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 ther
2、efrom, 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 2017 SAE International All rights reserved. No part of this
3、publication 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: +1 724-776-49
4、70 (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:/standards.sae.org/J2394_201712 SURFACE VEHICLE STANDARD J2394 DEC2017 Issued 1998-06 Revised 2013-02 Reaffirmed
5、2017-12 Superseding J2394 FEB2013 Seven Conductor Cable for ABS Power - Truck and Bus RATIONALE J2394 has been reaffirmed to comply with the SAE Five-Year Review policy. FOREWORD This document, first published in 1998, superseded the traditional SAE J1067 standard that referred to the 1/8-1/10-5/12
6、gauge configuration used in non-ABS equipped tractors vehicles. The SAE J2394 standard was developed for a 1/8-2/10-4/12 construction where the blue circuit was upgraded to 10 gauge enabling power for ABS. The traditional seven conductor cable standard was often associated with the tractor-trailer i
7、nterface cable while the lighter duty low tension primary cable standards became a common reference for the internal primary cables of the seven-conductor cable in truck, trailer and harness manufacturer specifications. Studies prompted by increased safety awareness suggest that voltage losses in wi
8、ring and connectors had become of serious concern and both the SAE J1067 and SAE J2394 standards had been written to better address the demanding physical and electrical performance needs of seven conductor cable used throughout the entire truck and trailer electrical system. While SAE J1067 still e
9、xists as a standard to support those few users who still purchase it for older equipment, a switch to this SAE J2394 standard is strongly encouraged. 1. SCOPE This SAE standard establishes the minimum construction and performance requirements for seven conductor 1/8-2/10-4/12 cable for use on trucks
10、, trailers and converter dollies. Where appropriate, the standard refers to two types of cables, (Type F and S, described later in the standard), due to the variation in the performance demands of cables used in flexing and stationary applications. While the documents title refers to ABS Power to di
11、fferentiate the document from the SAE J1067 standard that it supersedes, the scope applies to both the primary green cable for powering ABS and lighting and the yellow auxiliary cable of the same construction. 2. REFERENCES 2.1 Applicable Documents The following publications form a part of this spec
12、ification to the extent specified herein. The latest issue of publications shall apply. 2.1.1 SAE Publications Available from SAE 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 J844 Nonmetall
13、ic Airbrake System Tubing SAE J1067 Seven Conductor Cable Truck and Bus SAE J1128 Low Voltage Primary Cable 2.1.2 ASTM Publications Available 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 3 Specification for So
14、ft or Annealed Copper Wire ASTM B 33 Specification for Tinned Soft or Annealed Copper Wire for Electrical Purposes ASTM B 172 Specification for Rope Lay Stranded Copper Conductors having Bunch- Stranded Members for Electrical Conductors ASTM B 174 Specification for Bunch-Stranded Copper Conductors f
15、or Electrical Conductors ASTM B 189 Specification for Lead Coated and Lead-Alloy-Coated Soft Copper Wire for Electrical Purposes ASTM B 263 Standard Test Method for Determination of Cross-Sectional Area of Standard Conductors ASTM B 117 Method of Salt Spray (Fog) Testing ASTM D 412 Standard Test Met
16、hods for Vulcanized Rubber and Thermoplastic Rubbers and Thermoplastic Elastomers - Tension 2.1.3 UL (Underwriters Laboratories) Publications Available from Underwriters Laboratories Inc., 333 Pfingsten Road, Northbrook, IL 60062-2096, Tel: 847-272-8800, . UL 1581 Reference Standard for Electrical W
17、ires, Cables, and Flexible Cords - Section 593 _ SAE INTERNATIONAL J2394 DEC2017 Page 2 of 102.2 Related Publications The following publications are noted for information purposes only and are not a required part of this specification. 2.2.1 SAE Publications Available from SAE International, 400 Com
18、monwealth Drive, Warrendale, PA 15096-0001, Tel: 877-606-7323 (inside USA and Canada) or 724-776-4970 (outside USA), www.sae.org. SAE J560 Seven Conductor Electrical Connector for Truck-Trailer Jumper Cable SAE J1067 Seven Conductor Cable Truck and Bus SAE J2222 Coiled Electrical Cable Truck and Bus
19、 SAE J2174 Heavy Duty Wiring for Trailers 2032 mm or More in Width SAE J2202 Heavy Duty Wiring Systems for On-Highway Trucks 3. DEFINITIONS 3.1 FLEXING Describes a condition where the cable is installed in an unsupported way over a distance of greater than 0.5 m (18 in) and/or where there is a reaso
20、nable likelihood that the cable will be subjected to bending, longitudinal extension, or significant movement. As an example all cables connecting the tractor to trailer or dolly to trailer are to be considered flexing cables. 3.2 STATIONARY Describes a condition where the cable is installed in a fa
21、shion where its weight is supported within a distance of 0.5 m (19.7 in) or less, and where there is little likelihood of flexing as described above. An example of a stationary application is cable that is connected with clamps to a vehicle chassis. 3.3 CONDUCTOR The current carrying element(s) in a
22、 cable comprised of a series of copper strands twisted together. 3.4 STRAND The solid component members of a conductor. 3.5 LAY The measure along a single plane, between an individual strand or series of copper strands or insulated conductors starting and ending points in a complete spiral wrap arou
23、nd the grouping of which it is a part. 3.6 INSULATION The material applied to the conductor to provide electrical insulation and a level of mechanical protection. _ SAE INTERNATIONAL J2394 DEC2017 Page 3 of 103.7 CABLE CORE The grouping of insulated conductors twisted together. 3.8 JACKET The outer
24、sheath applied to the cable core to maintain inner conductor positioning and to enhance the mechanical strength and durability of the cable. 4. TYPES Due to the variation in the performance demands of cables used in different applications within the truck-trailer system, this document addresses two
25、types of cables, determined by their mode of installation. 4.1 Type F - Flexing Pertains to cables that are subjected to flexing as defined in Section 3.1. 4.2 Type S - Stationary Pertains to cables that are stationary as defined in Section 3.2. 5. IDENTIFICATION CODE DESIGNATION Cable conforming to
26、 this document shall be identified with the manufacturers identification, and shall be identified with SAE J2394 and the revision (month and year) of this document along with the cable type as described in this document. For example: XYZ Corp. SAE J2394 (mo/yr) - Type S (or F) 6. TECHNICAL REQUIREME
27、NTS 6.1 Conductors 6.1.1 Material All conductors shall be of stranded, soft-annealed copper, complying with ASTM B 3, and ASTM B 174-Class K or ASTM B 172-Class K. Strands may be uncoated or may be coated in a tin complying with ASTM B 33 or a tin/lead coating complying with ASTM B 189. 6.1.2 Cross-
28、Sectional Area The cross-sectional area of stranded conductors shall not be less that the values specified in Table 1. The cross-sectional area may be verified by measuring actual strand sizes or by using the weight method in ASTM B 263 with a calculated factor to allow for the twist loss. 6.1.3 Str
29、anding The individual strands contained within a conductor shall be of the same nominal diameter. The minimum number of strands per wire size for the two types of cable covered by this document are as shown in Table 1. 6.1.4 Strand Lay The maximum acceptable lay of strands for each wire size, regard
30、less of the number of strands in the conductor, is as shown in Table 1. _ SAE INTERNATIONAL J2394 DEC2017 Page 4 of 106.1.5 Conductor Splicing When agreed between the supplier and purchaser, splices may be used for the individual strands or for the conductor as a whole, provided that they are made i
31、n a workmanlike manner as described in ASTM B 172/174, and that they fulfill the following criteria: 6.1.5.1 The break strength shall not be reduced by more than 20%. 6.1.5.2 The resistance shall not be increased. 6.1.5.3 The diameter of the splice must not exceed the diameter of the uninsulated str
32、and or conductor being spliced by more than 20%. 6.1.5.4 Single strand splices are not to be closer together than two lay lengths in a bunched or concentric stranded conductor and twenty lay lengths in a rope-lay construction and there shall be no more than three single strand splices per 3 m of con
33、ductor. 6.1.5.5 Whole conductor splices are not to be closer together than twenty conductor lay lengths in the cable core and there shall be no more than three whole conductor splices per 100 m of cable. TABLE 1 - CONDUCTORS SAE Wire Size mm2 METRIC Min. Cond. Area mm2 Max. Strand Lay Length mm Type
34、 F (Flexing) Min. Strands Type S (Stationary) Min. Strands SAE Wire Size No. ENGLISH Min. Cond. Area cir mils Max. Strand Lay Length Inches 3 3.24 70 65 19 12 6334 2.75 5 5.16 64 104 19 10 10069 2.50 8 8.20 76 133 19 8 16104 3.00 NOTE 1: English units are not direct conversions from metric. NOTE 2:
35、The metric wire size is the approximate nominal area of the conductor. NOTE 3: The SAE wire size number indicates that the cross-sectional area of the conductor approximates the area of the American Wire Gauge for the equivalent size. 6.2 Insulation 6.2.1 Material Physical Properties The unaged phys
36、ical properties of insulation material, tested in accordance with the method identified in ASTM D 412 at room temperature, (23 C 5 C) shall be a minimum of the following values: 6.2.1.1 Minimum tensile strength of 10 MPa (1500 psi). 6.2.1.2 Minimum elongation of 150%. An accelerated aging test invol
37、ving heat aging for 168 hours at 110 C shall be conducted in accordance with SAE J1128. 6.2.2 Application Insulation shall be homogeneous and shall be placed concentrically within commercial tolerances about the conductor. Insulation shall adhere closely to, but strip readily from the conductor leav
38、ing it reasonably clean and in suitable condition for termination. _ SAE INTERNATIONAL J2394 DEC2017 Page 5 of 106.2.3 Insulated Conductor Outside Diameter The outside diameter of each insulated conductor shall be measured in accordance with SAE J1128. The mean of the diameter readings shall determi
39、ne the finished insulated conductor diameter and shall be no greater than the maximum values shown in Table 2. 6.2.4 Wall Thickness The minimum wall thickness shall be measured using the method outlined in SAE J1128. All individual wall thickness values must be in accordance with those listed in Tab
40、le 2. 6.2.5 Dielectric Voltage Withstand Test This test is only practical for use by manufacturers of the wire or cable. Refer to 6.2.6 for an alternate test for use by those wishing to test cable before installation or use in harness assemblies. Unless otherwise specified, all specimens shall be th
41、e entire length of wire conductors subjected to continuous spark testing with voltage set at 1500 volts, AC. 6.2.5.1 Apparatus 6.2.5.1.1 Spark Tester A transformer of sufficient capacity to maintain the test voltage specified in the detailed specification under all normal conditions of leakage curre
42、nt shall be used. The core of the transformer and one end of the secondary winding shall be connected to ground. A voltmeter shall be so located in the circuit that it will indicate at all times the actual test voltage applied. The spark tester shall not be simultaneously connected to more than one
43、electrode. 6.2.5.1.2 Electrode An electrode which makes direct mechanical contact with the surface of the insulation of the wire or cable undergoing test shall be used. A pipe, coiled spring or the like shall not be acceptable. If the link bead-chain type of electrode is used, the bottom of the meta
44、l electrode enclosure shall be “V”-shaped. The chains shall have a length appreciably greater that the depth of the enclosure. The width of the trough shall be approximately 38 mm (1.5 in) greater than the diameter of the largest wire or cable to be tested. If a bead-chain type of electrode is used,
45、 the beads shall have a diameter of 5 mm (3/16 in). The longitudinal spacing of the chains shall not be more than 13 mm (1/2 in). The transverse spacing of the chains shall not be more than 9.5 mm (3/8 in), except that the spacing may be 13 mm (1/2 in) if the transverse rows of chain are staggered.
46、The electrode shall be provided with a grounded metallic screen or the equivalent as a guard against contact by personnel. The length of the electrode shall be sufficient to meet the requirements in 6.2.5.2. 6.2.5.1.3 Fault Signaling Device A fault signaling device or system shall include a visible
47、signal, a defect recording device, and/or an automatic stop device. The arrangement shall operate in such a way that when the fault signal is given, it will be maintained until manually reset. 6.2.5.2 Procedure The spark test shall be conducted as near to the end of the manufacturing process as is p
48、racticable. The test voltage shall be as specified in the detailed specification. The specimen shall be attached to the electrode and the electrode connected to one lead of the transformer secondary. Both ends of the conductor of the specimen, the other secondary lead and the transformer core shall be grounded. A direct connectio
