SAE J 1654-2016 Unshielded High Voltage Primary Cable.pdf

1、_SAE Technical Standards Board Rules provide that: “This report is published by SAE to advance the state of technical and engineering sciences. The use of this report is entirely voluntary, and its applicability and suitability for any particular use, including any patent infringement arising theref

2、rom, is the sole responsibility of the user.”SAE reviews each technical report at least every five years at which time it may be revised, reaffirmed, stabilized, or cancelled. SAE invites your written comments and suggestions.Copyright 2016 SAE InternationalAll rights reserved. No part of this publi

3、cation may be reproduced, stored in a retrieval system or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of SAE.TO PLACE A DOCUMENT ORDER: Tel: 877-606-7323 (inside USA and Canada)Tel: +1 724-776-4970 (out

4、side USA)Fax: 724-776-0790Email: CustomerServicesae.orgSAE WEB ADDRESS: http:/www.sae.orgSAE values your input. To provide feedbackon this Technical Report, please visithttp:/www.sae.org/technical/standards/J1654_201609SURFACE VEHICLESTANDARDJ1654 SEP2016Issued 1994-06Revised 2016-09Superseding J165

5、4 OCT2012Unshielded High Voltage Primary CableRATIONALEStandard updated to clarify test procedures and add new tests.TABLE OF CONTENTS1. SCOPE. 22. REFERENCES. 22.1 Applicable Documents . 22.2 Related Publications 23. DEFINITIONS 34. GENERAL REQUIREMENTS 54.1 General Test Conditions 54.2 Tolerances

6、. 54.3 Representative Conductor Sizes for Testing . 55. ADDITIONAL REQUIREMENTS . 55.1 Dielectric Test 55.2 Spark Test 65.3 Insulation Resistance. 65.4 Abrasion Resistance 65.5 Pinch Resistance . 66. NOTES. 76.1 Revision Indicator. 7SAE INTERNATIONAL J1654 SEP2016 Page 2 of 71. SCOPEThis SAE Standar

7、d covers unshielded cable intended for use at a nominal system voltage up to 600 V or 1000 V (AC rmsor DC). It is intended for use in surface vehicle electrical systems.2. REFERENCES2.1 Applicable DocumentsThe following publications form a part of this specification to the extent specified herein. U

8、nless otherwise indicated, the latest issue of SAE publications shall apply.2.1.1 SAE PublicationsAvailable from SAE International, 400 Commonwealth Drive, Warrendale, PA 15096-0001, Tel: 877-606-7323 (inside USA and Canada) or +1 724-776-4970 (outside USA), www.sae.org.SAE J1127 Low Voltage Battery

9、 CableSAE J1128 Low Voltage Primary CableSAE J1678 Low Voltage Ultra Thin Wall Primary CableSAE Dictionary of Materials and Testing2.1.2 ASTM PublicationsAvailable from ASTM International, 100 Barr Harbor Drive, P.O. Box C700, West Conshohocken, PA 19428-2959, Tel: 610-832-9585, www.astm.orgASTM B 3

10、54 Standard Terminology Relating to Uninsulated Metallic Electrical ConductorsASTM F 1251 Standard Terminology Relating to Polymeric Biomaterials in Medical and Surgical Device2.1.3 IEC PublicationCopies of these documents are available online at http:/webstore.ansi.org/IEC, Electricity, Electronics

11、 and Telecommunications, Multilingual Dictionary 2.2 Related Publications The following publications are provided for information purposes only and are not a required part of this SAE Technical Report.2.2.1 SAE PublicationsAvailable from SAE International, 400 Commonwealth Drive, Warrendale, PA 1509

12、6-0001, Tel: 877-606-7323 (inside USA and Canada) or +1 724-776-4970 (outside USA), www.sae.org.SAE J156 Fusible LinksSAE J1673 High Voltage Automotive Wiring Assembly DesignSAE J2501 Round, Screened and Unscreened, 60 V and 600 V Multi-Core Sheathed CablesSAE J2840 High Voltage Shielded and Jackete

13、d CableSAE INTERNATIONAL J1654 SEP2016 Page 3 of 72.2.2 ASTM PublicationsAvailable from ASTM International, 100 Barr Harbor Drive, P.O. Box C700, West Conshohocken, PA 19428-2959, Tel: 610-832-9585, www.astm.org.ASTM B 1 Standard Specification for Hard-Drawn Copper WireASTM B 3 Standard Specificatio

14、n for Soft or Annealed Copper WireASTM B 8 Concentric-Lay-Stranded Copper conductors, Hard, Medium-Hard, or SoftASTM B 174 Standard Specification for Bunch-Stranded Copper Conductors for Electrical ConductorsASTM B 787 19 Wire Combination Unilay-Stranded Copper Conductors for Subsequent Insulation2.

15、2.3 ISO PublicationsCopies of these documents are available online at http:/webstore.ansi.org/ISO 6722-1 Road vehicles - 60 V and 600 V single core cables - Test methods, dimensions and requirementsISO 14572 Road vehicles - Round, screened and unscreened, 60 V and 600 V multicore sheathed cables - B

16、asic and high performance test methods and requirements3. DEFINITIONS3.1 ADDITIONAL MASS (ref. “Resistance to Sandpaper Abrasion” test)The mass which is applied to the support rod. The combination of the forces exerted by the additional mass and the 0.63 Nexerted by the remaining apparatus (bracket,

17、 support rod, and pivoting arm) is applied to the cable.3.2 COATED WIREWire comprised of a given metal covered with a relatively thin application of a different metal. (ASTM B 354)3.3 CABLESee primary cable.3.4 CABLE FAMILYA group with multiple conductor sizes having the same conductor strand coatin

18、g, insulation formulation, and wall thickness type.3.5 CONDUCTORA wire or combination of wires not insulated from one another, suitable for carrying an electrical current. (ASTM B 354)3.6 CONDUCTOR SIZESee “SAE Conductor Size”.3.7 COREOne of the components in an assembly. A component may be an unins

19、ulated conductor, an insulated conductor, a twisted pair, a shielded assembly, a coaxial cable, or any finished cable.SAE INTERNATIONAL J1654 SEP2016 Page 4 of 73.8 FLUID COMPATIBILITYThe ability of a cable to resist the effects of various fluids found in surface vehicles.3.9 HOT PLATEAn electricall

20、y heated device used to test thermoset cables.3.10 LOW VOLTAGE (Low Tension)Usually considered to be d60 V DC (25 V AC).3.11 MINIMUM WALL (Thickness)The lowest allowable insulation thickness at any point.3.12 NOMINALName or identifying value of a measurable property by which a conductor or component

21、 or property identified, and to which tolerances may be applied.3.13 PLASTICSA material that contains as an essential ingredient one or more organic polymeric substances of large molecular weight, is solid in its finished state, and, at some stage in its manufacture or processing into finished artic

22、les, can be shaped by flow. 3.14 PRIMARY CABLEThe single or multi-stranded, single conductor, insulated cable used to carry electric current, by attachment to the low voltage side of an ignition coil in surface vehicles.3.15 RESISTANCE TO OZONEThe ability of a material to withstand the deteriorating

23、 effect of ozone (surface cracking). (Dictionary of Materials and Testing)3.16 SAE CONDUCTOR SIZEA system that indicates the cross sectional area of the conductor. The “SAE Conductor Size” is the approximate area of the conductor.3.17 SEPARATORA thin layer used as a barrier to prevent mutually detri

24、mental effects between different components of a cable such as between the conductor and insulation or between the insulation and the sheath. (IEC, Electricity, Electronics and Telecommunications, Multilingual Dictionary)3.18 STRIP FORCEThe peak axial force required to overcome the adhesion between

25、the conductor and the insulation.3.19 STRANDSee “Wire”.SAE INTERNATIONAL J1654 SEP2016 Page 5 of 73.20 TCR, TEMPERATURE CLASS RATINGA class designation based on the retention of “Mechanical Properties” (tensile and elongation) after 168 hours of heat aging at 30 C above the temperature class rating.

26、3.21 THERMOPLASTICA plastic capable of being softened by heating and hardened by cooling through a temperature range characteristic of the plastic and, in the softened state, capable of being repeatedly shaped by flow into articles by molding, extrusion or forming. (IEC, Electricity, Electronics and

27、 Telecommunications, Multilingual Dictionary)3.22 THERMOSETA plastic which, when cured by heat or other means, changes into a substantially infusible and insoluble product. NOTE: Thermosets are often called thermosetting before curing and thermoset after cure. (IEC, Electricity, Electronics and Tele

28、communications, Multilingual Dictionary)3.23 WIRE (Strand)A rod or filament of drawn or rolled metal whose length is great in comparison with the major axis of its cross section. (ASTM B 354)4. GENERAL REQUIREMENTSThe cable shall meet all of the requirements of SAE J1127, SAE J1128, or SAE J1678 for

29、 the applicable cable type.4.1 General Test ConditionsTest samples shall be preconditioned for at least 16 h at a room temperature of (23 3) C. Unless otherwise specified, all tests shall be conducted at this same temperature.4.2 TolerancesUnless otherwise specified, all values are considered to be

30、approximate.4.3 Representative Conductor Sizes for TestingWhen a test is required, all combinations of conductor size, wall thickness, and insulation formulation shall meet the appropriate requirements. However, if testing representative conductor sizes is permitted, compliance for a cable family ma

31、y be demonstrated by testing examples of large and small conductor sizes only. Permission to show compliance for a cable family by testing “Representative conductor sizes” will be established by agreement between customer and supplier.5. ADDITIONAL REQUIREMENTS5.1 Dielectric TestImmerse the sample i

32、n a bath containing a 3% NACL solution for 4 hours. Apply the test voltage between the conductor DQGWKHEDWKIRUPLQXWHV .9IRUVLHVDQG .9IRUVLHV 7KLVWHVWVKDOOEHXVHGIRUY LUgin cable and after all other tests which require a “Dielectric Test,“ such as cold bend, fluid exposure, etc.SAE INTERNATIONAL J1654

33、 SEP2016 Page 6 of 75.2 Spark Test100% of the in process cable shall be subjected to a spark test. Every point on the cable shall withstand a minimum of 18 positive and negative crests of the supply voltage (the equivalent of nine full cycles of the supply voltage) without failure of the insulation.

34、 AC is the preferred method but DC can be used if agreed between the supplier and customer. The conversion is:DC peak = 1.414 x AC (RMS)Spark test voltages: Less than or equal to SAE size 20 = 6KV minimumGreater than SAE size 20 = 10KV minimum5.3 Insulation Resistance25 mm of insulation shall be rem

35、oved from each end of a 5 meter sample of finished cable. Twist the ends together. Immerse the sample to within 50 millimeter from the end of the insulation in tap water at 21 C 3 C for a minimum of 6 hours. Measure the resistance between the conductor and water using a bridge that is accurate to wi

36、thin 10% of the measured value and having an open circuit potential of 125 V or more. The sample shall have a minimum resistance of 30 M.SAEConductorSize RangeMinimum ResistanceAbrasionRef. 5.4PinchRef. 5.526 - 22 J1128 Type GPTSAE Size 2020 86 250 MCMJ1128 Type GPTJ1128 Type GPT SAE Size 8Figure 1

37、- Minimum abrasion and pinch resistance, reference 5.4 and 5.55.4 Abrasion ResistanceThe cable shall meet the “Abrasion Resistance” requirements of SAE J1128 for the applicable cable type or the requirements of Figure 1, whichever is greater.5.5 Pinch ResistanceThe cable shall meet the “Pinch Resist

38、ance” requirements of SAE J1128 for the applicable cable type or the requirements of Figure 1, whichever is greater.SAE INTERNATIONAL J1654 SEP2016 Page 7 of 76. NOTES6.1 Revision IndicatorA change bar (l) located in the left margin is for the convenience of the user in locating areas where technica

39、l revisions, not editorial changes, have been made to the previous issue of this document. An (R) symbol to the left of the document title indicates a complete revision of the document, including technical revisions. Change bars and (R) are not used in original publications, nor in documents that contain editorial changes only.PREPARED BY THE SAE CABLE STANDARDS COMMITTEE