saej378v002

SURFACEVEHICLERECOMMENDEDPRACTICE(R)MarinePropulsionSystemWiringSAETechnicalStandardsBoardRulesprovidethat:“ThisreportispublishedbySAEtoadvancethestateoftechnicalandengineeringsciences.Theuseofthisreportisentirelyvoluntary,anditsapplicabilityandsuitabilityforanyparticularuse,includinganypatentinfringementarisingtherefrom,isthesoleresponsibilityoftheuser.”SAEreviewseachtechnicalreportatleasteveryfiveyearsatwhichtimeitmaybereaffirmed,revised,orcancelled.SAEinvitesyourwrittencommentsandsuggestions.Copyright©2004SAEInternationalAllrightsreserved.Nopartofthispublicationmaybereproduced,storedinaretrievalsystemortransmitted,inanyformorbyanymeans,electronic,mechanical,photocopying,recording,orotherwise,withoutthepriorwrittenpermissionofSAE.TOPLACEADOCUMENTORDER:Tel:877-606-7323(insideUSAandCanada)Tel:724-776-4970(outsideUSA)Fax:724-776-0790Email:custsvc@sae.orgSAEWEBADDRESS:http://www.sae.orgIssued1969-01Revised2004-10SupersedingJ378JAN1988®J378REV.OCT20041.ScopeThisSAERecommendedPracticecoverstherequirementsforallmarineinboardenginewiring,wiringassemblies,wiringcomponents,andwiringconnectorsconnectedtomicroprocessorsassociatedwiththeoperationofthepropulsionsystem.EXCEPTION—OutboardenginesandenginesinPersonalWaterCraft(PWC).NOTE—SeeABYCE11foradditionalrequirementsrelatedtoelectricalinstallationsonsmallcraft.1.1PurposeThepurposeofthisdocumentistoinsurethatelectricalandelectronicwiringandwiringcomponentsusedinamarinepropulsionsystemmeetthenecessarysafetyandperformancerequirementsbaseduponthemarinemechanicalandelectricalenvironment.Therecommendationsincludemethodsthatmaybeemployedbymanufacturerstominimizethepossibilitythatenginewiringmaybeasourceofignitionofexplosiveorflammablevaporsandprovidemanufacturersinstallingengineelectricalsystemssufficientinformationtodesignanddevelopenginewiringharnessesformarineusage.1.2GeneralNormally,marineenginesareinstalledinenclosedcompartmentswhicharedifficulttoventilatewellenoughtopurgequicklyanyexplosivemixturesofflammablegases,particularlyifacontinuousfuelleakispresent.Forthisreason,itisessentialthatprecautionsbetakentominimizeallsourcesofpossibleignitionofexplosivefuelairmixturesthatmaybepresent.Wiringcanbecomeapotentialsourceoffuelvaporignitioninnumerousways,includingdamagetoinsulationcovering,looseconnections,accidentalshortingatterminals,fatiguefailures,etc.Theseoccurrencescanbeasmuchamatterofinstallationasofdesign.Performanceteststodeterminethenecessaryexternalignition-protectionofcompletewiringharnessesarenotpractical.Protectioncanbeaffordedbyproperselectionofcomponentsandinstallationpracticesinaccordancewiththefollowingrecommendations.Forinboardandsterndriveengines,theminimumfederalrequirementsforelectricalwiringarecoveredbyTitle33CodeofFederalRegulationsPart183Sections183.410to183.460.SAEJ378RevisedOCT2004-2-2.References2.1ApplicablePublicationsThefollowingpublicationsformapartofthisspecificationtotheextentspecifiedherein.Unlessotherwiseindicated,thelatestversionofSAEpublicationsshallapply.2.1.1SAEPUBLICATIONSAvailablefromSAE,400CommonwealthDrive,Warrendale,PA15096-0001,http://www.sae.orgSAEJ858—ElectricalTerminals—BladeTypeSAEJ1127—BatteryCableSAEJ1128—Low-TensionPrimaryCableSAEJ1191—HighTensionIgnitionCableAssemblies—MarineSAEJ2030—Heavy-DutyElectricalConnectorPerformanceStandardSAEJ2202—Heavy-DutyWiringSystemsforOn-HighwayTrucks2.1.2FEDERALPUBLICATIONSAvailablefromtheSuperintendentofDocuments,U.S.GovernmentPrintingOffice,MailStop:SSOP,Washington,DC20402-9320.Web:http://www.access.gpo.gov/nara/cfr/waisidx_99/33cfr183_99.htmlTitle33CodeofFederalRegulationsPart183—BoatsandAssociatedEquipment2.1.3ASTMPUBLICATIONSAvailablefromtheAmericanSocietyforTestingandMaterials,100BarrHarborDrive,WestConshohocken,PA19428-2959.Orderonlineathttp://www.astm.orgASTMD412—TestMethodsforVulcanizedRubberandThermoplasticRubbersandThermoplasticElastomers-TensionASTMD573—TestMethodforRubber—DeteriorationinanAirOvenASTMD471—StandardTestMethodforRubberProperty—EffectofLiquids2.1.4ABYCPUBLICATIONABYCdocumentscanbeorderedonlineathttp://www.abycinc.orgABYCE11—ACandDCElectricalSystemsonBoatsSAEJ378RevisedOCT2004-3-3.Definitions3.1ButtSpliceAspliceinwhichthewireendsarepositionedintheconnectionbutttobutt.3.2LowVoltageCapsAninsulatingshieldtoprotectagainstaccidentalshortingofterminalorterminationsinlow-tensioncircuits.3.3ConnectorAninsulateddevicethatholdsaterminal(s)forelectricallyinterconnectingoneormorewires.ConnectorsshallconformtoSAEJ2030.3.4EndCapSpliceAspliceinwhichallwiresenteratthesameend.3.5EngineWiringAnyinsulatedelectricalwiringofamarineenginenecessaryforoperation,monitoring,and/orcontrol.3.6LowTensionWiringWiringusedinalessthat50Vapplication.3.7PersonalWaterCraft(PWC)Avesselthatusesaninboardenginepoweringawaterjetpumpasitsprimarysourceofmotivepowerandwhichisdesignedtobeoperatedbyapersonsitting,standing,orkneelingonthevesselratherthantheconventionalmannerofsittingorstandinginsidethevessel.3.8Sonic-WeldSpliceAweldproducedbytheintroductionofhigh-frequencymechanicalvibrationbetweentwocomponentsuntilametallurgicbondisformedattheweldinterface.3.9TerminalAmetalfittingattachedtotheendofawiretofacilitatemakingelectricalconnections.3.10TeeConnectionAformofaspliceinwhichthereare3to4connectionpoints,each90degreestoeachother.SAEJ378RevisedOCT2004-4-3.11WireThecombinationofaconductorsurroundedbyinsulation.4.LowTensionWiringThetemperatureratingofthewireinsulationshallbedeterminedbyanacceleratedagingtestconductedinaccordancewithASTMD573,exceptsamplesofinsulationaretoberemovedfromthefinishedwireandaged168hours.Thetesttemperatureshallbe30°C(86°F)abovetheintendedratedtemperature.Tensilestrengthafteragingshallnotbelessthan80%oftheoriginaltensilestrength.Theelongationafteragingshallbeatleast50%oftheoriginalelongation.Exceptforintermittenthighercurrents,eachcircuitmustnotcarryacurrentgreaterthanspecifiedinFigure1forthewiregaugeandtemperaturerating.ResistanceconductorsthatcontrolcircuitamperageandcrankingmotorcircuitconductorsareexemptfromtherequirementsofFigure1.Wiringlongerthan455mm(18in),notgroupedtogetherandprotected,shallbenolessthan1mm2(metricwire)orAWG16gauge(USinchdimensionedwire).Thewiringassemblyshallbesupportedatintervalsnotgreaterthan455mm(18in)shallbelocatedsoastobeprotectedfrommovingparts,andspacedorshieldedfromhightemperaturesurfacessothatthewireinsulationorsheathwillnotexceeditstemperaturerating.Wiringpassingthroughholesshallbeprovidedwithgrommets,bushingsorothermeanstoprotectagainstabrasion.Wiringshallberoutedaboveanticipatedlevelsofbilgewaterorawayfromareaswherewatermayaccumulate,exceptwiringforsubmergedequipmentsuchasbilgepumps.Foradditionalcablespecification,seeSAEJ1127andSAEJ1128.Exceptwhereotherwiseprotectedornotincontactwithmetalsurfaces,thewiringcircuitsshallbegroupedtogetherandprotectedbynon-metallictapeorbraidcoveringwhichshallbecapableofwithstandingtheabrasiontestcoveredinSection5.5.AbrasionTestforNon-metallicTapeorBraidCovering5.1PrincipleThreeindividualsamplesofidenticalconstructionshallbeselectedfromatestlot.Thesesamplesshallbeconstructedthesameasforallothersizestobequalifiedbythistestsample.Thesamplestobequalifiedbythistestlotshallnothaveacoverthicknesslessthanthoseofthetestlot.After1000testcycles,eachsampleinthetestlotshallnothaveanyconductormaterialexposed.5.2ProcedureThetestsamplesshallbepreconditionedforatleast24hat23°C±2°C(73°F±3.6°F)and(50%±5%)relativehumidity.Testingshallbeperformedattheprevioustemperaturewithanunusedabrasivesurfaceforeachsample.Theabrasivesurfaceshallbe25x76mm±5mm(1x3in±0.2in)240grit,mediumgrade,AIO3emeryclothfirmlyaffixedtoahardsurfacewhichwillcyclebackandforth76mm±5mm(3in±0.2in)ineachdirection.SAEJ378RevisedOCT2004-5-FIGURE1—ALLOWABLEAMPERAGEOFCONDUCTORSFORSYSTEMSUNDER50VOLTSSAEJ378RevisedOCT2004-6-Onetestcycleequals360degreesrotationoftheoutsidediameterandonebackandforthmovementoftheabrasivesurface.Aconstantnormalforceof45N±0.5N(10lb±2oz)shallbeappliedtotheabrasivesurface(seeFigure2).FIGURE2—TYPICALABRASIONTESTFIXTURE6.WireTerminationRequirements6.1Allterminal-to-wireandspliceconnectionsmustpassthepull-offforcesaslistedinTable1.Theseforcesarethetotalseparatingforces,whichincludestheweightoftheconnectingwirewhentestedinaverticalposition.SAEJ378RevisedOCT2004-7-TABLE1—MINIMUMPULL-OFFFORCEVALUESWireSizeMETRIC(mm2)WireSizeENGLISH(AWG)1MinDesignTestTensionForceN1MinDesignTestTensionForcelb1sAlternateQualityControlTestTensionForceN1sAlternateQualityControlTestTensionForcelb(0.8)1844108018(1)16661512428(2)141333015535(3)121553517740(5)101774020045(8)82004522250(13)62225035580(19)431170444100(32)240090600135(40)1444100666150(50)0556125778175(62)006671501000225(81)0007781751155260(103)0000100022514653306.2ProcedureThemethodofsettingupthespecimensinthepullofftestfixturewillvaryaccordingtothetypeofterminalorsplicebeingtested.Thetestfixtureshallbedesignedtoholdoneendoftheterminalorwirestationarywhilethepullforceisappliedtotheotherend.Adaptersmayberequiredtoallowacommontestfixturetobeusedtotestthevarioustypesofterminalsandsplices.Ingeneral,eachtypeshallbesecuredinapositionwiththenecessaryadapterstoholdtheterminalorspliceandkeepthedirectionofpullalongtheaxisofthewire.Theforceshallthenbeappliedgraduallysothereisnosuddenapplication,jerking,orswinging.Figure3Aillustratestheintentionofthepulltestsetuponsometypesofterminalsandsplices.Endcaptypesplices,however,shallhavetheirwirespulledfirstinoppositedirections,thenwiththeendcapheldsecurely,thewiresshallbepulledindividuallyawayfromthecapalongtheaxisofthewire.Ifthecapcontainswiresofdifferentsizes,testthesmallerwirefirst.Teeconnectionsandbuttsplicesthatcontainmorethanonewireateitherendshallbepulledparalleltothemainwirethenperpendiculartoit.Sometypesofterminalsmaybetestedinpairs,suchas,ringandlugtypesboltedbacktobackandknifedisconnectsmatedtogether,providedtheterminalwirebarrelsarekeptparalleltoeachotherandtotheaxisofthewire(SeeFigures3Aand3B).SAEJ378RevisedOCT2004-8-FIGURE3A—EXAMPLESOFSOMETERMINALPULL-OFFMETHODSFIGURE3B—PAIRINGOFTERMINALSSAEJ378RevisedOCT2004-9-7.ConnectorMoistureResistanceRequirements7.1Connectorsusedonorconnectedtomicroprocessorsassociatedwithmarinepropulsionsystemsshallpassthewaterimmersionandfluidimmersiontests.7.2WaterImmersion7.2.1PRECONDITIONINGThewired,ormated,connectorsshallbeplacedinanovenat125°C±3°C(257°F±5°F)for1h.7.2.2PROCEDURERemovethesamplesfromthepreconditioningovenandimmediatelyimmersethesamplesina5%byweightsaltwatersolutioncontaining0.1g/Lwettingsolutiontoadepthofonemeterfor4hat23°C±3°C(73°F±5°F).7.2.3PASS/FAILCRITERIA7.2.3.1WeatherproofConnectorsContinuitywithoneprobeinthetestsolutionandoneprobeattachedtotheconductorshallconstitutefailure.7.2.3.2ExposedConnectorsAnyvisualevidenceofwaterontheconductoraftercompleteremovalofthecovershallconstitutefailure.7.3FluidImmersionTest7.3.1PROCEDURESubmergeasampleofwiredandmatedconnectortoeachlistedfluidat85°C±3°C(185°F±5°F)for5min,thenallowtoairdryfor24h.Thiscompletesonecycle.Eachsampleistobesubjectedtoatotalof5cycles.Anuntestedsampleisrequiredtopassthistestineachfluid.Thefluidsare:a.Gasoline:ASTMD471,ReferencefuelBb.PowerSteeringFluid:ASTMD471,IRM903c.EngineCoolant:50%distilledwaterand50%ethyleneglycolmixture7.3.2PASS/FAILCRITERIAVisualswelling,crackingorcontinuitywithoneprobeinthesolutionandoneprobeconnectedtotheconductorshallconstitutefailure.SAEJ378RevisedOCT2004-10-8.TerminalandMulti-ConnectorPlugSeparationRequirements8.1Eachsinglefrictionterminal,springtypeterminalandnon-lockingmulti-conductorplugthatisoutsideoftheelectricaljunctionboxmustnotseparatewhensubjectedtoa26.7N(6lb)tensileforcefor1minalongtheaxialdirectionoftheterminalorconnectorbladeterminals,whenused,shallconformtoSAEJ858.Thisforceincludestheweightoftheconnectingwireswhentestedinaverticalposition.Conditiontheterminalsorconnectorspriortotestingbyconnectinganddisconnectingthemsixtimes,unlesstheterminalsorconnectorsarespecificallydesignednottobedisconnectedandinstalledintheboatinsuchawaythattheywouldnotrequiredisconnectionfornormalaccess,servicing,ormaintenance.8.2ProcedureMatedterminalsandconnectorsshallbeinstalledinatestfixture(Figure4)suchthatoneofthehalvesoftheterminalorconnectorisheldsecureandstationarywhiletheotherhalfissubjectedtothe26.7N(6lb)tensileforce.Theforceshallbeappliedgraduallysothereisnosuddenapplication,jerking,orswinging.Differentadapterswillberequiredtoholdthevarioustypesofterminalsandconnectortypes.FIGURE4—SEPARATIONTESTFIXTURE9.LowVoltageCaps9.1Capmaterialshallbeagedfor168h.atatemperatureof90°C±2°C(194°F±4°F)inanovenandallowedtocooltoroomtemperature.Thetensilestrengthafteragingshallnotbelessthan80%oftheoriginaltensilestrength.Theelongationafteragingshallbeatleast50%oftheoriginalelongation.TestsshallbeconductedasperASTMD412.SAEJ378RevisedOCT2004-11-9.2Capmaterialshallbesubmergedineachofthefollowingliquidsforaperiodof5hat23°C±3°C(73°F±6°F).Testsmaybeinanysequence:a.Gasoline:ASTMD471,ReferenceFuelBb.PowerSteeringFluid:ASTMD471,IRM903c.EngineCoolant:50%distilledwaterand50ethyleneglycolmixture9.2.1Thetestspecimensshallberemoved,blotteddry,andjudgedwithrespecttountestedspecimens.9.3Testedspecimensshallnotlosemorethan40%oftheirtensilestrengthorswellbymorethan50%ofanydimensionasaresultofbeingsubjectedtotheconditionsunder9.2,Items(a)(b)(c).9.4Dielectricstrengthofcapmaterialshallbe100VDC/milminimumaftercompletionofagingtestsunder9.1and9.2.10.HighTensionWiringHigh-tensioncableassembliesusedinengineignitionsystemsshallconformtoSAEJ1191.Separators,stand-offs,looms,conduit,raceways,orabrasionresistantsleevingshallbeusedwherenecessarytomaintainadequateseparationbetweencablesandtoprotectcableinsulationfromphysicaldamage.Harnessclampsshallbedesignedwithsmoothroundededgestopreventdamagefromtheclamptotheconductororinsulation.Non-metallicstrapsorclampsshallbedesignedtopreventfailureifusedinareasofhightemperatures,oroverengine(s),movingshafts,othermachineryorpassageways.High-tensioncabletoterminalconnectionsshallwithstandthetensileforcesof89N(20lb)minimum.Thecablewithterminalsandbootattachedshallnotdisconnectfromasparkplugwhena26.7N(6lb)tensileforceisappliedfor1mintotheleadandpulledparalleltotheaxisofthesparkplug.11.ColorCodeThemarkingshowninTable2isrecommendedformarineenginesandtheirassociatedcomponents.Asalternatives,thecolorcodeinSAEJ1128LowTensionWiring,SAEJ2202TruckWiringorthemanufacturerscodemaybeused.Ifalternativemethodsareused,awiringdiagramofthesystemindicatingthemethodofidentificationmustbesuppliedwiththecraft.Coloredsleevesattheterminalendsofwiresmaybeusedinlieuofsolidcoloredwires.Thecircuitdiagram(Figures5Aand5B)isforthepurposeofclarifyingcolor-codingandnottorecommendparticularcircuitingorcomponents.Componentsthatmaybewiredinvariouswaysshouldbewiredwiththemarkingcorrespondingtotheparticularbranchofthecircuitinwhichtheyareused.SAEJ378RevisedOCT2004-12-TABLE2—MARINEENGINEWIRINGColorNumberDescriptionPurple1XXIgnitionswitchcontrolledBlackorYellow2XXGroundsRed(1)3XXUnprotectedbatterywiresRed/Purple4XXOvercurrentprotectedbatterywiresGreenorGreen/YellowStripe6XXBondingBrownandBrown/Stripe7XXAlternatorstartertoignitionmoduleOrange8XXAlternatorDCoutputandaccessoryfeedsLightBlue9XXOilpressureTan10XXWatertemperatureGray11XXTachometerGreen/White12XXEnginetriminand/ortiltdownGreen/Orange13XXEngineindependenttrimdownBlue/White14XXEnginetrimoutand/ortiltupBlue/Orange15XXEngineindependenttrimupWhite16XXMustnotbeusedinunder50VwiringYellow/Red17XXStartingcircuitYellow/Black18XXChokeBlack/Yellow19XXIgnitionstopBrown/White20XXTrimpositionsenderManufacturer’sDiscretionIgnitiontriggeringandcolor/stripeforfunctionsnotdesignated1.Red/Purplemaybeusedforovercurrentprotectedwires.SAEJ378RevisedOCT2004-13-FIGURE5A—CIRCUITDIAGRAM(ENGINE)SAEJ378RevisedOCT2004-14-FIGURE5B—CIRCUITDIAGRAM(INSTRUMENTATION)SAEJ378RevisedOCT2004-15-12.Notes12.1MarginalIndiciaThechangebar(|)locatedintheleftmarginisfortheconvenienceoftheuserinlocatingareaswheretechnicalrevisionshavebeenmadetothepreviousissueofthereport.An(R)symboltotheleftofthedocumenttitleindicatesacompleterevisionofthereport.12.2KeywordsConnectors,lowtensionwiring,lowvoltagecaps,terminalsPREPAREDBYTHESAEMARINETECHNICALCOMMITTEESAEJ378RevisedOCT2004RationaleThetitleandscopeofthisdocumenthavebeenrevisedtoreflecttherequirementsnecessarytoupgrademarinewiringtoaccommodatetheuseofmicroprocessorsinthemarineindustry.Non-Wickingwire,waterandfluidimmersiontesthavebeenaddedtoimprovetheintegrityofwireterminationpoints.Anabrasiontesthasbeenaddedtoqualifythe“severeabrasionresistance”requirementsfornon-metallictapeorbraidcovinginthelowtensionwiringsection.Rationaleforrevisions:SectionChanges1.0ClarifydefinitionofPWCtomatchDefinitionsSection1.2CorrecterrorinreferencetotheFederalRegisterandaddedtextforclarity2.1SeveralchangestoupdatecontactinformationandaddWEBaddresses.3.2Change3.2tomatchsection94.0Clarifydefinitionofwiregauge5.2RevisedimentionsometricandEnglishunitsarecloserwhenconverted.7.2.1,7.2.2,7.3.1Revisetolerancessounitsarecloserwhenconverted7.3,9.2Clarifymaterialsusedintesting11.0RemoveobsoletestandardReferenceSectionAddASTMD471referenceAddedKeywordsRelationshipofSAEStandardtoISOStandardNotapplicable.ApplicationThisSAERecommendedPracticecoverstherequirementsforallmarineinboardengineswiringassembliesandcomponents.ReferenceSectionSAEJ858—ElectricalTerminals—BladeTypeSAEJ1127—BatteryCableSAEJ1128—Low-TensionPrimaryCableSAEJ1191—HighTensionIgnitionCableAssemblies—MarineSAEJ2030—Heavy-DutyElectricalConnectorPerformanceStandardSAEJ2202—Heavy-DutyWiringSystemsforOn-HighwayTrucksABYCE11—ACandDCElectricalSystemsonBoatsSAEJ378RevisedOCT2004ASTMD412—TestMethodsforVulcanizedRubberandThermoplasticRubbersandThermoplasticElastomers-TensionASTMD471—StandardTestMethodforRubberProperty—EffectofLiquidsASTMD573—TestMethodforRubber—DeteriorationinanAirOvenTitle33CodeofFederalRegulationsPart183—BoatsandAssociatedEquipmentDevelopedbytheSAEMarineTechnicalCommittee