SAE J163-2001 Low Tension Wiring and Cable Termina

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Copyright 2001 Society of Automotive Engineers, Inc.

5.

Test Procedure—Tests shall be conducted at 23 °C ± 3 °C (73 °F ± 5 °F). Test samples shall consist of terminals or splice clips attached to 305 mm (12 in) of wire. It is suggested that at least 10 specimens of each wire size be subjected to each test.

6.

Voltage Drop Test—Measurements shall be made after the temperature of the specimen has stabilized (2 h under test load).

Measurements across a wire to terminal attachment shall be made between the center of the conductor grip and a point on the cable core 76.2 mm (3 in) behind the conductor grip. Probe point on the cable core shall be stripped and solder dabbed. For preinsulated terminals, the measurements shall be made between a point in front of the conductor grip within 1.6 mm (1/16 in) of the end of the insulation and a point on the cable core 76.2mm (3 in) behind the conductor grip. The voltage drop across the attachment is defined as the difference between this reading and the voltage drop through the 76.2 mm (3 in) of wire.

Measurements across a splice clip connection shall be made between points on cable cores 76.2 mm (3 in)behind the center of the conductor grip crimp. Probe points on the cable core shall be stripped and solder dabbed. The voltage drop across the splice is defined as the difference between this reading and the voltage drop through the 152 mm (6 in) of wire. Measurements shall be made across each combination of conductor pairs in the splice. The current value shall be selected according to the smaller gage cable in the cable pair being measured.

TABLE 1—WIRE TO TERMINAL OR WIRE TO WIRE (SPLICE CLIP METHOD) VOLTAGE DROP

(AFTER HUMIDITY TEST)

Wire/Cable (SAE Gage)

Test Current, A

Drop, mV Uninsulated Terminal

Drop, mV Preinsulated Terminal

20 5 3 3.518 10 5 5.516 15 8 914 20101112 30151710 402022 8 5025 -- 6 6015 -- 4 7018 -- 2 8020 -- 0 9023 --00

100

25

--

TABLE 2—FRICTION VOLTAGE DROP (AFTER HUMIDITY TEST AND FOUR INSERTIONS)

Wire/Cable (SAE Gage)

Test Current, A

Drop, mV 20 5 7.5181015161522.5142030123045104060 8

50

75

For preinsulated terminals, the voltage drop across the wire to terminal attachment plus the 76.2 mm (3 in) of cable shall be determined first per the above procedure. Then the terminals shall be connected and measurements across the connection shall be made from the stripped solder dabbed points on the cable cores of two joined line connector type terminals and from the same point on the cable core to a point on a joined fixed terminal equivalent to that used for uninsulated terminals. The voltage drop across the friction connection is defined as the difference between this reading and the previous measurement(s) for the same specimen(s) (wire drop plus attachment drop).

7.Humidity Test—The humidity test shall consist of 100 h at 95 to 100% relative humidity at 38 °C ±3°C

(100°F ± 5 °F). (Demineralized water shall be used.) Specimens shall be prepared as follows:

1.Mounted at least 25.4 mm (1 in) apart on test boards.

2.Placed in the humidity cabinet with the axis of each specimen in a horizontal plane and such that it has

all surfaces of the terminal completely exposed and not in contact with other objects.

3.Removed from the cabinet after the prescribed exposure period and allowed to dry 24 h at room

condition before final MVD test.

PREPARED BY THE SAE ELECTRICAL EQUIPMENT COMMITTEERationale—The changes to this document include:

Metric is now the primary unit followed by English in parentheses.

In Section 6, the word “dabbed” has replaced the word “dapped”.

Relationship of SAE Standard to ISO Standard—Not applicable.

Application—The SAE Recommended Practice covers the application requirements for terminals and splice clips attached to stranded low tension wiring and cable as shown in SAE J878 and SAE J558. In addition, it covers maximum voltage drop limits for friction type connections.

Reference Section

SAE J558—Low Tension Cable

SAE J878—Low Tension Cable Thermosetting Insulation

Developed by the SAE Connector Systems Task Force