saej163v003

__________________________________________________________________________________________________________________________________________SAETechnicalStandardsBoardRulesprovidethat:“ThisreportispublishedbySAEtoadvancethestateoftechnicalandengineeringsciences.Theuseofthisreportisentirelyvoluntary,anditsapplicabilityandsuitabilityforanyparticularuse,includinganypatentinfringementarisingtherefrom,isthesoleresponsibilityoftheuser.”SAEreviewseachtechnicalreportatleasteveryfiveyearsatwhichtimeitmaybereaffirmed,revised,orcancelled.SAEinvitesyourwrittencommentsandsuggestions.Copyright©2006SAEInternationalAllrightsreserved.Nopartofthispublicationmaybereproduced,storedinaretrievalsystemortransmitted,inanyformorbyanymeans,electronic,mechanical,photocopying,recording,orotherwise,withoutthepriorwrittenpermissionofSAE.TOPLACEADOCUMENTORDER:Tel:877-606-7323(insideUSAandCanada)Tel:724-776-4970(outsideUSA)Fax:724-776-0790Email:CustomerService@sae.orgSAEWEBADDRESS:http://www.sae.orgJ163REV.JUL2006SURFACEVEHICLERECOMMENDEDPRACTICEIssued1974-01Revised2006-07SupersedingJ163DEC2001LowTensionWiringandCableTerminalsandSpliceClipsRATIONALEThisdocumenthasbeenrevisedtodeletereferencedSAEdocumentsthatareobsoleteandreplacethemwiththeapplicablecurrentSAEdocuments.Wire/CablesizeshavebeenconvertedtometricsizesperSAEJ1127andSAEJ1128.1.SCOPETheSAERecommendedPracticecoverstheapplicationrequirementsforterminalsandspliceclipsattachedtostrandedlowtensionwiringandcableasshowninSAEJ1127andSAEJ1128.Inaddition,itcoversmaximumvoltagedroplimitsforfrictiontypeconnections.2.REFERENCES2.1ApplicablePublicationsThefollowingpublicationsformapartofthisspecificationtotheextentspecifiedherein.Unlessotherwiseindicated,thelatestversionofSAEpublicationsshallapply.2.1.1SAEPublicationsAvailablefromSAE,400CommonwealthDrive,Warrendale,PA15096-0001,Tel:877-606-7323(insideUSAandCanada)or724-776-4970(outsideUSA),www.sae.org.SAEJ1127BatteryCableSAEJ1128LowTensionPrimaryCable3.USEOFTERMINALSFriction(quickdisconnect)typebrassconnectionsshouldbeusedonlywherethemaximumtemperature(environmentalambientplusriseduetocurrent),measuredatthecenteroftheterminalsurface,doesnotexceedthecapabilitiesofthephysicalpropertiesofthematerial.Maximumtemperaturesforterminalmaterialsotherthanbrassshouldalsobedeterminedpriortousingsoastobecompatiblewiththephysicalpropertiesofthesematerials.Electricalconnectionsandsplicesofstandardtypesmustbeprotected,asapplicationdictates,frommoisture,salt,soilaccumulation,acid,orcorrosivevaporwhichwilldeterioratetheconnectionbeyondthelimitsofthisrecommendedpractice.SAEJ163RevisedJUL2006-2-4.PERFORMANCEREQUIREMENTS(ELECTRICAL)Terminalsorspliceclipsshallbeattachedtowireorcableinsuchamannerthat,followingthehumiditytest,thevoltagedropacrosstheattachmentshallnotexceedthevaluesinTable1.Frictionconnections(terminaltoterminal)shallbesuchthatfollowingfourrepeatedinsertionsandthehumiditytest,thevoltagedropacrosstheconnectionshallnotexceedthevaluesinTable2.Foraterminaltobeacceptable,allspecimenstestedmustmeettherequirements.TABLE1-WIRETOTERMINALORWIRETOWIRE(SPLICECLIPMETHOD)VOLTAGEDROP(AFTERHUMIDITYTEST)Wire/Cable(SAEGage)TestCurrent,ADrop,mVUninsulatedTerminalDrop,mVPreinsulatedTerminal0.5mm(20ga)533.50.8mm(18ga)1055.51mm(16ga)15892mm(14ga)2010113mm(12ga)3015175mm(10ga)4020228mm(8ga)5025--13mm(6ga)6015--19mm(4ga)7018--32mm(2ga)8020--50mm(1/0ga)9023--62mm(2/0ga)10025--TABLE2-FRICTIONVOLTAGEDROP(AFTERHUMIDITYTESTANDFOURINSERTIONS)Wire/Cable(SAEGage)TestCurrent,ADrop,mV0.5mm(20ga)57.50.8mm(18ga)10151mm(16ga)1522.52mm(14ga)20303mm(12ga)30455mm(10ga)40608mm(8ga)50755.TESTPROCEDURETestsshallbeconductedat23°C±3°C(73°F±5°F).Testsamplesshallconsistofterminalsorspliceclipsattachedto305mm(12in)ofwire.Itissuggestedthatatleast10specimensofeachwiresizebesubjectedtoeachtest.6.VOLTAGEDROPTESTMeasurementsshallbemadeafterthetemperatureofthespecimenhasstabilized(2hundertestload).SAEJ163RevisedJUL2006-3-Measurementsacrossawiretoterminalattachmentshallbemadebetweenthecenteroftheconductorgripandapointonthecablecore76.2mm(3in)behindtheconductorgrip.Probepointonthecablecoreshallbestrippedandsolderdabbed.Forpreinsulatedterminals,themeasurementsshallbemadebetweenapointinfrontoftheconductorgripwithin1.6mm(1/16in)oftheendoftheinsulationandapointonthecablecore76.2mm(3in)behindtheconductorgrip.Thevoltagedropacrosstheattachmentisdefinedasthedifferencebetweenthisreadingandthevoltagedropthroughthe76.2mm(3in)ofwire.Measurementsacrossaspliceclipconnectionshallbemadebetweenpointsoncablecores76.2mm(3in)behindthecenteroftheconductorgripcrimp.Probepointsonthecablecoreshallbestrippedandsolderdabbed.Thevoltagedropacrossthespliceisdefinedasthedifferencebetweenthisreadingandthevoltagedropthroughthe152mm(6in)ofwire.Measurementsshallbemadeacrosseachcombinationofconductorpairsinthesplice.Thecurrentvalueshallbeselectedaccordingtothesmallergagecableinthecablepairbeingmeasured.Measurementsacrossafrictionconnectionshallbemadebetweenthecentersoftheconductorgripsoftwojoinedlineconnectortypeterminalsandfromthecenteroftheconductorgripofalineterminaltoasimilarpointonajoinedfixedterminal.Forpreinsulatedterminals,thevoltagedropacrossthewiretoterminalattachmentplusthe76.2mm(3in)ofcableshallbedeterminedfirstpertheaboveprocedure.Thentheterminalsshallbeconnectedandmeasurementsacrosstheconnectionshallbemadefromthestrippedsolderdabbedpointsonthecablecoresoftwojoinedlineconnectortypeterminalsandfromthesamepointonthecablecoretoapointonajoinedfixedterminalequivalenttothatusedforuninsulatedterminals.Thevoltagedropacrossthefrictionconnectionisdefinedasthedifferencebetweenthisreadingandthepreviousmeasurement(s)forthesamespecimen(s)(wiredropplusattachmentdrop).7.HUMIDITYTESTThehumiditytestshallconsistof100hat95to100%relativehumidityat38°C±3°C(100°F±5°F).(Demineralizedwatershallbeused.)Specimensshallbepreparedasfollows:1.Mountedatleast25.4mm(1in)apartontestboards.2.Placedinthehumiditycabinetwiththeaxisofeachspecimeninahorizontalplaneandsuchthatithasallsurfacesoftheterminalcompletelyexposedandnotincontactwithotherobjects.3.Removedfromthecabinetaftertheprescribedexposureperiodandallowedtodry24hatroomconditionbeforefinalMVDtest.8.NOTES8.1MarginalIndiciaThechangebar(l)locatedintheleftmarginisfortheconvenienceoftheuserinlocatingareaswheretechnicalrevisionshavebeenmadetothepreviousissueofthereport.An(R)symboltotheleftofthedocumenttitleindicatesacompleterevisionofthereport.PREPAREDBYTHESAEELECTRICALDISTRIBUTIONSYSTEMSSTANDARDSCOMMITTEE