1、UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM ULAugust 14, 20091SUBJECT 2726OUTLINE OF INVESTIGATIONFORBATTERY LEAD WIREIssue Number: 1August 14, 2009Summary of TopicsThis is the first issue of the Outline of Investigation for Battery Lead Wir
2、e.The effective date for this issue is November 1, 2011.The UL Foreword is no longer located within the UL Standard. For informationconcerning the use and application of the requirements contained in thisStandard, the current version of the UL Foreword is located onULStandardsInfoNet at: http:/ 2009
3、 UNDERWRITERS LABORATORIES INC.UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM ULAUGUST 14, 2009SUBJECT 27262No Text on This PageUL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM ULCONTENTSINT
4、RODUCTION1 Scope .42 Units of Measurement .43 Components 44 Undated References 5CONSTRUCTION5 Materials and Workmanship 56 General 56.1 Assembly 56.2 Conductors 56.3 Insulation 6PERFORMANCE7 General 68 Manufacturing and production test .11MARKINGS9 General .1110 Tag, Reel or Carton Markings 11AUGUST
5、 14, 2009 SUBJECT 2726 3UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM ULINTRODUCTION1 ScopeSection 1 effective November 1, 20111.1 This outline covers the requirements for single conductor battery leads for use in the Standard forIndustrial Tr
6、ucks, Internal Combustion Engine Powered, UL 558, and Electric Battery Powered IndustrialTrucks, UL 583. The wire is rated 60, 75, 90, or 105C (140, 167, 194, or 221 F) and 30, 48, 60, 90 or150 Vdc.2 Units of MeasurementSection 2 effective November 1, 20112.1 In addition to being stated in the inch/
7、pound units that are customary in the USA, each of therequirements in this outline is also stated in units that make the requirement conveniently usable incountries employing the metric system (practical SI). Equivalent although not necessarily exactlyidentical results are to be expected from applyi
8、ng a requirement in USA or metric terms. Equipmentcalibrated in metric units is to be used when a requirement is applied in metric terms.3 ComponentsSection 3 effective November 1, 20113.1 Except as indicated in 3.2, a component (including gaskets and polymeric materials) of a productcovered by this
9、 outline of investigation shall comply with the requirements for that component.3.2 A component is not required to comply with a specific requirement that:a) Involves a feature or characteristic not required in the application of the component in theproduct covered by this outline of investigation,
10、orb) Is superseded by a requirement in this outline of investigation.3.3 A component shall be used in accordance with its rating established for the intended conditions ofuse.3.4 Specific components are incomplete in construction features or restricted in performance capabilities.Such components are
11、 intended for use only under limited conditions, such as certain temperatures notexceeding specified limits, and shall be used only under those specific conditions.AUGUST 14, 2009SUBJECT 27264UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM UL4 U
12、ndated ReferencesSection 4 effective November 1, 20114.1 Any undated reference to a code or standard appearing in the requirements of this outline ofinvestigation shall be interpreted as referring to the latest edition of that code or standard.CONSTRUCTION5 Materials and WorkmanshipSection 5 effecti
13、ve November 1, 20115.1 Only materials that are acceptable for the particular use shall be employed in a wire. Wires shall bemade and finished with the degree of uniformity and grade of workmanship that are practicable in awell-equipped factory.5.2 Each material used in a wire shall be compatible wit
14、h all of the other materials used in the wire.6 GeneralSection 6 effective November 1, 20116.1 Assembly6.1.1 These wires consist of a single insulated conductor.6.2 Conductors6.2.1 Conductors shall be 13 mm2 103 mm2(6 AWG 4/0 AWG) in size and shall comply with theminimum area as shown in Table 1 and
15、 Table 2, as applicable. Conductors shall consist of copper inaccordance with Standard Specification for Soft or Annealed Copper Wire, ASTM B3, StandardSpecification for Tinned Soft or Annealed Copper Wire for Electrical Purposes, ASTM B33, StandardSpecification for Silver-Coated Soft or Annealed Co
16、pper Wire, ASTM B298, or Standard Specification forNickel-Coated Soft or Annealed Copper Wire, ASTM B355. The conductor stranding is not defined , butshall be judged based on compliance of the wire with the test program in Section 7.Table 1Conductor area, metric conductorsMetric conductor size, mm2M
17、inimum conductor area, mm213 12.119 18.332 31.140 38.150 48.362 59.881 77.6103 98.5AUGUST 14, 2009 SUBJECT 2726 5UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM ULTable 2Conductor area, AWG conductorsAWG Size Minimum conductor Area, cmil6 24,538
18、4 37,3602 62,4501 77,7901/0 98,9802/0 125,1003/0 158,6004/0 205,5006.3 Insulation6.3.1 The insulation material shall be one described in the Tables in Section 50 of the ReferenceStandard for Electrical Wires, Cables, and Flexible Cords, UL 1581, suitable for the temperature rating ofthe wire. Regard
19、less of what is noted in the Table, the minimum unaged tensile strength value shall be1200 psi (8.27 MPa).6.3.2 The insulation shall be solid in form and shall be extruded directly over the conductor.6.3.3 The average insulation thickness shall not be less than 0.060 inch (1.5 mm) for a wire smaller
20、 thanor equal to 2 AWG and shall not be less than 0.080 inch (2.0 mm) for a wire larger than or equal to 1AWG. The average insulation thickness for metric sized wires shall not be less than 1.5 mm (0.060 inch)for a wire less than or equal to 32 mm2and shall not be less than 2.0 mm (0.080 inch) for a
21、 wire largerthan or equal to than 40 mm2.PERFORMANCE7 GeneralSection 7 effective November 11, 20117.1 The following tests shall be performed in accordance with, and comply with the requirements ofReference Standard for Electrical Wires, Cables, and Flexible Cords, UL 1581, unless otherwise specified
22、below.7.1.1 Detailed Examination To confirm that the construction of the wire meets the requirementsdescribed in CONSTRUCTION.7.1.2 Physical Properties of Insulation and Jacket Values for the materials as stated in the applicabletable in Section 50 of the Reference Standard for Electrical Wires, Cab
23、les, and Flexible Cords, UL 1581.Regardless of what is noted in the table, minimum unaged tensile strength 1200 psi (8.27 MPa).7.1.3 Conductor Corrosion (uncoated copper only) The aging time and temperature shall be the sameas used for Physical Properties of Insulation and Jacket described in 7.1.2.
24、 Upon examination of theconductor after removal of the insulation, there shall be no evidence of pitting or corrosion of theconductor.AUGUST 14, 2009SUBJECT 27266UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM UL7.1.4 Heat Shock (thermoplastic i
25、nsulation only) The specimens are to be conditioned for one hour atthe temperature shown in Table 3 based on material. The specimens shall be wrapped in a U-bendaround the mandrel. The mandrel used shall be two times (2X) the diameter of the insulated wire. Uponvisual examination, there shall be no
26、cracks in the insulation.7.1.5 Cold Bend The specimens shall be conditioned for 4 hours at 29C (20F) (required), or 40C(40F) (optional). The specimens shall be wrapped in a U-bend around the mandrel. The mandrel usedshall be two times (2X) the diameter of the insulated wire. There shall be no cracks
27、, tears or splits in theinsulation.7.1.6 Deformation (thermoplastic and XL insulation only) A flat, rectangular specimen shall be used forthis test. The specimens shall be conditioned at the temperature shown in Table 3. The load appliedduring the test shall be 2000 gf. The decrease in thickness sha
28、ll not be more than 50%.Table 3Heat shock and deformation test temperaturesMaterial Temperature rating of wire,CAging temperature, 2.0 C Aging temperature, 3.6 FFRPE or PE 60 or 75 100 212TPE 60, 75, 90, or 105 150 302All other materials 60, 75, 90, or 105 121 2507.1.7 Flexibility The aging time and
29、 temperature shall be the same as used for Physical Properties ofInsulation and Jacket described in 7.1.2. The mandrel used shall be two times (2X) the diameter of theinsulated wire. The specimen shall be wrapped around the mandrel in a U-bend. Upon visual examination,there shall be no cracks in the
30、 insulation.7.1.8 Impact at Abnormally Low Temperature The test shall be conducted at 29C (20F) (required)or at 40C (40F) (optional). There shall be no cracks, ruptures or other damage in 8 of the 10specimens.7.1.9 FT2.7.1.10 VW-1 (optional).7.1.11 Durability of Indelible-Ink Printing The aging time
31、 and temperature shall be the same as used forPhysical Properties of Insulation and Jacket described in 7.1.2.7.1.12 Dielectric Voltage-Withstand Test of Straight Foil-Wrapped Specimens A potential of twice therated voltage + 1000 Vdc shall be applied between the conductor and the foil. The test vol
32、tage is to beapplied for 1 minute.7.1.13 Crushing Resistance (thermoplastic insulation only) Per the Standard for Wire and Cable TestMethods, UL 2556, Crush resistance test, Method 1. 32 mm2(2 AWG) samples shall be representative ofthe complete range of conductor sizes. The average force of the ten
33、crushing trials shall not be less than2.67 kN (600 lbf).AUGUST 14, 2009 SUBJECT 2726 7UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM UL7.1.14 Abrasion test (thermoplastic insulation only).7.1.14.1 A wire shall not wear through exposing the cond
34、uctor in fewer than 70 complete cycles ofabrasion against sharp steel edges. The test is to be conducted as described below.7.1.14.2 Six straight untwisted 380 mm (15 inch) specimens are to be cut from a sample length of wire.They are to be laid flat and parallel to one another on a flat horizontal
35、steel plate and are to be individuallysecured in place at their ends. An abrasion tool consisting of a weighted solid steel right-circular cylinderacross one face of which three straight parallel teeth are machined symmetrically about a diameter (seeFigure 1) is to be supported above (not touching)
36、the center of each specimen with its teeth perpendicularto the longitudinal axis of the specimen. The support is to minimize the play of the tool at the ends of eachstroke during the abrasion process. Die-and-tool steel alloy KW hardened after machining to Rockwell C62. The teeth are to be sharpened
37、 to an edge having no burrs every 1600 2500 cycles. The hardnessis to be checked after each sharpening and, if necessary, the teeth are to be re-hardened. The abrasiontools are to be used and re-sharpened in sets. Hence, at least two sets of six are needed.7.1.14.3 The plate on which the specimens a
38、re mounted is to be made to reciprocate horizontally insimple harmonic motion at 30 cycles per minute in the direction parallel to the longitudinal axes of thespecimens. The stroke is to center on the abrasion tools, and the length of stroke is to be the 150 mm (6inch) occupying the center portion o
39、f the specimens.7.1.14.4 The test is to be started with the plate on which the specimens are mounted at rest at either endof the stroke and the stroke counter set at zero and for the beginning of a cycle. Weight is to be addedto the top of each of the abrasion tools to make the combination of each t
40、ool and its added weight exertdownward 13.34 0.14 N or 1.36 0.01 kgf. The abrasion tools are to be lowered gently onto thespecimens and the plate is to be started reciprocating immediately. The action is to be continued withoutinterruption until one or more of the tools wear through the insulation o
41、n the wire or until 70 full cycleshave been completed without any tool wearing through. An operator is to be present throughout the testto observe the wear, brush away accumulations of debris during the test that might influence the abradingaction of the tools in subsequent tests, and to notice and
42、record the number of strokes at which the wireon each specimen wears through if it wears through.7.1.14.5 The insulation on one or more of the specimens shall not be worn through in fewer than 70complete cycles.7.1.14.6 After the abrasion test, the dielectric test as described in 7.1.12 shall be per
43、formed. The abradedportion of the sample shall be covered with foil. There shall be no evidence of breakdown of insulation.7.1.15 Fluid Compatibility7.1.15.1 25 mm (1 inch) of insulation shall be removed from each end of 1000 mm (40 inch) samples ofthe finished wire. A separate sample shall be used
44、for each fluid.7.1.15.2 The outside diameter shall be determined by measuring the maximum and minimum diameter atthree points spaced no less than 50 mm (2 inch) apart along the axis of the specimen and recorded. Theaverage diameter shall be calculated.AUGUST 14, 2009SUBJECT 27268UL COPYRIGHTED MATER
45、IAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM ULFigure 1Essentials of cylindrical abrasion toolAUGUST 14, 2009 SUBJECT 2726 9UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM UL7.1.15.3 The sample shall be form
46、ed into a loose loop and center 800 mm (32 inch) shall be immersedin the fluid shown in Table 4 for a period of 20 (+1, 0) h.Table 4Fluid compatibility conditioning and requirementsTest fluid Test Temperature, C (F) Outside wire diametermaximum change %Name FluidEngine oil ASTM D 471, IRM-902 50 3 (
47、122 5.4) 15Gasoline ASTM D 471, Ref. Fuel C 23 5 (73 9.0) 15Ethanol 85% Ethanol + 15% ASTM D471, Ref. Fuel C23 5 (73 9.0) 15Diesel fuel 90 % ASTM D 471, IRM-903+ 10% p-xylene23 5 (73 9.0) 15Power steering ASTM D 471, IRM-903 50 3 (122 5.4) 30Auto transmission Dexron III, SAE J311 50 3 (122 5.4) 25En
48、gine coolant 50% Distilled Water + 50%ethylene glycol50 3 (122 5.4) 15Battery acid H2SO4Specific gravity =1.260 .00523 5 (73 9.0) 5Note: Solutions are determined by percent of volume. Only battery acid exposure is required for wires marked Battery LeadWire for Electric Battery Powered Industrial Tru
49、cks or BLW-BP. All exposures are required for wires marked Battery LeadWire for Internal Combustion Engine Powered Industrial Trucks or BLW-IC.7.1.15.4 After removal from the fluid, remove excess fluid from the sample and then condition the samplefor4hatroom temperature. After conditioning, the outside diameter of the wire shall again be measuredusing the procedure in 7.1.15.2. The average of the diameter re
