameer SeatRetnton- Vonetes 2aN | 42.48 _| Locked Connector Disengagement Force 28 | 42.48 | Unlocked Connector Disengagement Force 280 4220 Cameco ea (Coding) Feature 7k | _446 | Flammability 285__ | 4221 _| Mechanical Shook 285; 44.8 | Vibration with Thermal Cycling | Sealed Connector Environmental Tests [ea | 4412 [Fluid Resistance T 298 | 447 _| Corrosion 2c__| 44a __| Thermal Aging 200 442 | Thermal Shock 295 443 Humid Heat Cyclic (HHC) 25, 444 | Humid Heat Constant (HCO) | 200 thea 449 | Water Submersion 29F | 200 tra | 44.10 | Preseurervacuum Leak 2F 29 i tra | 44.11 | High Pressure Spray 20F Unsealed Connector Environmental Tests 308 443 | Thermal Aging 308 442 _ | Thermal Shock | 0c 443 Humid Heat Cyclic (HHC) 300 444 | Humid Heat Constant (HHCO) 30 447 | Corrosion | | Note Seq. = Sequence © Conyight 2012 General Mears Company Al Rights Reserved June 2072 Page 78 of 79[ GM WORLDWIDE ENGINEERING STANDARDS, ‘GMw3191 Result | Acceptable Values * PIF Test Pass, Fail or Not Applicable (N/A) Min Minimum valve obtained during testing or NYA Max Maximum value obtained during testing or NVA Avg Average ofthe values obtained during testing or NIA STD ___| Standard Deviation of values obtained during testing or NIA ‘Note: No ther valuse are accepabi, Failure Report Out ‘Any failure that occurs during testing shall be detailed out in the following table. The supplier shail provide the failure reason as well as the correct requirement that should have been met. ‘Seq. Notes | Section Name of Test Failure Detail Tater Seq = Sequence (© Copyright 2012 General Motoe Company Al Rights Reserved June 2012 Page 79 of 79