WORLDWIDE
General Specification
ENGINEERING
HVAC & PT Cooling
STANDARDS
Pressure Relieve Devices for Low and High Pressure Side
1 Introduction
Note: Nothing in this standard supersedes
applicable laws and regulations.
Note: In the event of conflict between the English
and domestic language, the English language
shall take precedence.
1.1 Scope. Pressure relieve device is for use in all
passenger car and light commercial vehicle air
conditioning.
1.2 Mission/Theme. This standard defines the
minimum requirements for pressure relieve
devices of the passenger car air conditioning
system (not valid with/for R744 heating system),
which are operated with refrigerant R744.
The pressure relive devices cause a refrigerant
blow-off from the car air conditioning system in
any event of a system over pressure.
2 References
Note: Only the latest approved standards are
applicable unless otherwise specified.
2.1 External Standards/Specifications.
DIN 50014 ISO 9227
DIN 8964 SAE J639
ISO 9001
2.2 GM Standards/Specifications.
GM10009C GMW3059
GME14090 GMW3116
2.3 Additional References. German OEM safety
concept, draft.
3 Requirements
3.1 System/Subsystem/Component/Part
Definition.
3.1.1 Appearance. All exterior and interior
surfaces shall be clean and free of manufacturing
lubricants, flux, soluble flux residue, metal chips,
scale, and other contaminants that are not
associated with the function. Flux residue shall not
be considered a contaminant if it is insoluble in
© Copyright 2008 General Motors Corporation All Rights Reserved
May 2008 Originating Department: GME Specification Center
GMW15867
water, R744 or PAG/POE oil and does not
contribute to corrosion in the system.
Appearance and finish of parts shall be free of
weld and/or braze splatter, flash, ridges,
roughness and of tool lubricants and other
contamination according to DIN 8964.
3.1.2 Content. The major function of the pressure
relieve device in the R744 AC system is to protect
the components and the AC system from
exceeding the maximum pressure. While current
R134a refrigeration systems have mostly one
pressure relieve device on the high pressure side
in the compressor, two pressure relieve devices
shall be provided on both the high pressure and
low pressure sides of R744 refrigeration systems
respectively per SAE J639 and German OEM
safety concept.
The main reasons for exceeding the maximum
pressures are due to either refrigerant overfill of
the refrigerant circuit, or malfunctions of the
compressor control or blocking of a component
e.g. evaporator.
3.1.2.1 Physical Content. The pressure relieve
device shall provide sealing to refrigerant R744.
Sealing and function shall be designed for vehicle
life time. Refrigerant flow out from the pressure
relieve device shall be planned and executed
carefully to assure that the refrigerant can escape
from the system with the lowest possible risk.
3.1.2.2 Functional Content. Two fundamental
functional types of pressure relieve devices are
possible for the refrigerant circuit with R744:
• The self closing reversible relief valve, which
closes itself and consequently the refrigerant
circuit automatically and tightly after each
overpressure incident and
• The irreversible burst device, which responds
once. The entire refrigerant inside the AC
system with part of the lubricant is discharged
to the environment and the AC circuit is
remaining open to the environment.
The probability that the pressure relieve device on
the low pressure side responds is much lower than
a response of the high pressure side. Usually the
excessive operating pressure on the low pressure
side is caused by a significant overfill or blocking
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GMW15867
behind the burst device e.g. evaporator. On the
high pressure side excessive operating pressure is
caused by malfunction of high pressure limitation
of the compressor.
Each pressure relieve device shall operate
automatically. No other methods by mechanical,
thermostatically and electrical control are allowed
to use for the activation of the pressure relieve
device.
The most important differences between the relief
valve and the burst device are:
• Lower component strain than by explosive
decompression, because normally the system
is not completely emptied to ambient pressure
level.
• Because the relief valve closes at a certain
pressure the system normally never run
without refrigerant.
• The noise level in case of relief valve
response relative to burst device response is
lower.
• The function of the relief valve shall be tested
without damaging the relief valve.
3.1.3 Ambient Environment and Operating
Conditions. This defines the ambient
temperatures and refrigerant temperatures which
the components are exposed to. As orientation the
following values are defined for operating and non
operating AC system. If the AC system is switched
off the ambient conditions are equal to
environment temperatures which are relevant for
the design and construction of the pressure relive
devices.
3.1.3.1 High Pressure Side. The pressure relieve
device shall be mounted directly in the compressor
as part of compressor assembly. Due to the typical
location of the compressor is near the hot engine,
therefore, the environmental temperatures are in
the range of:
• -40 °C in switched off condition and/or
• -12 °C during refrigeration system operation to
• +130 °C permanent to
• +150 °C short term (5 minutes max. each for a
total of 168 h).
For special application - extreme hot - which shall
be defined by GM
• -40 °C in switched off condition and/or
• -12 °C during refrigeration system operation to
• +150 °C permanent to
• +180 °C short term (5 minutes max. each for a
total of 168 h).
© Copyright 2008 General Motors Corporation All Rights Reserved
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GM WORLDWIDE ENGINEERING STANDARDS
The refrigerant temperature during operation is
between (-12…+165) °C and +180 °C short term
(5 minutes max. each for a total of 168 h).
3.1.3.2 Low Pressure Side The pressure relieve
device shall not be located near the hot engine or
other heat source underhood, therefore, the
environmental temperatures are in the range of
• -40 °C in switched off condition and/or
• -12 °C during refrigeration system operation to
• +120 °C permanent to
• +135 °C short term (5 minutes max. each for a
total of 168 h)
The refrigerant temperature during operation is
between (-12…+80) °C.
3.1.4 Interfaces.
3.1.4.1 High Pressure Side. Pressure relieve
devices shall in principle be integrated in the
system directly or close to the pressure source.
The relief valve and/or the burst device on the high
pressure side are therefore part of the
compressor.
3.1.4.2 Low Pressure Side. Additionally another
pressure relieve device shall be provided on the
low pressure side because of the maximum
operating pressure on the low pressure side.
In compliance with SAE J639, overpressure by
overcharging and also by blocking shall be
avoided, therefore, the relief valve or burst device
on the low pressure side shall be located
upstream directly after the expansion device and
before the evaporator.
3.1.4.3 Non-Interchangeability. The pressure
control devices for high and low pressure side are
not allowed to interchange one another. Therefore
the outside design of the pressure control
elements shall be so different that mismatch is
impossible. A metric fine left threat shall be used
for high pressure side with size M12x1 and for low
pressure side with size M14x1. A hexagonal bolt
head without thread marking is required.
3.1.4.4 No Cross Section Reduction. When
installing the pressure relieve devices in the
respective AC pipe and compressor, the detail
dimensions of the interface shall be reviewed
carefully to ensure that the end plugged into the
line and the housing of the compressor does not
negatively influence the flow cross section of the
medium. The reduced cross section of the flow
path will cause pressure losses. Such pressure
losses are not allowed for the normal function of
the pressure relieve device.
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GM WORLDWIDE ENGINEERING STANDARDS
3.1.5 Safety and Usage Definition. The
installation location of both pressure relieve
devices shall be selected to assure that refrigerant
blow-off is outside the passenger compartment
including AC unit, air intake and luggage
compartment.
Additionally, the installation locations and blow-off
directions of the pressure relieve devices shall be
such that personal injury of persons near the
vehicle and the system is not possible in case of
refrigerant blow-off. The burst sound level shall be
such that no personal injury of persons near the
vehicle and the system is possible.
The integration of the pressure relieve devices into
a third component, e.g. expansion device or
connector block, shall be in such a way that the
pressure relieve devices is from the outside of the
component removable. To avoid that the pressure
relieve device will be opened or will be replaced
inappropriately e.g. through a screw, a warning is
required on the pressure relieve device. The
warning shall say e.g.: Do not remove or the
corresponding ‘ISO symbol’ shall be used.
3.2 Product Characteristics. The test
temperature for the following physical tests is
(+23 ± 5) °C according to DIN 50014 unless
otherwise specified.
A minimum of 5 test samples are required for each
test.
The test results shall be documented as part of
PPAP documents to GM.
3.2.1 Performance Requirements. The minimum
response pressures at which the pressure relieve
devices shall respond at the earliest are:
• 15 MPa on the high pressure side (HD)
• 11 MPa on the low pressure side (ND)
The pressure relieve devices shall be open
completely and at which the pressure in the
refrigerant circuit shall not increase any further
are:
• 17 MPa on the high pressure side (HD)
• 13 MPa on the low pressure side (ND)
The response pressure (RP) intervals of the
pressure relieve devices are:
• 15 MPa < RP for HD side < 17 MPa
• 11 MPa < RP for ND side < 13 MPa
Especially for relief valves: The relief valve shall
close at a pressure, which is 1.2 MPa below the
response pressure. After ten responses the
response pressure shall be still within the specified
response interval. After each response, the relief
valve shall return to a safe condition, i.e., the
© Copyright 2008 General Motors Corporation All Rights Reserved
May 2008
GMW15867
change of response pressure shall be in the
direction of lower pressures, whereby complete
resealing shall further be assured. The emptying
of the system shall be 250 kg/h.
Especially for burst device: The emptying of the
AC system to closely ambient pressure level
depends on drain diameter and design. The initial
emptying speed of the AC system shall be
5 MPa/s. As initial pressure the response pressure
of the burst device may be used.
3.2.1.2 Leak Rate. The R744 leak rates of the
pressure relieve devices are limited to a value of
1 g/year maximum.
These leak rates are determined according to the
load collectives shown in Appendix A, Table 1 for
the low pressure side and in Table 2 for the high
pressure side.
The pressure relieve devices shall be installed as
follows:
• HD: High Pressure side in test block e.g.
compressor block without further leakage
points such as tube connections and shaft
seal on it.
• ND: Low Pressure side in test block e.g.
refrigerant pipes or expansion device without
further leakage points.
The measurement is made with a mixture of R744
and the refrigerant oil specified. The ratio of the
mixture of R744 and the oil shall be same as the
specified value of the AC system of the vehicle.
After filling the test block, compressor block etc.
the test unit shall be shacked to allow the oil being
on the entire internal surface.
Each load condition shall be maintained until a
steady-state condition of the leakage reached, but
at least 48 h. Leakage shall be determined in a
system evacuated as required. C02 leakage is
determined with a mass spectrometer and/or an
equivalent leak detector. The average leak rate
shall be determined as follows:
n
VR m = ∑ VRi ⋅ Gewi
i =1
VRm average leak rate of the sample
VRi leak rate in the load condition i
Gewi weighting factor for the load
condition i
Compliance with these requirements shall be
assured after all function tests and for the entire
vehicle life cycle.
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GMW15867
Especially for Relief Valve: After five responses
the leak rate may increase to 1.5 g/year. After
> 10 actuations the leak rate may increase to
2 gram/year maximum.
Repeated leak rate test: The repeated leak rate
test is made under the load condition No.3 and
shall be used for the single and series tests which
will be defined later.
The leak rate determined according to
Appendix A, Table 1 and Table 2 (at standstill
+30 °C and a system pressure of 7 MPa) is
defined as the base leakage for the pressure
relieve device. This value shall not be exceeded
during all repeated leak rate tests. The tolerance is
set to 20 %. The load condition shall be
maintained for 48 h according to this paragraph.
3.2.1.2 Resistance to Under Pressure/Vacuum.
The pressure relieve devices shall be installed
according to paragraph 3.2.1.1 in test blocks
which are completely sealed to the environment by
soldering. A vacuum of 0.5 kPa absolute shall be
applied to the pressure relieve devices and
maintained constant for 5 minutes. The allowed
pressure increase shall not exceed 0.5 kPa within
30 minutes and with pump switched off.
During this test function shall not be impaired.
After this test, the leak rate test according to
paragraph 3.2.1.1 shall be repeated.
The under pressure resistance test with leak rate
test shall be performed subsequent 3 times.
3.2.1.3 Response Pressure Test. The response
pressure for high pressure side shall be tested at:
• 15 MPa at +200 °C < RP < 17 MPa at +80 °C.
The response pressure for low pressure side shall
be tested at:
• 11 MPa at +120 °C < RP < 13 MPa at +30 °C.
A separate burst pressure test for pressure relieve
valve and burst element is not required.
3.2.1.4 Pressure Cycling Test. The pressure
relieve devices shall be installed according to
paragraph 3.2.1.1 in test blocks which are
completely sealed to the environment by
soldering.
© Copyright 2008 General Motors Corporation All Rights Reserved
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GM WORLDWIDE ENGINEERING STANDARDS
Test conditions for low pressure side:
• pressure cycles: 150 000
• test duration: 292 h (150 000 x 7 s)
• test pressures: (2.5…9) MPa abs.
• test medium: hydraulic or refrigerator oil
• temperature of test oil: (+80 ± 2) °C
Test conditions for high pressure side without
creeping:
• pressure cycles: 150 000
• test duration: 292 h (150 000 x 7 s)
• test pressures: (5…14.5) MPa abs.
• test medium: hydraulic or refrigerator oil
• temperature of test oil: (+155 ± 2) °C
The timing of the pressure cycles for high and low
pressure side as shown in Figure 1, the duration of
the pressure ramp is 0.5 s and of the holding
pressure is 3 s.
Figure 1: Pressure cycles for high and low
pressure side without creeping
< 0.5 3s
Pressure in MPa
< 0.5 s 3s
0,0
Time in s
Creeping test only for high pressure side:
For each new technology it is mandatory to proof
one time that no creeping appears. If the proof
was performed it is not necessary to repeat this for
small design changes, but the supplier has to
inform GM. Test conditions for creeping on high
pressure side:
May 2008
GM WORLDWIDE ENGINEERING STANDARDS
Table 1: Test Conditions for Creeping on High Pressure Side
Pressure Cycles
im MPa
5 P 14.5 5500
5 P 14.5 11 000
5 P 14.5 38 500
During the creeping test function the pressure
relieve valve shall not be impaired nor the form
malleable changed.
After this test, the leak rate test according to
paragraph 3.2.1.1 shall be repeated and the
respond pressure according to paragraph 3.2.1.3
shall be repeated.
3.2.1.5 Temperature Cycling Test. The pressure
relieve devices shall be tested in the condition
assembled with the pipe, expansion device and/or
the compressor as follows:
Fill the test sample with test medium hydraulic or
refrigerator oil and apply following pressure:
ND: low pressure side 10.5 MPa
HD: high pressure side 14.5 MPa
The temperature cycle intervals are:
• ND: from [(-40…+120) ± 2] °C
• HD: from [(-40…+160) ± 2] °C
The soak and/or cooling speed is ±1 °C/minute.
The holding time at the min/max values are
30 minutes each, the total cycle duration:
• HD: 460 minutes (30 – 200 – 30 – 200)
• ND: 380 minutes (30 – 160 – 30 – 160)
Total test duration:
• HD: 77 h 10 cycles
• ND: 63 h 10 cycles
After this test, the leak rate test according to
paragraph 3.2.1.1 shall be repeated and the
respond pressure according to paragraph 3.2.1.3
shall be repeated.
3.2.1.6 Vibration Test. For the vibration test the
pressure relieve devices shall be installed
according to paragraph 3.2.1.1 in test blocks
which are completely sealed to the environment by
soldering.
The test sample shall be filled internally with water
or refrigerant oil to a level of 30 % and after with
nitrogen in the space above. The average
© Copyright 2008 General Motors Corporation All Rights Reserved
May 2008
GMW15867
Temperature Period Time
in °C (HD-ramp-ND-ramp) in h
in s
165 315 481
(300 - 5 - 5 - 5)
135 315 962
(300 - 5 - 5 - 5)
105 7 75
(3 – 0.5 - 3 – 0.5)
pressures are 14 MPa for the high pressure side
and 10 MPa for the low pressure side. The test
shall be performed at room temperature.
The test sample is exposed to a sinusoidal
vibration in vertical direction as follows:
• frequency 20 Hz sinusoidal
• No. of cycles: 3.6 x 106 (duration 50 h)
• acceleration: ± 31.4 m/s2 (this shall be result
to a amplitude: ± 2 mm)
After this test, the leak rate test according to
paragraph 3.2.1.1 shall be repeated and the
respond pressure according to paragraph 3.2.1.3
shall be repeated.
If functional component parts made from plastic:
Subsequently this test shall be made in the cold
chamber at -20 °C and a pressure 2 MPa with the
other conditions remaining the same.
After this test, the leak rate test according to
paragraph 3.2.1.1 shall be repeated and the
respond pressure according to paragraph 3.2.1.3
shall be repeated.
3.2.1.7 Corrosion Test. The salt spray tests are
accelerated corrosion test of the pressure relieve
devices using a cyclically sprayed aqueous, acetic
sodium chloride solution as corrosion agent.
The corrosion test shall be performed 20 days
according to:
• SWAAT ISO 9227
and 24 weeks according to
• Alternating Climatic Corrosion Test to
ISO 9227
Both tests are described in Appendix A Table 3
and Table 4.
The pressure relieve devices shall be leak tight
over the total test. After the test no functional
failure shall be occur due to corrosion.
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GMW15867
After this test, the leak rate test according to
paragraph 3.2.1.1 shall be repeated and the
respond pressure according to paragraph 3.2.1.3
shall be repeated.
If aluminum parts are used an even surface
corrosion and/or shallow pitting corrosion is
permitted with a wall thickness up to 30 %. Pitting
corrosion and other corrosion mechanisms e.g.
inter-crystalline corrosion are not allowed.
3.2.1.8 Decompression Test. In case an
elastomer is in direct or indirect contact with the
refrigerant, a decompression test shall be made.
The pressure relieve device shall be assembled
with a test block as described
paragraph 3.2.1.1. With a suitable fixture the
pressure relieve device is kept open permanently,
such that the elastomers shall be tested in direct
contact with the refrigerant.
The pressure relieve devices are exposed to a
pressure of 14 MPa for high pressure side and
10 MPa for low pressure side at a temperature of
+130 °C.
For the actual compression test the pressure is
reduced to environment level within < 10 s.
Malfunctions are not allowed.
After this test, the leak rate test according to
paragraph 3.2.1.1 shall be repeated and the
respond pressure according to paragraph 3.2.1.3
shall be repeated.
3.2.1.9 Minimum Number of Relief Valve blow-
off. After ten responses, the response pressure of
the relief valves shall be still within the specified
response interval.
The response intervals according to paragraph
3.2.1.3 are:
• 15 MPa < PR < 17 MPa high pressure side
• 11 MPa < PR < 13 MPa low pressure side
To inspect the repeatability of the blow-off
process, a test shall be performed with a
refrigerant/oil mixture with 5 % oil content. The
response valve pressure is uniformly increased at
a rate of (0.8…1.0) MPa/s until the valve opens.
The pressure shall be reached within the
respective response interval.
Compliance with these requirements shall be
assured after all function tested including ten
responses.
After this test, the test pressure shall be reduced
until the relief valve closes. The pressure resulting
shall not be more than 1.2 MPa below opening
pressure.
© Copyright 2008 General Motors Corporation All Rights Reserved
Page 6 of 14
GM WORLDWIDE ENGINEERING STANDARDS
The leak rate test according to paragraph 3.2.1.1
shall be repeated after each response. In this
case, the test time may be reduced to 6 h.
3.2.2 Physical Characteristics.
3.2.2.1 Dimensions and Capacity. The
dimension of the pressure relieve devices shall be
designed together with the component in which
the device will be integrated.
3.2.2.2 Mass Properties. The mass of the
pressure relieve device on the low pressure side
shall not exceed 50 g and of the high pressure
side 75 g.
3.2.3 Dependability.
in
3.2.3.1 Target Life. Due to the fact that the
pressure relieve devices are safety components
the function of the pressure relieve devices shall
be assured for an average vehicle life of at least
15 years and/or 300 000 km and/or
6200 operating hours.
For pressure relief valve: At least ten times of the
responses or the resealing within the activation
interval shall be assured for the vehicle life. After
this test, the relief valves shall return to a “safe
condition“, i.e., the change of the response
pressure shall be towards lower pressures only,
whereby the defined leak rate shall further be
assured.
The function of pressure relieve valve seals shall
be assured for vehicle life time.
3.2.3.2 Class 1 and Class 2 Type Problems.
3.2.3.2.1 Class 1 Type. Not applicable.
3.2.3.2.2 Class 2 Type. Not applicable.
3.2.3.3 Reliability Requirements. Not applicable.
3.2.4 Serviceability. The pressure relieve devices
of high and low pressure side shall not be
interchangeable and shall therefore be at least of
different outer designs, see paragraph 3.1.4.3.
Both pressure relieve devices shall be installed
such that a visual inspection is possible in vehicle
service. At the same time it shall assured that
there is no risk of injury for service personnel due
to refrigerant blow-off or due to burst sound level.
The orientation of the pressure relieve device shall
be controlled in the packaging design.
Removal of the pressure relieve devices from the
outside of the component shall be possible without
special tools.
3.2.5 User System/Subsystem/Component/Part
Interface. Not applicable.
May 2008
GM WORLDWIDE ENGINEERING STANDARDS
3.3 Design and Construction. The pressure
relieve devices shall be designed such that
external influences (temperature, weather, dirt,
etc.) do not impair their function. Under certain
circumstances a protective cap and/or shield shall
be provided, which shall not negatively impact the
pressure relief function of the refrigeration circuit
(reduction of cross section, icing, etc.).
Sealing of the pressure relieve devices shall be
metallic, i.e., without elastomers.
Especially for relief valves only: For the relief
valves used, it shall be assured that the relief bore
is not plugged by icing in case of refrigerant blow-
off.
3.3.1 Materials, Processes and Parts Selection
Guidelines.
3.3.1.1 Material Guidelines. All the materials
used shall be in compliance with the applicable
GM material standards and the drawing
requirements.
Materials used shall be hazardous to human
health and environment not at any time during the
components life cycle.
The component shall be compatible externally with
oil, fuel and any other media used in vehicles and
internally with each media used for the AC system
per GM engineering (oil, refrigerant, odorant).
The inner surfaces of the component shall be
clean without any manufacturing residues, which
may be dissolved during operation by refrigerant
R744 or the respective compressor lubricant and
result in contamination and/or plugging of the
refrigerant circuit.
For component design and packaging design, the
underhood condition affected by temperature
(engine radiation), weather (salt in the winter
time), mechanical loads (rough track) and
comparable factors shall be considered. Neither
function nor service life of the pressure relieve
devices shall be impaired.
3.3.1.2 Processes Guidelines. The supplier shall
provide DFMEA and PFMEA to GM for review and
discussion. The design FMEA shall include
particularly computational demonstration of
compliance of strength and service life and
tolerances analyses of the components.
Development and manufacture to ISO 9001
standard shall be assured.
Materials developed to this standard shall be
optimized to provide maximum end-of-life cycle
value utilizing the Vehicle Recyclability /
Recoverability Calculation Sheet. Recycled
content shall be reported to the approving and
procuring Materials Engineering Department
© Copyright 2008 General Motors Corporation All Rights Reserved
May 2008
GMW15867
utilizing the Part Recyclability / Recoverability
Report Form. Reference Appendix A of
GMW3116, Recyclability, Recoverability
Guidelines.
Suppliers shall be use Statistical Process Control
(SPC) in all critical areas as determined by the
vehicle platforms. The hose suppliers and hose
couplers shall maintain records of audits and SPC
data for at least three years. These records shall
be available to the vehicle platforms and the
Global T/HVAC Center. Also, the hose supplier
records shall be available for the hose coupler.
3.3.1.3 Parts Guidelines. The component shall be
compatible with all climatic and driving conditions.
The function of the component shall be fulfilled
any time.
The components shall not be contaminated with
residues, such as deposits, scale, cuttings and
grease. The maximum permissible contaminations
due to flushable, soluble and solid residues shall
be 10 mg/m2 (unless otherwise specified), with
respect to the internal surface. 40 % max. may be
soluble and 60 % max. insoluble. The size of the
internal surface is determined from the appropriate
drawing for the component. The test shall be
performed according to DIN 8964.
3.3.2 Design Guidelines and Constraints. The
component shall be designed in compliance with
the GM drawing requirements. GM part numbers
and the drawings shall be used for GM production.
Compliance with the characteristics described in
the functional description in addition to those in the
drawing is the responsibility of the supplier if the
pressure relieve device.
Statistical methods shall be used to demonstrate
compliance by the supplier.
The supplier shall ask for the valid version.
Detailed design and process Failure Mode and
Effects Analysis (FMEA) shall be submitted to the
release engineer which will be maintained as part
of the records of the Design and Product
Validation. The FMEA shall be updated each time
a change occurs. FMEA shall be submitted with
the GM PPAP documentation
3.3.3 Identification and Marking. The pressure
relieve devices shall be permanently identified with
the date of manufacture of the assembly,
manufacturer's identification, manufacturing
location and assembly part number.
All pressure relieve devices shall be marked with
the appropriate GM part no. to GME14090.
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GMW15867
3.3.4 Workmanship. Due to the high pressures
inherent with R744, testing shall be only
performed by properly trained personnel using
equipment capable of these tests with adequate
safety margins. All material shall be used in
accordance with the supplier Material Safety Data
Sheet (MSDS).
3.3.5 Interchangeability. See paragraph 3.1.4.3.
3.4 Documentation. Samples of components or
material released to this standard shall be tested
for conformity with the requirements of this
standard and approved by the responsible GM
Department prior to the start of delivery of
production level components or materials.
Any change to the component or material e.g.,
design, function, properties, manufacturing
process and/or location of manufacture requires a
new release of the product. It is the sole
responsibility of the supplier to provide the
customer, unsolicited, with documentation of any
change or modification to the product/process, and
to apply for a new release.
If not otherwise agreed to the entire verification
test shall be repeated and documented by the
supplier prior to start of delivery of the modified or
changed product. In some cases a shorter test
may be agreed to between the responsible GM
Department and the supplier.
3.4.1 Test Results. With reference to this
standard the measurement results shall be
summarized in a test report.
3.4.2 Deviations from Test Procedure.
Deviations from the requirements of the test
procedures shall have been agreed upon. Such
requirements shall be specified on component
drawings, test certificates, reports etc.
3.5 Support of System/Subsystem/Component/
Part After Sale. Not applicable.
3.6 System/Subsystem/Component/Part
Operator Training. Not applicable.
3.7 System/Subsystem/Component/Part
Characteristics. Not applicable.
3.7.1 System/Subsystem/Component/Part
Definition. Not applicable.
4 Validation
4.1 General. The test temperature for the
following physical tests is (+23 ± 5) °C according
to DIN 50014 unless otherwise specified.
The validation report shall be delivered to GM.
Statistical test validation method shall be used to
ensure the required relieve burst pressure.
© Copyright 2008 General Motors Corporation All Rights Reserved
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GM WORLDWIDE ENGINEERING STANDARDS
4.2 Validation Cross Reference Index.
4.2.1 Combined Test. This is an aging test using
the tests described above in the following
sequence:
• 50 % of Pressure cycling
• 50 % of Temperature cycling
• 50 % of Vibration test
• 10 days SWAAT salt spray test
• 50 % of Pressure cycling
After this test, the leak rate test according to
paragraph 3.2.1.1 and the respond pressure
according to paragraph 3.2.1.3 shall be repeated.
4.3 Supporting Paragraphs.
4.3.1 Chemical requirements. Compliance with
the requirements to dryness and interior and
exterior cleanliness is required in assembly with
the compressor, expansion device and/or
refrigerant pipe or expansion device.
4.3.2 Interior Cleanliness. The internal parts of
pressure relieve device shall be free of all
contamination that could impair the operation
and/or the performance of the assembly, such as
metal particles, dirt, foreign material, and residual
manufacturing material.
The internal parts of pressure relieve device shall
contain zero moisture as received by GM.
The internal parts of pressure relieve device shall
be free of burrs, sharp corners, etc. which may be
detrimental to assembly and function.
All the definitions of interior cleanliness of GM
technical specification of R134a components shall
apply to this standard.
The soluble and solid residues which can be
washed away with solvent shall not exceed
10 mg/m2 (unless otherwise specified) and shall
not contain any abrasive materials. All residues
shall be < 15 mg/part.
The measures shall be performed according to
DIN 8964 C1 and C2.
Abrasive materials are not allowed. The particle
size shall be 60 µm (depending on
R744 compressor standard) unless otherwise
specified.
4.3.3 Exterior Cleanliness. The exterior surface
of the pressure relieve devices shall be
30 mg/part of residues, lubricants and any other
contaminants.
The assembly and component parts shall be free
of all contamination that could impair the operation
and/or the performance of the assembly, such as
metal particles, dirt, foreign material, and residual
manufacturing material.
May 2008
GM WORLDWIDE ENGINEERING STANDARDS GMW15867

The assembly shall contain zero moisture as 5.1 Shipping Caps. All assemblies shall have
received by GM. shipping caps, as specified by the detail drawing
The assembly and component parts shall be free which maintain a fully installed position, until the
of burrs, sharp corners, etc. which may be hose / pressure relieve valve / compressor etc.
detrimental to assembly and function. assembly is installed into a final system assembly.
The shipping caps shall be according to
4.3.4 Quality Assurance in Production. The test
GM10009C. During removal, there shall be no
temperature for the following physical tests is
degradation of features as represented by the
(+23 ± 5) °C according to DIN 50014 if not
detail drawings. This would include but not be
otherwise specified.
limited to, dislodging of sealing mechanism (if
The validation report shall be delivered to the required), damage to threads or sealing areas.
responsible GM department.
4.3.4.1 Response Pressure for Valves. Each 6 Notes
part (100 %) shall be tested when it is installed 6.1 Glossary. Not applicable.
into its component (compressor, lines, expansion
device) similar to paragraph 3.2.1.1. 6.2 Acronyms, Abbreviations, and Symbols.
To inspect the blow-off, the component is filled
with R744. The pressure is uniformly increased at AC Air Condition
a rate of (0.5…0.1) MPa/s until the valve opens. CASS Copper-Accelerated Salt Spray
The pressure reached shall be within the
respective response interval: CDS Component Data Standard
• 15 MPa < PR < 17 MPa high pressure side DFMEA Design Failure Mode effect Analysis
• 11 MPa < PR < 13 MPa low pressure side FMEA Failure Mode effect Analysis
4.3.4.2 Response Pressure for Burst Devices.
Statistical test validation method shall be used to HD High pressure side
ensure the required relieve burst pressure. As an LSL Lower Standard Limit
example the statistical method is shown in
Appendix 2 for the low pressure side. For the high MSDS Material Safety Data Sheet
pressure side the parameters has to be adapted. ND Low pressure side
4.3.4.3 Leak Rate. Each part (100 %) shall be
tested when it is installed into its component PAG Polyalkylene glycol
(compressor, lines, expansion device) similar to PFMEA Process Failure Mode Effect Analysis
paragraph 3.2.1.1 at (+23 ± 5) °C with e.g. R744,
He, air. POE Polyolester
The applied pressures are for low pressure side PPAP Production Part Approval Process
9 MPa and for high pressure side 14.5 MPa. The
pressure shall be applied for 10 s. Leak detector PXV Pressure Expansion Valve
or mass spectroscopy shall be used for detection. RP Response pressure
The leak rate of 10 g/year R744 shall be proofed.
SPC Statistical Process Control
A correlation between used test medium and R744
is required. SWAAT Sea Water Acetic Acid Test
USL Upper Standard Limit
5 Provisions for Shipping
The refrigerant pressure relieve devices All physical parameters and units used refer SI
assemblies shall be compatible with commercial units; in particular it shall be observed that the
shipping by air, rail, truck. and/or boat and include pressures indicted are always absolute pressures.
retaining provisions if necessary. Degradation of Symbol Unit Description
the pressure relieve devices assemblies M R744 kg/h Refrigerant Mass Flow
appearance, performance, and/or durability due to
T R744 °C Refrigerant Temperature
shipping is not acceptable. Upon successful
completion of required manufacturing quality P R744 MPa Refrigerant Pressure
levels, the pressure relieve devices assembly shall
be prepared for delivery in accordance with the
requirements specified below:

© Copyright 2008 General Motors Corporation All Rights Reserved

May 2008 Page 9 of 14

GMW15867 GM WORLDWIDE ENGINEERING STANDARDS

7 Additional Paragraphs 7.3 Approved Sources. Engineering qualification

of an approved source is required for this
7.1 All parts or systems supplied to this standard
standard. Only sources listed in the GM Corporate
must comply with the requirements of GMW3059,
Materials File under this standard number have
Restricted and Reportable Substances for
been qualified by engineering as meeting the
Parts.
requirements of this standard. Sources are
7.2 Inspection and Rejection. All shipments of available through the on-line MATSPC System.
material or parts under contract or purchase order
manufactured to this specification shall be
8 Coding System
equivalent in every respect to the initial samples
approved by engineering. There shall be no This standard shall be referenced in other
changes in either formulation or manufacturing documents, drawings, etc. as follows:
processes permitted without prior notification and GMW15867
approval by engineering. Lack of notification by
the supplier constitutes grounds for rejection of 9 Release and Revisions
any shipment. While samples may be taken from
9.1 Release. This standard originated in
incoming shipments and checked for conformance
April 2008. It was first approved by GSSLT HVAC
to this specification, the supplier shall accept the
in MAY 2008. It was first published in MAY 2008.
responsibility for incoming shipments meeting this
standard without dependence upon purchaser's
inspection.

© Copyright 2008 General Motors Corporation All Rights Reserved

Page 10 of 14 May 2008

GM WORLDWIDE ENGINEERING STANDARDS GMW15867

Appendix A

A1
Table 2: Statistic Load Collectives Low Pressure Side
p t weighting factor
n load collective (ND)
in MPa in °C in %
1 standstill -30 °C 1.43 -30 4
2 standstill 0 °C 3.5 0 16
3 standstill +30 °C 7.2 +30 70
4 operation +10 °C evaporator 4.5 +45 2
5 operation 0 °C evaporator 3.5 +30 3
6 heating 7.0 +100 5
Table 3: Statistic Load Collectives High Pressure Side
p t weighting factor
n load collective (HD-hot)
in MPa in °C in %
1 standstill -30 °C 1.43 -30 4
2 standstill 0 °C 3.5 0 16
3 standstill +30 °C 7.2 +30 70
4 operation 10.0 +130 4
5 idle 13.0 +165 1
6 heating 7.0 +100 5

Table 4: SWAAT Test according to ISO 9227

SWAAT
Aging:
Zn Fe: > 24 h at +100 °C
Zn Ni: > 24 h at +150 °C
salt solution: 42 g/l NaCl
acetic acid: 10 g/l
Salt Spray Test
pH value of condensate:2.8…3.0
temperature: +50 °C
30 min spray
Cycle (2 h) composed of:
90 min rest

© Copyright 2008 General Motors Corporation All Rights Reserved

May 2008 Page 11 of 14

GMW15867 GM WORLDWIDE ENGINEERING STANDARDS

Table 5: Alternating Climatic Corrosion Test according to ISO 9227

Alternating Climatic Corrosion
Aging:
Zn Fe: > 24 h at +100 °C
Zn Ni: > 24 h at +150 °C
salt solution: 40 g/l NaCl
salt solution: 10 g/l CaCl2l
Salt Spray Test
pH value of condensate: 6.5…7.2
temperature: +35 °C
Week Cycle
4 h spray
5 days = (5 x 24) h corrosion 4 h cool down to (+23 ± 5) °C
16 h store at +40 °C / 100 % relative humidity
2 h cool down
4 h store at -40 °C
2 days =(4 x 12) h alternating climatic
2 h warm up
4 h store at + 80 °C

A2 For each temperature a sample size of 125 pieces

A2.1 Statistical Evaluation and Interpretation.
Test procedure, statistical evaluation and
interpretation to ensure that the low pressure burst
device meets the pressure response requirements
with respect to the opening pressure over a certain
temperature range in production process. The
statistical evaluation of this test procedure is
based according to ISO 9001 standard.
Specification of the analysis of a test procedure for
proofing that the opening pressure stays within the
critical specification limits (LSL = 11.0 MPa / USL
= 13.0 MPa) for temperatures range from
(+30…+120) °C. (LSL / USL = lower / upper
specification limit): It is presumed that the mean
opening pressure changes monotonic with
changing temperature (the bigger the temperature,
the lower the opening pressure). For this reason it
shall be determined that the opening pressure
stays within the standard limits for the highest
(+120 °C, see paragraph 3.2.1.3) as well as for the
lowest relevant temperature
(+30 °C, see paragraph 3.2.1.3). In order to proof
the capability of the process both temperatures
need to be tested individually.
shall be tested to ensure statistical relevance. On
the basis of these tests the mean value of the
opening pressure shall be determined according to
Eq 1 for each temperature separately. The
standard deviation shall be determined likewise for
each temperature according to Eq 2. Using these
values for the mean opening pressure and its
standard deviation one has to determine the
process capability indices Cp and Cpk using Eq 3,
(for details refer to QS 9000, as part of ISO 9001)
and the specification limits LSL=11.0 MPa and
USL=13.0 MPa. For the determined capability
indices the following limits shall be reached:
Cp > 2.0 and Cpk > 1.67
A Cpk value of 1.67 corresponds to < 1 ppm out of
the specification limits, see Table 7. In Figure 2
the estimated normal probability distributions for
the qualitatively expected results of the tests are
depicted. The used numerical values to generate
this plot are provided in Table 6 (Notice these are
just estimated numbers to illustrate what kind of
results are expected). The stability of the
production process and the staying within the
specification limits shall be checked by analyzing
samples periodical according to ISO 9001.

Table 6: Expected qualitative results of the tests at +30°C and +120°C with respect to the obtained
opening pressure of the valve
Estimated quantity Measurements at +120°C Measurements at +30°C
mean value 11.90 MPa 12.20 MPa
standard deviation s 0.16 MPa 0.14 MPa
Cp 2.08 2.38
Cpk 1.88 1.90

© Copyright 2008 General Motors Corporation All Rights Reserved

Page 12 of 14 May 2008

GM WORLDWIDE ENGINEERING STANDARDS GMW15867

Figure 2: Expected qualitative results of the tests at +30 °C and at +120 °C with respect to the
obtained opening pressure

LSL USL
0.35

0.3 mean value 120°C mean value 30°C

probability density

0.25

0.2
s
0.15 s

0.1

0.05

0
110 112 114 116 118 120 122 124 126 128 130

opening pressure in bar

1 MPa 10 bar
Depicted are the fitted normal probability densities which correspond to the capability indices Cp and Cpk
computed according to Eq 1 – Eq 3.

1 n
Eq 1: x= ∑ xi
n i =1
(sample size n = 125)

Eq 2: s=
1 n
n − 1 i =1
(
∑ xi − x )2
(sample size n = 125)

USL − LSL   USL − x   x − LSL  

Eq 3: Cp = C pk = min   , 
  3s  


6s  3 s  

© Copyright 2008 General Motors Corporation All Rights Reserved

May 2008 Page 13 of 14

GMW15867 GM WORLDWIDE ENGINEERING STANDARDS

Example:

Table 7: Cpk values and corresponding number of parts out of the specification limits in ppm (parts
per million), worst case values are given, i.e. the distribution is assumed to be centered so that an
equally portion of parts out of the specification limits at both sides is expected.

Cpk < ppm

1.00 2699.796
1.10 966.848
1.20 318.217
1.30 96.193
1.33 63.342
1.40 26.691
1.50 6.795
1.60 1.587
1.67 0.573
1.70 0.340
1.80 0.067
1.90 0.012
2.00 0.002

Table 7 is added to make the meaning of the Cpk value more comprehensible.

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Page 14 of 14 May 2008