1、UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM ULSEPTEMBER 19, 20171UL 2726Outline of Investigation for Battery Lead WireIssue Number: 2September 19, 2017Summary of TopicsThis is the second issue of the Outline of Investigation for Battery Lead
2、Wire. This issue expands the size range of acceptable conductors to10 mm2 210 mm2(10 AWG 400 kcmil).ULs Outlines of Investigation are copyrighted by UL LLC. Neither a printed norelectronic copy of an Outline of Investigation should be altered in any way. All ofULs Outlines of Investigation and all c
3、opyrights, ownerships, and rights regardingthose Outlines of Investigation shall remain the sole and exclusive property of ULLLC.COPYRIGHT 2017 UL LLCUL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM ULSEPTEMBER 19, 2017UL 27262No Text on This Pag
4、eUL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM ULCONTENTSINTRODUCTION1 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 6PERFO
5、RMANCE7 General 68 Manufacturing and Production Test 11MARKINGS9 General .1110 Tag, Reel or Carton Markings 11SEPTEMBER 19, 2017 UL 2726 3UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM ULINTRODUCTION1 Scope1.1 This outline covers the requiremen
6、ts for single conductor battery leads for use in the Standard forIndustrial Trucks, Internal Combustion Engine-Powered, UL 558, and the Standard forElectric-Battery-Powered Industrial Trucks, UL 583. The wire is rated 60, 75, 90, or 105C and 30, 48, 60,90 or 150 V DC.2 Units of Measurement2.1 Values
7、 stated without parentheses are the requirement. Values in parentheses are explanatory orapproximate information.2.2 Conductor sizes are stated in both AWG and mm2. These values are not considered equivalent.3 Components3.1 Except as indicated in 3.2, a component (including gaskets and polymeric mat
8、erials) of a productcovered by this 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
9、 by this outline of investigation, orb) Is superseded by a requirement in this outline of investigation.3.3 A component shall be used in accordance with its rating established for the intended conditions ofuse.3.4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 performan
10、ce capabilities.Such components are intended for use only under limited conditions, such as certain temperatures notexceeding specified limits, and shall be used only under those specific conditions.SEPTEMBER 19, 2017UL 27264UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUT
11、ION WITHOUT PERMISSION FROM UL4 Undated References4.1 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 Workmanship5.1 Only materials t
12、hat 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 with all of the other materials used in th
13、e wire.6 General6.1 Assembly6.1.1 These wires consist of a single insulated conductor.6.2 Conductors6.2.1 Conductors shall be 10 mm2 210 mm2or 10 AWG 400 kcmil in size and shall comply with theminimum area as shown in Table 6.1 and Table 6.2, as applicable. Conductors shall consist of copper inaccor
14、dance with Standard Specification for Soft or Annealed Copper Wire, ASTM B3, StandardSpecification for Tin-Coated Soft or Annealed Copper Wire for Electrical Purposes, ASTM B33, StandardSpecification for Silver-Coated Soft or Annealed Copper Wire, ASTM B298, or Standard Specification forNickel-Coate
15、d 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 6.1Conductor area, metric conductorsMetric conductor size, mm2Minimum conductor area, mm210 9.313 12.116 14.919 18.325 24.13
16、2 31.135 34.040 38.150 48.362 59.870 67.581 77.695 91.0103 98.5120 114.8210 200.6SEPTEMBER 19, 2017 UL 2726 5UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM ULTable 6.2Conductor area, AWG conductorsAWG Size Minimum conductor Area, cmil10 9,3438
17、14,8106 24,5384 37,3602 62,4501 77,7901/0 98,9802/0 125,1003/0 158,6004/0 205,500400 382,0006.3 Insulation6.3.1 The insulation material shall be one described in the Tables in Specific Materials, Section 50 of theReference Standard for Electrical Wires, Cables, and Flexible Cords, UL 1581, suitable
18、for thetemperature rating of the wire. Regardless of what is noted in the Table, the minimum unaged tensilestrength value shall be 1200 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 les
19、s than 0.060 inch (1.5 mm) for a conductor sizebetween 10 AWG and 2 AWG and shall not be less than 0.080 inch (2.0 mm) for a wire larger than orequal to 1 AWG. The average insulation thickness for metric sized wires shall not be less than 0.060 inch(1.5 mm) for a conductor size between 10 mm2and 32
20、mm2shall not be less than 0.080 inch (2.0 mm)for a wire larger than or equal to than 40 mm2.PERFORMANCE7 General7.1 The following tests shall be performed in accordance with, and comply with the requirements in theStandard for Wire and Cable Test Methods, UL 2556, unless otherwise specified below.7.
21、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 Specific Materials, Section 50 of the Reference Standard for Electrica
22、l Wires, Cables, and FlexibleCords, UL 1581. Regardless of what is noted in the table, minimum unaged tensile strength shall not beless than 1200 psi (8.27 MPa).SEPTEMBER 19, 2017UL 27266UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM UL7.1.3 Co
23、nductor 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. Upon examination of theconductor after removal of the insulation, there shall be no evidence of pitting or corrosion of theconductor.7
24、.1.4 Heat Shock (thermoplastic insulation only) The specimens are to be conditioned for one hour atthe temperature shown in Table 7.1 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. Uponvisu
25、al examination, there shall be no 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 insula
26、ted wire. There shall be no cracks, tears or splits in theinsulation.7.1.6 Deformation (thermoplastic and XL insulation only) A flat, rectangular specimen shall be used forsamples taken from samples 6 AWG or 13 mm2and larger. As received specimens shall be used for 8 10AWGor10mm2. The specimens shal
27、l be conditioned at the temperature shown in Table 7.1. The loadapplied during the test shall be as shown in Table 7.2. The decrease in thickness shall not be more than50 percent.Table 7.1Heat shock and deformation test temperaturesMaterial Temperature rating of wire,CAging temperature, 2.0 C Aging
28、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 250Table 7.2Load for deformation testConductor size LoadAWG mm2gf10 8 10 5006 400 13 203 20007.1.7 Flexibility The aging time and temperature shall be the same as used for Physical P
29、roperties 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 for sizes 6 AWG or 13mm2and larger, and for 6 turns for sizes810AWGor10mm2. Upon visual examination, there sh
30、all beno cracks in the insulation.7.1.8 Impact at Abnormally Low Temperature The test shall be conducted at 29C (20F) (required)or at 40C (40F) (optional). 6 AWG or 13 mm2samples shall be considered representative of thecomplete range of conductor sizes. There shall be no cracks, ruptures or other d
31、amage in 8 of the 10specimens.SEPTEMBER 19, 2017 UL 2726 7UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM UL7.1.9 FT2.7.1.10 VW-1 (optional).7.1.11 Durability of Indelible-Ink Printing The aging time and temperature shall be the same as used for
32、Physical 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 plus 1000 V DC shall be applied between the conductor and the foil. The test voltage is tobe applied for 1 min.7.1.13 Crus
33、hing 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 crushing trials shall not be less than2.67 kN
34、 (600 lbf).7.1.14 Abrasion test (thermoplastic insulation only).7.1.14.1 A wire shall not wear through exposing the conductor 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 15 inch (380 mm) specime
35、ns 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 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 st
36、raight parallel teeth are machined symmetrically about a diameter (seeFigure 7.1) is to be supported above (not touching) the center of each specimen with its teethperpendicular to the longitudinal axis of the specimen. The support is to minimize the play of the tool atthe ends of each stroke during
37、 the abrasion process. Die-and-tool steel alloy KW hardened aftermachining to Rockwell C 62. The teeth are to be sharpened to an edge having no burrs every 1600 2500cycles. The hardness is to be checked after each sharpening and, if necessary, the teeth are to bere-hardened. The abrasion tools are t
38、o be used and re-sharpened in sets. Hence, at least two sets of sixare needed.This is generated text for figtxt.SEPTEMBER 19, 2017UL 27268UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM UL7.1.14.3 The plate on which the specimens are mounted is
39、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 6 inch (150mm) occupying the center portion of the specimen
40、s.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 tool and its ad
41、ded 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 on the wire or
42、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 record the num
43、ber 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 performed. The ab
44、radedportion of the sample shall be covered with foil. There shall be no evidence of breakdown of insulation.Figure 7.1Essentials of cylindrical abrasion toolSEPTEMBER 19, 2017 UL 2726 9UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM UL7.1.15 Fl
45、uid compatibility7.1.15.1 1 inch (25 mm) of insulation shall be removed from each end of 40 inch (1000 mm) samples ofthe finished wire. A separate sample shall be used for each fluid.7.1.15.2 The outside diameter shall be determined by measuring the maximum and minimum diameter atthree points spaced
46、 no less than 2 inch (50 mm) apart along the axis of the specimen and recorded. Theaverage diameter shall be calculated.7.1.15.3 The sample shall be formed into a loose loop and center 32 inch (800 mm) shall be immersedin the fluid shown in Table 7.3 for a period of 20 ( plus 1, minus 0) h.Table 7.3
47、Fluid compatibility conditioning and requirementsTest fluid Test Temperature, C (F) Outside wire diametermaximum change percentName FluidEngine oil ASTM D471, IRM-902 50 3 (122 5.4) 15Gasoline ASTM D471, Ref. Fuel C 23 5(73 9.0) 15Ethanol 85% Ethanol + 15% ASTMD471, Ref. Fuel C23 5(73 9.0) 15Diesel
48、fuel 90% ASTM D471, 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) 25Engine coolant 50% Distilled Water + 50%ethylene glycol50 3 (122 5.4) 15Battery acid H2SO4Specific gravity =1.260 .00523 5(73 9.0) 5Note
49、: Solutions are determined by percent of volume. Only battery acid exposure is required for wires marked Battery LeadWire for Electric Battery Powered Industrial Trucks 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 diame
