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 there
2、from, 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 2013 SAE International All rights reserved. No part of this p
3、ublication 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: +1 724-776-497
4、0 (outside USA) Fax: 724-776-0790 Email: CustomerServicesae.org SAE WEB ADDRESS: http:/www.sae.org SAE values your input. To provide feedback on this Technical Report, please visit http:/www.sae.org/technical/standards/J1495_201302 SURFACE VEHICLE STANDARD J1495 FEB2013 Issued 1986-05 Revised 2013-0
5、2 Superseding J1495 AUG2012 Test Procedure for Battery Flame Retardant Venting Systems RATIONALE This standard is being revised to correct errors in the numerical references contained within. 1. SCOPE This SAE Standard details procedures for testing lead-acid SLI (starting, lighting, and ignition),
6、Heavy-Duty, EV (electric vehicle) and RV (recreational vehicle) batteries to determine the effectiveness of the battery venting system to retard the propagation of an externally ignited flame of battery gas into the interior of the battery where an explosive mixture can be present. NOTE: At this tim
7、e 2011, there is no known comparable ISO Standard. 2. REFERENCES 2.1 Applicable Documents The following publications form a part of this specification to the extent specified herein. Unless otherwise indicated, the latest issue of SAE publications shall apply. 2.1.1 SAE Publications Available from S
8、AE International, 400 Commonwealth Drive, Warrendale, PA 15096-0001, Tel: 877-606-7323 (inside USA and Canada) or 724-776-4970 (outside USA), www.sae.org. SAE J537 Storage Batteries SAE J1495 Revised FEB2013 Page 2 of 8 3. SAFETY PRECAUTIONS AND PROCEDURES WARNING: Testing of a battery venting syste
9、m can result in an explosion. Extreme caution must be exercised to avoid personal injury. Absolutely no testing should be permitted where the prescribed safety precautions and procedures are not followed or exceeded. 3.1 All test apparatus, except the charging source, must be fully contained in an e
10、xternally vented explosion test chamber, for example, Figure 1. 3.2 The battery-charging source must be located outside the explosion test chamber convenient to the control of the testing personnel. The charging circuit must have two emergency disconnect switches located (1) readily accessible to th
11、e testing personnel and (2) at a remote position at least 3 m from the explosion test chamber. These disconnect switches are intended for emergency use only, since their use may damage some types of chargers. 3.3 A suitable test area should be designated, for example, 3 m2or more. Signs restricting
12、unauthorized persons from this area should be posted and observed while any electrical circuit in the explosion test chamber is or could be energized. 3.4 During testing, entry to the area in which the explosion test chamber is located should be clearly marked to restrict all persons not fully famil
13、iar with all safety requirements and not wearing full protection from the hazard to be encountered. FIGURE 1 - TEST CHAMBER 3.5 Smoking, open flames, unprotected lights, or other spark sources must not be permitted in the area during testing. 3.6 Full face protection devices must be worn by all pers
14、ons within the restricted area. 3.7 The battery spark source circuit must have an emergency disconnect switch readily available to the testing personnel. SAE J1495 Revised FEB2013 Page 3 of 8 3.8 The exhaust fan of the explosion test chamber, if so equipped, should be operated during the entire spar
15、k test procedure. A damper in the exhaust fan stack may be used during the test to avoid removing the gas to the extent that the spark does not ignite the hydrogen. On completion of any test sequence, all charging and sparking circuits used for the testing must be interrupted for at least 5 min (wit
16、h the exhaust fan operating if available) before anyone is permitted access to the chamber. This time interval allows any hydrogen to be purged from the chamber and to preclude the possibility of a delayed explosion occurring due to a sustained “hidden“ flame. WARNING: HYDROGEN GAS CAN BURN WITHOUT
17、VISIBLE FLAME. 4. EQUIPMENT REQUIRED FOR SPARK TEST 4.1 Spark testing conducted using a battery; Spark testing is always conducted with the vent (s) installed on a battery for final design verification testing. 4.1.1 An explosion chamber, for example, Figure 1, recommended to be equipped with an exp
18、losion-proof fan of adequate size to produce approximately one chamber volume change per minute, vented directly to the exterior of the building. 4.1.2 A battery-charging source capable of current control, with an output current of 40 100 A at 18.0 V 4.1.3 A fully-charged 12-V battery equipped with
19、a functional flame retardant venting system to serve as an ignition source for 12 V spark source systems 4.1.4 Battery on which the test is to be performed. 4.1.5 Wiring and fixture equivalent to those shown in Figures 2A or 2B. FIGURE 2A - SCHEMATIC FOR TEST ON BATTERY SAE J1495 Revised FEB2013 Pag
20、e 4 of 8 FIGURE 2B - SCHEMATIC FOR TEST ON BATTERY 4.2 Spark testing conducted using a fixture; Spark testing can be conducted on a test fixture for research and development, and initial design verification activities. Fixture testing is not to be used for final design verification testing. 4.2.1 An
21、 explosion chamber, for example, Figure 1, recommended to be equipped with an explosion-proof exhaust fan of adequate size to produce approximately one chamber volume change per minute, vented directly to the exterior of the building. 4.2.2 A charging source capable of current control, with an outpu
22、t current of 40 - 100 A at 18 V 4.2.3 A fully charged 12-V battery equipped with a functional flame retardant venting system to serve as an ignition source for 12 V spark source systems. 4.2.4 A second fully charged battery to serve as a gas mixture source. This battery must be vented only through t
23、he test fixture or functional flame retardant venting system. 4.2.5 A test fixture, similar to that shown in Figure 3. SAE J1495 Revised FEB2013 Page 5 of 8 FIGURE 3 - TEST FIXTURE 4.2.6 Tubing and fittings equivalent to those shown in Figure 4. 5. EQUIPMENT ARRANGEMENT AND SPARK TEST PREPARATION 5.
24、1 Spark testing conducted using a battery; Spark testing is always conducted with the vent (s) installed on a battery for final design verification testing. 5.1.1 Arrange test apparatus as shown in Figure 2A or alternate 2B. 5.1.2 Before spark testing, the test battery system should be checked for g
25、as leakage at any place other than the vent opening, for example, with a soap solution. 5.1.3 Prior to the start of the test, the spark source battery must be fully charged. 5.1.4 Prior to the start of the test, the battery to which the test vent is affixed must be fully charged and gassing vigorous
26、ly. SAE J1495 Revised FEB2013 Page 6 of 8 FIGURE 4 - SCHEMATIC FOR TEXT FIXTURE 5.1.5 Prior to the start of the test, the test vent must be preconditioned as in 6.1. 5.2 Spark testing conducted using a fixture; Spark testing can be conducted on a test fixture for research and development, and initia
27、l design verification activities. Fixture testing is not to be used for final design verification testing. 5.2.1 Arrange the test apparatus as shown in Figure 4. Note that the gas inlet to the test fixture must be well below the water level as shown in Figure 3 to prevent ignited gases from entering
28、 the gas-generating battery. 5.2.2 Fill the test fixture with water to a level 3 6 mm (1/8 1/4 in) below the underside of the top. The water should be at a level that will avoid splashing water up into the vent if there is a wave action at high charge current levels Place the hold-down frame over a
29、25 m (1-mil) thickness of polyethylene film cut as shown in Figure 3. Place the frame, with film in place, over the four studs so that the film covers the open area between the fixture and the frame. Tighten the frame down finger tight with wing nuts to insure a gas-tight seal around the gasket. Fit
30、 the vent system to be tested into the fixture. 5.2.3 Before spark testing, the whole system should be checked for gas leakage at any place other than the vent opening, for example, with a soap solution. 5.2.4 Prior to the start of the test, the spark source battery must be fully charged. 5.2.5 Prio
31、r to the start of the test, the gas-generating battery must be fully charged and gassing vigorously. 5.2.6 Prior to the start of the test, the test vent must be preconditioned as in 6.1. SAE J1495 Revised FEB2013 Page 7 of 8 6. PRECONDITIONING THE VENT SYSTEM 6.1 Standard Preconditioning Preconditio
32、ning shall consist of subjecting the battery to which the venting system is attached to the conditioning charge, reserve capacity test, and recharge specified in SAE J537 Storage Batteries. This will put the vent system in an acid moistened state as is typical of its in-service condition. The spark
33、test shall be conducted within 1 h of completion of the recharge. 6.2 Hot and Cold Cycle Preconditioning (Optional) 6.2.1 Place the vent system in a cold box at ;#23#23#23#23#23#23#23#23#23#23#23#23#23#23#23#2330 g113C 2 C, for 16 h, 0.25 h. 6.2.2 Remove from cold box and place it in an oven at 70 g
34、113C, 2 C, for 8 h, 0.25 h. 6.2.3 Repeat this sequence for a total of 3 full cycles. 6.2.4 At the completion of the third full cycle, condition the vent system as in 6.1. 7. SPARK TEST PROCEDURE 7.1 Spark testing is always conducted with the vent (s) installed on a battery for final design verificat
35、ion testing. When the spark test is to be conducted on a battery: 7.1.1 Spark testing is to be conducted at ambient room temperature (20 to 25 C). 7.1.2 Battery temperature shall be at ambient room temperature (20 to 25 C) at the start of the test. 7.1.3 Charge the battery under test using constant
36、current. The initial current rate in amps is 5% of the reserve capacity minutes measured in 6.1. (Charging current shall not exceed 100 A.) If experience shows that a current level greater than 5% of the reserve capacity minutes will be needed to produce the ignition required in 7.1.6, then testing
37、can start at the greater current level. 7.1.4 Allow the gas flow rate to stabilize. (Gas flow should stabilize in 1 to 5 min.) 7.1.5 Create a spark of not less that 0.02 mJ of energy no more than 1.3 cm (0.5 in) from the test vent opening in the path of the gas flow. 7.1.6 Repeat the spark at 10 s i
38、ntervals until a minimum of 6 ignitions occur. Evolved gases must be ignited as evidenced by audible “pops”, “whooshes”, or visible flame. (If the ignited evolved gases ignite the battery, time must be allowed for the battery to self-extinguish or ignite the gas within the battery.) If no ignition i
39、s produced, raise the charge current in 7.1.3 by an additional 5% of the reserve capacity minutes and repeat 7.1.4 to 7.1.6 until an ignition at the vent is produced. The distance between the spark and test vent opening can be adjusted within the restrictions of 7.1.5 to assist with producing an ign
40、ition. 7.1.7 If the vent system is functioning properly, no gas ignition will occur within the test battery. Any functional failure, damage to any component, or change in the intended design or operational performance of the tested items or assemblies shall be considered a SAE J1495 test failure. 7.
41、2 Spark testing can be conducted on a test fixture for research and development, and initial design verification activities. Fixture testing is not to be used for final design verification testing. Where the spark test is to be conducted on the test fixture: 7.2.1 Spark testing is to be conducted at
42、 ambient room temperature (20 to 25 C). 7.2.2 Battery temperature shall be at ambient room temperature (20 to 25 C) at the start of the test SAE J1495 Revised FEB2013 Page 8 of 8 7.2.3 Charge the battery under test using constant current. The initial current rate in amps is 5% of the reserve capacit
43、y minutes measured in 6.1. (Charging current shall not exceed 100 A.) If experience shows that a current level greater than 5% of the reserve capacity minutes will be needed to produce the ignition required in 7.2.6, then testing can start at the greater current level. 7.2.4 Allow the gas flow rate
44、to stabilize. (Gas flow should stabilize in 1 to 5 min.) 7.2.5 Create a spark of not less that 0.02 mJ of energy no more than 1.3 cm (0.5 in) from the test vent opening in the path of the gas flow. 7.2.6 Repeat the spark at 10 s intervals until a minimum of 6 ignitions occur. Evolved gases must be i
45、gnited as evidenced by audible “pops”, “whooshes”, or visible flame. (If the ignited evolved gases ignite the vent system, time must be allowed for the vent system to self-extinguish or ignite the gas within the test fixture.) If no ignition is produced, raise the charge current in 7.2.3 by an addit
46、ional 5% of the reserve capacity minutes and repeat 7.2.4 to 7.2.6 until an ignition at the vent is produced. The distance between the spark and the test vent opening can be adjusted within the restrictions of 7.2.5 to assist with producing an ignition. 7.2.7 If the test vent system is functioning p
47、roperly, no gas ignition will occur within the test fixture. Any functional failure, damage to any component, test fixture, or change in the intended design or operational performance of the tested items or assemblies shall be considered a SAE J1495 test failure. NOTE: When all gas generated in the
48、12-V battery is passed into the (simulated 3 cell) test fixture, the effective gassing rate is twice that indicated by the charger current reading, for either single or gang vents. 8. NOTES 8.1 Marginal Indicia A change bar (l) located in the left margin is for the convenience of the user in locatin
49、g areas where technical 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 BATTERY STANDARDS STARTER BATTERY COMMITTEE
