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GS-95024-2-1_2010-01_EN

By Martin Brooks,2014-12-23 17:32
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GS-95024-2-1_2010-01_EN GS-95024-2-1_2010-01_EN GS-95024-2-1_2010-01_EN GS-95024-2-1_2010-01_EN GS-95024-2-1_2010-01_EN GS-95024-2-1_2010-01_EN GS-95024-2-1_2010-01_EN GS-95024-2-1_2010-01_EN GS-95024-2-1_2010-01_EN GS-95024-2-1_2010-01_EN GS-95024-2-1_2010-01_EN GS-95024-2-1_2010-01_EN GS-95024-2-1_2010-01_EN GS-95024-2-1_2010-01_EN GS-95024-2-1_2010-01_EN GS-95024-2-1_2010-01_EN GS-95024-2-1_2010-01_EN GS-95024-2-1_2010-01_EN GS-95024-2-1_2010-01_EN GS-95024-2-1_2010-01_EN GS-95024-2-1_2010-01_EN GS-95024-2-1_2010-01_EN GS-95024-2-1_2010-01_EN GS-95024-2-1_2010-01_EN GS-95024-2-1_2010-01_EN GS-95024-2-1_2010-01_EN GS-95024-2-1_2010-01_EN GS-95024-2-1_2010-01_EN GS-95024-2-1_2010-01_EN GS-95024-2-1_2010-01_EN GS-95024-2-1_2010-01_EN GS-95024-2-1_2010-01_EN GS-95024-2-1_2010-01_EN GS-95024-2-1_2010-01_EN GS-95024-2-1_2010-01_EN GS-95024-2-1_2010-01_EN GS-95024-2-1_2010-01_EN GS-95024-2-1_2010-01_EN GS-95024-2-1_2010-01_EN GS-95024-2-1_2010-01_EN GS-95024-2-1_2010-01_EN GS-95024-2-1_2010-01_EN GS-95024-2-1_2010-01_EN GS-95024-2-1_2010-01_EN GS-95024-2-1_2010-01_EN GS-95024-2-1_2010-01_EN GS-95024-2-1_2010-01_EN GS-95024-2-1_2010-01_EN GS-95024-2-1_2010-01_EN GS-95024-2-1_2010-01_EN GS-95024-2-1_2010-01_EN GS-95024-2-1_2010-01_EN GS-95024-2-1_2010-01_EN GS-95024-2-1_2010-01_EN GS-95024-2-1_2010-01_EN GS-95024-2-1_2010-01_EN GS-95024-2-1_2010-01_EN GS-95024-2-1_2010-01_EN GS-95024-2-1_2010-01_EN GS-95024-2-1_2010-01_EN GS-95024-2-1_2010-01_EN GS-95024-2-1_2010-01_EN GS-95024-2-1_2010-01_EN GS-95024-2-1_2010-01_EN

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     BMW Group Standard

     Deskriptoren: Descriptors: Komponente, Kraftfahrzeug, Anforderung, Pr??fung Component, Motor vehicle, Requirement, Testing

     GS 95024- -1 -22010--01

     Ersatz f??r GS 95003--2 : 2007--03 Replacement for GS 95003--2 : 2007--03

     Elektrische und elektronische Komponenten in Kraftfahrzeugen

     Elektrische Anforderungen und Pr??fungen

     Electrical and electronic components in motor vehicles

     Electrical requirements and testings

     Ausdrucke unterliegen nicht dem ?nderungsdienst. Print-outs are not subject to the change service.

     Fortsetzung Seite 2 und 44 Seiten LV Continued on page 2 and 44 pages LV

     BMW AG Normung: 80788 M??nchen

     E BMW AG interleaf-doc Alle Rechte vorbehalten / All rights reserved Bearbeiter / Author: Robert Maier

     Seite/Page 2 GS 95024--2--1 : 2010--01

     Vorwort

     Grundlage dieses Group Standards ist die LV 124 :2009--10 ??Elektrische und elektronische Komponenten in Kraftfahrzeugen bis 3,5 t; Allgemeine Anforderungen, Pr??fbedingungen und Pr??fungen??. Diese Pr??frichtlinie wurde in Zusammenarbeit mit den Firmen Audi AG, Daimler AG, Porsche AG, Volkswagen AG erarbeitet. Die Pr??fungen (E--01 bis E--22) beschreiben hersteller??bergreifend harmonisierte Anforderungen, Pr??fbedingungen und Pr??fungen. Die Norm legt Mindestanforderungen f??r die Qualifikationspr??fung, die Betriebswerte, Beanspruchungsprofile und Pr??fbedingungen bez??glich der elektrischen Anforderungen f??r elektrische und elektronische Komponenten fest. Die bekannten weiteren Anforderungen,

    Pr??fbedingungen und Pr??fungen, sowie die notwendige

    Systembetrachtung aus GS 95003--2 : 2007--03 sind in GS 95024--2--2 und GS 95024--2--3 festgelegt. Die bisherige GS 95003- ist f??r Neukonstruktionen nicht -2 mehr anzuwenden.

     Foreword

     This Group Standard is based on LV 124 :2009--10 ??Electrical and electronic components in motor vehicles up to 3.5 t; General requirements, test conditions and tests??. This test guideline has been compiled jointly by the following companies: Audi AG, Daimler AG, Porsche AG, Volkswagen AG. The tests (E--01 bis E--22) describe

    requirements, testing conditions and tests which have been harmonized jointly by above automobile manufacturers. The standard defines minimum requirements of electrical and electronic components to be applied for qualification tests, operating values, stress profiles and test conditions. The known further requirements, testing conditions and tests as well as the required system specifications from GS 95003--2 : 2007--03 are defined in GS 95024--2--2 and GS 95024--2--3. In case of new designs the previously applicable Standard GS 95003- is no longer valid. -2

     nderungen

     Gegen??ber GS 95003--2 : 2007--03 wurden folgende ?nderungen vorgenommen: -- Inhalt der LV 124 ??bernommen.

     Amendments

     The following amendments have been made to GS 95003--2 : 2007--03 : -- Content of LV 124 adopted

     Fr??here Ausgaben

     Previous editions

     GS 95003--2 : 2000--03, 2001--10, 2003--06, 2007--03

     Version 1,3

     LV 124

     Creation date 18.01.2010

     LV124

     Electric and Electronic Components in Motor Vehicles up to 3.5 t - General Component Requirements, Test Conditions and Tests

     Page 1 of 44

     Version 1,3

     LV 124

     Creation date 18.01.2010

     Contents Part I - Electrical Requirements???? 4 1 Referenced standards ???? 4 2 General part ???? 4 2.1 Terms and definitions ???? 4 2.2 Sampling rate and measured value resolution ???? 5 2.3 Operating voltage ranges ???? 6 2.4 Functional statuses ???? 7 2.5 Operating modes ???? 8 2.6 Parameter test ???? 9 2.7 Continuous parameter monitoring with drift analysis ???? 10 2.8 Physical analysis ???? 10 2.9 Interface description ???? 10 2.10 Procedural limitations ???? 10 3 Test selection ???? 11 3.1 Test selection table ???? 11 4 Electricalrequirements and tests ???? 13 4.1 E-01 Long-term overvoltage ???? 13 4.2 E-02 Transient overvoltage ???? 14 4.3 E-03 Transient undervoltage???? 15 4.4 E-04 Jump start ???? 16 4.5 E-05 Load dump ???? 17 4.6 E-06 Superimposed alternating voltage ???? 18 4.7 E-07 Slow decrease and increase of the supply voltage ???? 19 4.8 E-08 Slow decrease, quick increase of the supply voltage ???? 21 4.9 E-09 Reset behavior ???? 23 4.10 E-10 Short interruptions ???? 25 4.11 E-11 Start pulses ???? 27 4.12 E-12 Voltage curve with intelligent generator control ???? 31 4.13 E-13 Pin

    interruption ???? 33 4.14 E-14 Connector interruption ???? 35 4.15 E-15 Reverse polarity ???? 35 4.16 E-16 Ground offset ???? 37 4.17 E-17 Short circuit in signal circuit and load circuits ???? 38 4.18 E-18 Insulation resistance ???? 39 4.19 E-19 Closed-circuit current ???? 40 4.20 E-20 Dielectric strength ???? 41 4.21 E-21 Backfeeds ???? 42 4.22 E-22 Overcurrents ???? 44

     Page 2 of 44

     Version 1,3

     LV 124

     Creation date 18.01.2010

     Scope

     This document specifies requirements, test conditions and tests for electric, electronic and mechatronic components and systems for the use in motor vehicles up to 3,5 t. Additional or deviating requirements, test conditions and tests must be defined in the respective Component Performance Specifications. Note: The represented tests do not serve for component qualification or a qualification of the manufacturing process.

     Page 3 of 44

     Version 1,3

     LV 124

     Creation date 18.01.2010

     Part I - Electrical Requirements 1 Referenced standards

     Table 1: Referenced standards

     DIN 72552

     UL94

     DIN EN ISO 17025

     Terminal Markings for Motor Vehicles: Examples for Application on Circuit Diagrams Test for Flammability of Plastic Materials for Parts in Devices and Appliances General Requirements for the Competence of Testing and Calibration Laboratories

     2

     2.1

     General part

     Terms and definitions

     Table 2: Abbreviations for voltages and currents

     2.1.1 Voltages and currents

     UN UBmin UB UBmax Umax Umin UPP Ueff Upr??f IN GND UA, UT, US, UR Nominal voltage Lower operating voltage limit Operating voltage Upper operating voltage limit Maximum voltage that may occur during a test Minimum voltage that may occur during a test Peak-peak voltage RMS value of a voltage Test voltage Nominal current Device ground Voltage level of the start voltage pulse

     All voltage and current specifications refer to the component

    (terminal voltage) and do not contain voltage drops, which result from line routing in the vehicle.

     2.1.2 Temperatures

     Table 3: Abbreviations for temperatures

     Tmin TRT Tmax TPr??f

     Minimum operating temperature Room temperature Maximum operating temperature Test temperature

     Page 4 of 44

     Version 1,3

     LV 124

     Creation date 18.01.2010

     2.1.3 Times/durations

     Table 4: Abbreviations for times/durations

     tr tf tPr??f

     Rise time (e.g. of a voltage curve) Fall time (e.g. of a voltage curve) Test duration

     All edge descriptions refer to the 10% or 90% voltage values.

     2.1.4 Other

     Table 5: Other definitions

     Ri Terminal designations f

     Internal resistance of the voltage source Acc. to DIN 72552 ff Frequency

     2.1.5 Standard tolerances

     Unless otherwise indicated, the tolerances acc. to Table 6 apply. Tolerances of envelopes must always be considered unilaterally as, otherwise, the requirement is mitigated. Tolerances refer to the required measured value.

     Table 6: Definitions of standard tolerances

     Frequencies Temperatures Humidity Times/durations Voltages Currents

     ?À 1% ?À 2?ã C ?À 5% + 5%; -0% ?À 2% ?À 2%

     2.1.6 Standard values

     Unless otherwise indicated, the standard values acc. to Table 7 apply.

     Table 7: Definitions of standard values

     Room temperature Humidity Test temperature Nominal voltage Operating voltage (for test)

     TRT = 23?ã ?À5?ã C C Frel = 45% - 75% RH TPr??f = TRT UN = 12 V UB = 14 V

     2.2

     Sampling rate and measured value resolution

     The sampling rate and bandwidth of the measuring system must be adapted to the respective test. All measured values with all maximum values (peaks) must be recorded.

     Page 5 of 44

     Version 1,3

     LV 124

     Creation date 18.01.2010

     The resolution of the measured values must be adapted to the respective test. It must be ensured that occurring voltage peaks do not lead to an overflow or cannot be measured in the case of an insufficient resolution.

     2.3

     Operating voltage ranges

     Table 8: Operating voltage ranges

     Enco ding UBmin UBmax a 6V 16 V

     b

     8V

     16 V

     Description For functions that must retain their performance during starting of the engine For functions that do not have to retain their performance during starting of the engine

     c

     9V

     16 V

     d

     9,8 V 16 V

     Note: This encoding must only be used if the component cannot be classified in the encoding a, c or d. For functions that must retain their performance when the engine is not running For functions that must retain their performance when the engine is running

     Test voltages, especially for over- and undervoltage tests may deviate significantly from the voltage ranges mentioned above and will be specified individually. Functional status A must always be fulfilled within the voltage range applicable for the component.

     Page 6 of 44

     Version 1,3

     LV 124

     Creation date 18.01.2010

     2.4

     Functional statuses

     This Section describes the functional status of the DUT during and after the test. The functional status of the DUT is to be specified for each test. Additional requirements must be defined and documented in the Component Performance Specifications. Memory functions must always remain in functional status A. The integrity (not up-to-dateness) of the non-volatile memories must be ensured at any time. The time sequences of the functional statuses must be specified in the Component

    Performance Specifications. Permissible event log entries must be coordinated with the purchaser and must be stipulated.

     2.4.1 Functional status A

     All functions of the DUT must be performed as specified during and after exposure to the test parameters. Note: The functional status A must also be achieved in the case of deviations of the designed performance (function limitation at high and low temperatures) when the operating voltage is fallen below or exceeded, if this is described in the Component Performance Specifications as permissible (derating).

     2.4.2 Functional status B

     All functions of the DUT must be performed as specified during exposure to the test parameters; however, one or more of them can go beyond the given tolerance. After the exposure to the test parameters, the DUT must fulfill all functions as specified.

     2.4.3 Functional status C

     One or more functions of the DUT are not performed as specified during exposure to the test parameters, but automatically continue tofulfill all functions as specified after the end of exposure. Undefined functions are not permitted.

     2.4.4 Functional status D

     One or more functions of the DUT are not performed as specified during exposure to the test parameters; however, after resetting or a simple technical measure (e.g. exchanging a defective fuse) the DUT continues to fulfill all functions as specified after the end of exposure. Undefined functions are not permitted.

     2.4.5 Functional status E

     One or more functions of the DUT are not performed as specified during and after exposure to the test parameters; after the end of exposure the DUT has to be repaired or replaced. The device under test (DUT) must comply with the requirements for nonflammability acc. to UL94-v0.

     Page 7 of 44

     Version 1,3

     LV 124

     Creation date 18.01.2010

     2.5

     Operating modes

     The electric, electronic and mechatronic components and systems are operated in different operating modes during service life, which must be simulated correspondingly during the tests. Details concerning the operating modes, operating loads (e.g. triggering, original sensors, original actuators or replacement circuitry) and the required boundary conditions must be coordinated between contractor and purchaser and must be documented.

     2.5.1 Operating mode I - DUT not electrically connected

     2.5.1.1 Operating mode I.a The DUT is not electrically connected, without plug and harness. 2.5.1.2 Operating mode I.b The DUT is not electrically connected, but with connected plugs and harness.

     2.5.2 Operating mode II - DUT electrically connected

     2.5.2.1 operating mode II.a each The DUT must be operated without operating load. 2.5.2.2 Operating mode II.b The DUT must be operated with minimal operating load. The DUT must be operated in a way that minimal self-heating occurs (e.g. by means of a reduction of a continuous output performance or unfrequent activation of external loads). 2.5.2.3 Operating mode II.c The DUT must be operated with maximum load (power user, but no misuse). The DUT must be operated in a way that maximum self-heating occurs (e.g. by means of a realistic maximization of a continuous output performance or frequent activation of external loads).

     Page 8 of 44

     Version 1,3

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     Creation date 18.01.2010

     2.5.2.4 Sample operating modes

     Table 9: Sample operating modes

     Operating mode II.a Car radio with Component as navigation system in parked vehicle (sleep). Follow-on current stopped T. 30 "ON". Anti-theft alarm No operation system when vehicle is running. Brake control system Component as in parked vehicle. Follow-on current stopped.

     Sample component

     Operating mode II.b

     Operating mode II.c

     Component in running vehicle. Component switched off by driver, BUS/?ÌC active, T. 15 "ON".

     Component in running vehicle. Component switched on (CD, navigation system, final stage), BUS/navigation computer active.

     Vehicle interior is monitored while vehicle is parked.

     Driving without brake Driving with frequent actuation. brake cycles (no misuse, such as uninterrupted brake control operation).

     2.6

     Parameter test

     A set of sensitive parameters, so-called key parameters, e.g. closed-circuit current consumption, operating currents, output voltages, contact resistances, input impedances, signal rates (rise/fall time) and bus specifications, must be defined in the Component Performance Specifications. Prior to testing and after each test, it must be checked whether these parameters meet the specifications.

     2.6.1 Parameter test (small)

     The key parameters TRT and UB must be measured. The basic functionalities of the components must be measured and documented in the test report.

     2.6.2 Parameter test (large)

     The key parameters must be measured at three different temperatures (Tmax, TRT, Tmin) and with three different voltage levels (UBmin, UB and UBmax) each. The basic functionalities of the components must be measured and documented in the test report.

     2.6.3 Parameter test (functional test)

     The key parameters must be measured at three specified temperatures and three different voltage levels (UBmin, UB and UBmax). The basic functionalities of the components must be measured and documented in the test report.

     Page 9 of 44

     Version 1,3

     LV 124

     Creation date 18.01.2010

     2.7

     Continuous parameter monitoring with drift analysis

     The key parameters to be monitored must be recorded during the whole test. For components with event log, the event log must be monitored continuously and the entries must be documented. The data resulting from the continuous parameter monitoring must be examined for trends and drifting to detect irregularities, aging or malfunctions of the component.

     2.8

     Physical analysis

     For the physical analysis, the DUT must be opened and evaluated visually. Additional analyses (e.g. X-ray examinations and metallographic examinations of the assembly and joining technology) must be coordinated between purchaser and contractor.

     2.9

     Interface description

     All interfaces must be described completely in their statuses and electrical properties. This description serves as a basis for the evaluation of the test results and, thus, must be available in detail.

     2.10

     Procedural limitations

     The test laboratory must be organized and operated acc. to DIN EN ISO/IEC 17025. All test equipment used for measuring must be calibrated acc. to DIN EN ISO/IEC 17025 (or as specified or recommended by the manufacturer). and it must be possible to track the equipment back to the PTB (Physikalisch-Technische Bundesanstalt, Germany) or an

    equivalent national standardized laboratory. The test equipment, setups and test methods used must be documented in Notes on Procedure. The purchaser reserves the right to check the laboratories and the laboratory procedures.

     Page 10 of 44

     Version 1,3

     LV 124

     Creation date 18.01.2010

     3

     3.1

     Test selection

     Test selection table

     The permissible event log entries and the functional statuses of the component must be specified for each test.

     Table 10: Test selection table

     Test

     Applicable to

     Additional specifications

     E-01 Long-term overvoltage

     E-02 Transient overvoltage

     E-03 Transient undervoltage

     E-04 Jump start

     E-05 Load dump

     E-06 Superimposed alternating voltage

     Components supplied via the 12V electric system Components supplied via the 12V electric system Components supplied via the 12V electric system Components supplied via the 12V electric system Components supplied via the 12V electric system Components supplied via the 12V electric system - for devices directly connected to battery plus: severity 1 - for devices between battery and generator: severity 2

     Test severity

     None

     Test severity

     None

     None

     Severity

     E-07 Slow decrease and increase of the supply voltage E-08 Slow decrease, quick increase of the supply voltage E-09 Reset behavior E-10 Short interruptions E-11 Start pulses

     If severity 2 is fulfilled (supplied to the DUT), no further proof is required. All components None

     All components

     None

     All components All components Components supplied via the 12V

electric system

     E-12 Voltage curve with intelligent generator control E-13 Pin interruption E-14 Connector interruption E-15 Reverse polarity

     Components supplied via the 12V electric system All components All components Components which may be subjected to reverse polarity in the vehicle

     None None Test severity warm start, test severity cold start Test setup

     None None Parameter set acc. to input circuitry

     Page 11 of 44

     Version 1,3

     LV 124

     Applicable to

     Creation date 18.01.2010

     Test

     Additional specifications

     E-16 Voltage offset E-17 Short circuit in signal circuit and load circuits E-18 Insulation resistance E-19 Closed-circuit current E-20 Dielectric strength

     All components All components

     None None

     E-21 Backfeeds E-22 Overcurrents

     All components All components Components with inductive parts (e.g. motors, relays, coils) All components All components

     None None None

     None None

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     Version 1,3

     LV 124

     Creation date 18.01.2010

     4

     4.1

     Electricalrequirements and tests

     E-01 Long-term overvoltage

     4.1.1 Aim

     The component's resistance to long-term overvoltage is tested. A generator control fault during driving operation is simulated.

     4.1.2 Test

     Table 11: Test parameters E-01 Long-term overvoltage

     DUT operating mode Test duration Continuous test voltage Test temperature Number of cycles Number of DUTs

     Operating mode II.c 60 min 17 V Tmax - 20 K 1 At least 6

     4.1.3 Requirement

     The evaluation of the test results depends on the use of the component.

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