SAE J 2202-2016 Heavy-Duty Wiring Systems for On-Highway Trucks.pdf

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1、 _ 6$(7HFKQLFDO6WDQGDUGV%RDUG5XOHVSURYLGHWKDW7KLVU eport is published by SAE to advance the state of technical and engineering sciences. The use of this report is entirely voluntary, and its applicability and suitability for any particular use, including any patent infringement arising therefrom, is

2、 the soOHUHVSRQVLELOLWRIWKHXVHU SAE reviews each technical report at least every five years at which time it may be revised, reaffirmed, stabilized, or cancelled. SAE invites your written comments and suggestions. Copyright 2016 SAE International All rights reserved. No part of this publication may

3、be reproduced, stored in a retrieval system or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of SAE. TO PLACE A DOCUMENT ORDER: Tel: 877-606-7323 (inside USA and Canada) Tel: +1 724-776-4970 (outside USA)

4、 Fax: 724-776-0790 Email: CustomerServicesae.org SAE WEB ADDRESS: http:/www.sae.org SAE values your input. To provide feedback on this Technical Report, please visit http:/www.sae.org/technical/standards/J2202_201604 SURFACE VEHICLE RECOMMENDED PRACTICE J2202 APR2016 Issued 1996-01 Revised 2016-04 S

5、uperseding J2202 MAY2004 Heavy-Duty Wiring Systems for On-Highway Trucks RATIONALE This recommended practice will be revised to use some more current terms. Test practices will be updated where needed and a general updating will take place. Diesel Exhaust Fluid exposure is being better defined as we

6、ll as using AWG to specify the size of wire as 2mm sizing has been discovered to be somewhat ambiguous. 1. SCOPE This SAE Recommended Practice provides general guidelines on the material selection, construction and qualification of components and wiring systems used to construct wiring systems for H

7、eavy Duty Vehicles The guidelines are limited to primary wiring systems of less than 50 V and includes cable sizes American Wire Gage 20 to AWG 4 on heavy-duty on-highway trucks. The document identifies appropriate operating performances requirements. This document excludes the male to female connec

8、tion of the SAE J560 connectors. 2. REFERENCES 2.1 Applicable Publications The following publications form a part of this specification to the extent specified herein. Unless otherwise indicated, the latest issue of SAE publications shall apply. 2.1.1 SAE Publications Available from SAE Internationa

9、l, 400 Commonwealth Drive, Warrendale, PA 15096-0001, Tel: 877-606-7323 (inside USA and Canada) or +1 724-776-4970 (outside USA), www.sae.org. SAE J156 Fusible Links SAE J163 Low Tension Wiring and Cable Terminals and Splice Clips SAE J553 Circuit Breakers SAE J560 Primary and Auxiliary Seven Conduc

10、tor Electrical Connector for Truck-Trailer Jumper Cable SAE J561 Electrical Terminals - Eyelet and Spade Type SAE J1067 Seven Conductor Cable - Truck and Bus SAE INTERNATIONAL J2202 Revised APR2016 Page 2 of 19 SAE J1127 Low Voltage Battery Cable SAE J1128 Low Voltage Primary Cable SAE J1284 Blade T

11、ype Electric Fuses SAE J1455 Recommended Environmental Practices for Electronic Equipment Design in Heavy-Duty Vehicle Applications SAE J1493 Guarding of Starter System Energization SAE J1614 Wiring Distribution Systems for Construction, Agricultural, and Off-Road Work Machines SAE J1678 Low Voltage

12、 Ultra Thin Wall Primary Cable SAE J1811 Power Cable Terminals SAE J1888 High Current Time Lag Electric Fuses SAE J1908 Electrical Grounding Practice SAE J1939 Recommended Practice for a Serial Control and Communications Vehicle Network SAE J1939/11 Physical Layer, 250K bits/s, Twisted Shielded Pair

13、 SAE J1939/13 Off-Board Diagnostic Connector SAE J1939/14 Physical Layer, 500Kbps SAE J1939/15 Reduced Physical Layer, 250K bits/sec, UN-Shielded Twisted Pair (UTP) SAE J2030 Heavy-Duty Electrical Connector Performance Standard SAE J2191 Recommended Practice for Identification of Standardized Truck

14、and Tractor Electrical Circuits SAE J2222 Coiled Electrical Cable - Truck and Bus SAE J2223/1 Connections for On-Board Vehicle Electrical Wiring Harnesses - Part 1: Single-Pole Connectors - Flat Blade Terminals - Dimensional Characteristics and Specific Requirements SAE J2223/2 Connections for On-Bo

15、ard Vehicle Electrical Wiring Harnesses - Part 2: Tests and General Performance Requirements SAE J2223/3 Connections for On-Board Vehicle Electrical Wiring Harnesses - Part 3: Multipole Connectors - Flat Blade Terminals - Dimensional Characteristics and Specific Requirements SAE J2247 Truck Tractor

16、Power Output for Trailer ABS SAE J2394 Seven Conductor Cable for ABS Power - Truck and Bus SAE J2497 Power Line Carrier Communications for Commercial Vehicles SAE J2549 Single Conductor Cable for Heavy-Duty Applications - Truck and Bus SAE INTERNATIONAL J2202 Revised APR2016 Page 3 of 19 2.2 Related

17、 Publications 2.2.1 ASTM Publications Available from ASTM International, 100 Barr Harbor Drive, P.O. Box C700, West Conshohocken, PA 19428-2959, Tel: 610-832-9585, www.astm.org ASTM B 117 Standard Method of Salt Spray (Fog) Testing ASTM D 471 Standard Test Method for Rubber Property-Effect of Liquid

18、s 2.2.2 Federal Publications Available from the Document Automation and Production Service (DAPS), Building 4/D, 700 Robbins Avenue, Philadelphia, PA 19111-5094, Tel: 215-697-6257, http:/assist.daps.dla.mil/quicksearch/. Federal Motor Carrier Safety Regulations 393.27 Military Standard - MIL Standar

19、d 1344A Method 3002/Low Voltage Dry Circuit Requirements and acceptance for cable and wire harness assemblies - IPC/WHMA-A-620 available from IPC-2215 Sanders Road-Northbrook, Illinois 60062-6135. 2.2.3 International Organization for Standardization (ISO) Publications Copies of these documents are a

20、vailable online at http:/webstore.ansi.org/ ISO 22241 NOx reduction agent AUS 32 - Part 1: Quality requirements 3. DEFINITIONS 3.1 ELECTRICAL CIRCUITS An electrical circuit includes all of the components and connecting cables, starting from the electrical energy source, going to the functional compo

21、nent(s) and the return route through the energy source. 3.2 ELECTRICAL COMPONENT An electrical component is normally a combination of parts, subassemblies, or assemblies creating a self-contained element intended to store, generate, distribute, alter, or consume electrical energy or affect an electr

22、ical junction. 3.3 CONDUCTOR The current carrying element of an electrical cable. 3.4 ELECTRICAL CABLE Insulated stranded electrical conductor used to establish a single current path. 3.5 HARNESS A group of two or more cables bundled together. SAE INTERNATIONAL J2202 Revised APR2016 Page 4 of 19 3.6

23、 TERMINAL An electrically conductive device attached to a cable to facilitate connection to an electrical component, cable, or termination. 3.7 CONNECTION An electrical and/or mechanical junction between two connectors, cables or between a cable(s) and an electrical component. 3.8 WIRING The cables,

24、 terminations, and supporting accessories collectively used in the electrical distribution system. 3.9 CONNECTOR A separable coupling device which contains the electrical interface and mechanical interface components. 3.10 POINT OF ELECTRICAL CONNECTION The point where the conductor and terminal are

25、 crimped or joined together. 3.11 SEALED A condition which provides a non-leaking union between two mechanical components or any place within an electrical distribution system. A sealed union is defined as one which does not allow the ingress of moisture. 3.12 SIGNAL LEVEL CIRCUIT A circuit in which

26、 open circuit voltages are low and the currents are low (100 mA and 20 mV open circuit) and at the levels where the current is not able to break through the film of oxides, sulfides, or other films or contaminants which may build up on the contact surfaces. 4. TESTS 4.1 Test Procedures The testing s

27、hall validate the appropriate design and performance characteristics of the primary wiring distribution system including the connector interfaces of mating devices but not the mating device itself. Conformance to the requirements of this document shall be determined by subjecting each component to t

28、he test procedure listed in this document. Unless otherwise stated, the tests are to be performed at 25 qC r 5 qC and at 12.5 Vdc 0.1 Vdc or per the manufacturers recommendations. The tests shall be conducted as defined in the following test procedures. Minimum sample size to be 6 parts unless other

29、wise specified by customer requirements. 4.1.1 Voltage Drop 4.1.2 Low Voltage Resistance (Dry Circuit) 4.1.3 Oil Absorption 4.1.4 Thermal 4.1.4.1 Thermal Cycle 4.1.4.2 Thermal Shock 4.1.5 Humidity 4.1.6 Salt Fog * 4.1.7 Salt Water Immersion * 4.1.8 Spray Wash * 4.1.9 Vibration 4.1.10 Insulation Resi

30、stance Multi-conductor Assemblies SAE INTERNATIONAL J2202 Revised APR2016 Page 5 of 19 4.1.11 Tensile Strength Wire to Terminal 4.1.12 Tensile Strength Wire to Wire 4.1.13 Connector Pull Force 4.1.14 Connector Mis-engagement Force 4.1.15 Connector Terminal Retention Force 4.1.16 Chemical Exposure 4.

31、1.17 Circuit Identification (Stand Alone Test) * Tests conducted on sealed connector systems NOTICE: Some test procedures are potentially dangerous. SAE Technical Reports do not purport to address all of the safety problems, if any, associated with their use. It is the responsibility of the user of

32、an SAE Technical Report to establish and employ appropriate safety practices. Tests should only be conducted by individuals who have been properly trained in the test procedure and who are aware of any hazards which may be present. Appropriate safety and health precautions must be employed when cond

33、ucting any test. 4.1.1 Voltage Drop The measurement of connection voltage drop shall be per SAE J163 and Figures 1 and 2. The voltage drop of the cables shall be subtracted from the measured values. 4.1.2 Low-Voltage Dry Circuit Resistance 6LJQDO/HYHO Method 3002.1) Test with applied voltage not exc

34、eeding 20 mV open circuit and the test current shall be limited to 100 mA. Utilizing Figure 1 record connection resistance. 4.1.3 Oil Absorption Connectors shall be capped prior to testing to prevent entry of oil into the connector cavities during the test. The wiring assembly shall be immersed in A

35、STM D 471, IRM-902 engine oil at 50 qC 3 qC for a period of 20 hours. After removal from the engine oil, remove excess oil from the surface and allow sufficient time for excess oil trapped in the assembly to drain completely. 4.1.4 Thermal Shock The cable to cable or cable to component connector ass

36、emblies shall be subjected to 10 cycles of thermal shock. One cycle shall consist of 30 minutes at a temperature of 40 qC 2 qC followed by 30 minutes at a temperature of 80 qC 2 C with a transfer time of 2 minutes maximum. 4.1.4.1 Thermal Cycle Connector and cable assemblies shall be connected to th

37、eir mating parts. The assemblies shall be exposed to 25 cycles of the thermal cycle. The assemblies shall be energized with test voltage commencing at 20 qC and transferring to 40 qC for 1 hour and then transfer to +70 qC within 10 minutes. Hold +70 qC for 1 hour and then transfer to +20 qC within 3

38、0 minutes. This completes the cycle. The current shall be limited to 1 Ampere. 4.1.5 Humidity SAE J1455 Temperature/Humidity-Test samples to be placed in a temperature/humidity chamber and shall be subjected to 42 cycles described as follows: a. Chamber temperature raised to 55 qC at 3 qC/minute r 1

39、 qC/minute b. Chamber temperature held for 16 hours at a relative humidity of 95% r 5% c. Chamber temperature lowered to -55 qC at 3 qC/minute r 1 qC/minute d. Chamber temperature held for 2 hours SAE INTERNATIONAL J2202 Revised APR2016 Page 6 of 19 e. Chamber temperature raised to 125 qC at 3 qC/mi

40、nute r 1 qC/minute f. Chamber temperature held for 2 hours g. Chamber temperature lowered to 25 qC at 3 qC/minute r 1 qC/minute h. Chamber temperature held for remainder of 24 hour cycle 4.1.6 Salt Fog 4.1.7 Testing shall be performed per ASTM B 117-73 test method for 240 hours. During the test, eac

41、h circuit shall be operating at the test currents specified in Table 2. (Voltage Drop) Salt Water Immersion (For sealed connection systems only). The wired mated sealed connectors shall be placed in an oven at 125 qC r 3 qC for 1 hour then immediately be placed in water with a 5% salt in weight cont

42、ent and 0.1 g/L wetting agent, to a depth of 1 m for 4 hours. Water temperature is to be 23 qC r 3 qC. Non terminated ends of the test cable are not to be immersed in salt water bath. 4.1.7.1 Cable to Cable Assembly (splice) a. Immerse the assembly at a minimum depth of 300 mm in a 5% solution of sa

43、lt (sodium chloride) water b. Extend the cable ends out of the solution. c. Connect the assembly to a source with 1 Ampere minimum current flowing. d. Energize the splice for 30 minutes each hour. e. Terminate test after 60 hours. 4.1.7.2 Electrical Harness Component Assembly a. Immerse the assembly

44、 at a minimum depth of 300 mm in a 5% solution of salt (sodium chloride) water. b. Extend the ends of the cable assembly out of the solution. c. Connect the assembly to a power source set at component rated voltage or test voltage. The current flowing shall be at the rated current. d. Energize the a

45、ssembly for 30 minutes each hour. e. Terminate test after 60 hours. 4.1.8 Spray Wash Test Method (Reference SAE J1455) The mated and cabled connectors under test shall be mounted in its normal operating position with drain holes, if used, open. The test apparatus should be designed to provide 100% c

46、overage of the exposed surface of the mated and cabled connectors using flat fan spray nozzles located 20 to 30 cm (7.9 to 11.8 in) away. This apparatus should provide a source pressure of approximately 7000 kPa gauge (1020 lbf/in2 gauge) with a flow rate of approximately 9460 cm3/minute (150 gal/ho

47、ur). The test item should be exposed to the spray for 3s of a 6s period for a total of 375 cycles. The test should be run at 40 qC (104 qF) with water/detergent. An Insulation Resistance test (4.1.10) shall be conducted after this test. SAE INTERNATIONAL J2202 Revised APR2016 Page 7 of 19 4.1.9 Vibr

48、ation Connectors under test are fixed to the vibrating plane with the wire harness fixed to non-vibrating objects no closer than 100 mm and not farther than 300 mm from the rear of the connector. a. Sine sweep rate from 10 to 2,000 Hz and back to 10 Hz completed in 15 minutes b. Initial displacement 1.78 mm DA c. Maximum acceleration 20 g d. Duration of test to be 24 hours e. X, Y, and Z-axis to be tested 8 hours each f. Apply current as specified in Table 2 for the first 3 hours in each axis 4.1.10 Insulation Resistance Multi