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--- articles:overvoltage_protection_relay [2020/11/17 07:50] – created john5788
+++ articles:overvoltage_protection_relay [2020/11/17 08:49] (current) – [Testing] john5788
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 ====== Overvoltage Protection Relay  ======
+===== Function  =====
+A 5, 7, or 9-pin overvoltage protection relay is installed depending on the vehicle model and special equipment. This relay protects the control units (ABS, CIS-E, etc.) from excessively high voltage.
+The battery voltage is present continuously at relay terminal 30. With the 7 and 9-pin versions the battery voltage is also connected to terminal 30a over the 10 A flat plug-in fuse. When the ignition/starter switch is turned to position 2 (driving position), the voltage is present at terminal 15 causing the relay to pull in. Power is supplied to terminals 87 (5-pin version) or 87E and 87L (7 and 9-pin versions).
+Voltages > 22 V in the vehicle electrical system are connected directly to ground by the Z diode (fuse defective).
+In the event of overloads occurring after the overvoltage cutout, the circuit is interrupted by the 10 A flat plug-in fuse. The 9-pin version is also fused separately at terminals 87E and 87L, whereby when the fuse for 87E blows 87L is also switched off.
+===== Diagrams and Pinout =====
+<grid>
+<col sm="6">
+<panel type="default" title="Pinout" no-body="true">
+^ Pin ^ Function ^
+| 30 | Battery voltage input (12 V)|
+| 31 | Ground |
+| 15 | Ignition switch input |
+| 87E | Fused and diode protected output (12 V) |
+| 87L | Fused and diode protected output (12 V) |
+| 30a | Fused output (12 V) |
+</panel>
+</col>
+<col sm="6">
+<thumbnail>
+<image shape="responsive">{{ articles:ovp_pinout.png?600}}</image>
+<caption>OVP pinout</caption>
+</thumbnail>
+</col>
+</grid>
+<grid>
+<col sm="4">
+<thumbnail>
+<image shape="responsive">{{ articles:ovp_5-pin.png?600 }}</image>
+<caption>5-pin OVP</caption>
+</thumbnail>
+</col>
+<col sm="4">
+<thumbnail>
+<image shape="responsive">{{ articles:ovp_7-pin.png?600}}</image>
+<caption>7-pin OVP</caption>
+</thumbnail>
+</col>
+<col sm="4">
+<thumbnail>
+<image shape="responsive">{{ articles:ovp_9-pin.png?600}}</image>
+<caption>9-pin OVP</caption>
+</thumbnail>
+</col>
+</grid>
+===== Testing =====
+The following procedure is a static test for basic relay operation. Passing the following test does not guarantee that the OVP relay is functioning correctly, but will accurately tell if the OVP relay is faulty.
+  - Apply 12V to pin 30 and ground 31
+    - Verify with a multimeter that 30a has 12V and 87E/87L has no voltage
+  - Apply 12V to pin 15
+    - The internal relay should click
+    - Verify with a multimeter that 87E and 87L have 12V as well as 30a.
+===== Part numbers =====
+<grid>
+<col sm="6">
+<panel type="default" title="Part Numbers for OVP Relay" no-body="true">
+^ Part Number ^ Description ^
+| 201 540 32 45 | 7-pin relay, black top, single 10A fuse |
+| 201 540 38 45 | 7-pin relay, black top, single 10A fuse |
+| 201 540 37 45 | 9-pin relay, red top, double 10A fuse |
+</panel>
+</col>
+</grid>