SAE J 553-2016 Circuit Breakers.pdf

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1、_ SAE Technical Standards Board Rules provide that: “This report 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 there

2、from, is the sole responsibility of the user.” 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 p

3、ublication may 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: +1 724-776-497

4、0 (outside USA) 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/J553_201607 SURFACE VEHICLE STANDARD J553 JUL2016Issued 1951-11 Revised 2016-07 S

5、uperseding J553 JUN2004 Circuit Breakers RATIONALE Incorporated requirements of SAE J1625 (Heavy-Duty Circuit Breakers). Changed references that have become obsolete. Clarified use of power supplies vs. batteries, and test condition details. Added monitoring of current during failure (interrupt test

6、) to better capture actual failure mode. 1. SCOPE This SAE Standard defines the test conditions, procedures, and performance requirements for circuit breakers in ratings up to and including 200 A. The document includes automatic reset, modified reset, and manually reset types of circuit breakers for

7、 12 V and 24 V DC electrical systems. Some circuit breakers may have dual voltage ratings (AC and DC), however, this document evaluates DC performance only. 2. REFERENCES 2.1 Applicable Documents The following publications form a part of this specification to the extent specified herein. Unless othe

8、rwise indicated, the latest issue of SAE publications shall apply. SAE INTERNATIONAL J553 JUL2016 Page 2 of 32 2.1.1 SAE Publications Available from SAE International, 400 Commonwealth Drive, Warrendale, PA 15096-0001, Tel: 877-606-7323 (inside USA and Canada) or 724-776-4970 (outside USA), www.sae.

9、org. SAE J1127 Low Voltage Battery Cable Battery Cable SAE J1128 Low Voltage Primary Cable SAE J1171 External Ignition Protection of Marine Electrical Devices SAE J1211 Handbook for Robustness Validation of Automotive Electrical/Electronic Modules SAE J1428 Marine Circuit Breakers SAE J1455 Recommen

10、ded Environmental Practices for Electronic Equipment Design (Heavy Duty Trucks) 2.2 Related Publications The following publications are provided for information purposes only and are not a required part of this SAE Technical Report. 2.2.1 SAE Publications Available from SAE International, 400 Common

11、wealth Drive, Warrendale, PA 15096-0001, Tel: 877-606-7323 (inside USA and Canada) or 724-776-4970 (outside USA), www.sae.org. SAE J554 Electric Fuses (Cartridge Type) SAE J537 Storage Batteries SAE J1127 Battery Cable SAE J1284 Blade Type Electric Fuses SAE J1888 High Current Time Lag Electric Fuse

12、s SAE TSB 002 Preparation of SAE Technical Reports 2.2.2 CSA Publications Available from CSA International, 178 Rexdale Boulevard, Toronto, Ontario, Canada M9W 1R3, Tel: 416-747-4000, www.csa-international.org. CSA C22.2 No. 14-M1987 Industrial Control Equipment CSA C22.2 No. 235-M89 Supplementary P

13、rotectors SAE INTERNATIONAL J553 JUL2016 Page 3 of 32 2.2.3 U.S. Government Available from DLA Document Services Building 4/D, 700 Robbins Avenue, Philadelphia, PA 19111-5094,MIL-STD-202GTest Method Standard. Electronic and Electrical Component Parts 2.2.4 UL Publications Available from the Underwri

14、ters Laboratories Inc., 333 Pfingsten Road, North borrk, IL 60062-2096, Tel:847-272-8800, . U.L. 1077 Standard for Supplementary Protectors for use in Electrical Equipment 2.2.5 Appendices Appendix A Circuit Protection Application Guidelines Appendix B Glossary of Document Terminology 3. DEFINITIONS

15、 3.1 CIRCUIT BREAKERS Overcurrent protection devices, responsive to electric current and to temperature. NOTE: There are no implied restrictions on circuit breaker design as to component form or ornamental housing designs provided the circuit breaker exhibits performance characteristics within the s

16、cope of this standard. This standard has been developed for use by the ground transportation industry, however other users of DC circuit protection may find the test and performance requirements of benefit. 3.2 EXTERNALLY MOUNTED CIRCUIT BREAKERS Self-contained circuit breakers, which are mounted in

17、dividually or in assemblies via brackets, bus bars, electrical centers, compatible fuse holders, or mechanically in or through panels. Designed for easy replacement. 3.3 INTERNALLY MOUNTED CIRCUIT BREAKERS Protection sub-assemblies that are integrated with other electrical devices, such as part of a

18、 switch with circuit breaker function or in a motor housing to provide overload protection to the motor windings. Replacement will require disassembly of a parent device. 3.4 There are three general classes of circuit breaker, defined as follows: 3.4.1 TYPE 1 AUTOMATIC RESET is defined as cycling or

19、 continuously self-resetting unit, which is opened by overcurrent. The terms “cycling” and “continuously self-resetting” refer to the functional characteristic in which the reset feature is not dependent upon any deliberate action or intervention by the user or users application system to initiate t

20、he reset of the tripped circuit breaker. These terms do not imply that the trip and reset function can continue unabated without consequence to either the life of the circuit breaker or potentially adverse effects to an electrical system wiring and/or components, if a fault condition persists undete

21、cted and uncorrected. NOTE: Type 1 automatic reset circuit breakers are best utilized in applications that provide for other self-limiting or non-resettable means (such as after a main fuse, main manual reset circuit breaker, or momentary switch). Intermittent electrical short circuit operation, whi

22、ch may be observed during a cycling event on a Type 1 automatic reset circuit breaker after overload or short, could be misinterpreted as loose connections by operators if self-limiting means are not in place, which in turn may lead to delayed service of a fault. 3.4.2 TYPE 2 MODIFIED RESET is defin

23、ed as a device that is opened by overcurrent and remains open as long as a minimum voltage and current is available to the affected circuit (as established in this standard). A sequence of trip and reset cycles may occur prior to achieving the steady-state open condition as defined in the test and p

24、erformance requirements. SAE INTERNATIONAL J553 JUL2016 Page 4 of 32 3.4.3 TYPE 3 MANUAL RESET is defined as a non-cycling unit that is opened by overcurrent. A manual reset circuit breaker, once opened by overcurrent requires manual actuation of a reset mechanism in order to re-establish continuity

25、. NOTE: Trip free designation on manual reset circuit breakers as it applies to this standard - indicates a manual reset circuit breaker in which any forced restriction of the reset mechanism in the operating mode does not prevent cycling under fault current, or causes the circuit breaker to keep pa

26、ssing electrical current in lieu of any form of trip function. 3.4.3.1 TYPE 3 MANUAL RESET WITH SWITCHABLE FEATURE - Functions as a conventional manual reset circuit breaker as defined in 3.4.3, but also has a mechanism, which when exercised at the discretion of the user, permits opening of the brea

27、kers internal circuit to stop current flow. The breaker is reset to its normal operating condition by the manual reset function, whether tripped unattended by a real fault condition or by the user. 3.4.3.2 TYPE 3 MANUAL RESET/SWITCH an integrated switch design that provides both switching function f

28、or on-off activations and includes a circuit breaker feature to “toggle” the switch to an off position in the event of overcurrent or short circuit. Reset function is likely to be incorporated into the on/off activating mechanism, permitting reset of the circuit breaker portion of the device. 4. TES

29、T REQUIREMENTS 4.1 Test Equipment, Instrumentation, and Conditions 4.1.1 Power Supplies 4.1.1.1 A current and voltage regulated DC power supply shall be used for all tests except 4.2.6 Interrupt Test. The power supply shall be capable of delivering 14.0 VDC and 28.0 VDC during open circuit portion o

30、f tests and have sufficient current output capacity to meet highest load requirements. Voltage and current settings shall be accurate to within 1% of set point. Power transient response shall be such that when a 30% step increase in power is demanded by the load, the transient in the regulation outp

31、ut shall typically recover to within 3% of the final value within 100 ms or better. The power supply shall be operated with controlling circuitry to achieve all necessary test conditions. NOTE: DC power supplies used for testing could have large storage capacitors in the DC output section. Load swit

32、ching may induce current spikes, which while brief in duration, may be significant enough to bias test results or affect reset and re-trip activity of circuit breakers (especially more vulnerable lower amperage rated devices). For this reason, it is necessary to buffer the output by placing low resi

33、stance power resistors (generally one ohm or less) in series with the DC power supply output as part of the overall circuit breaker test circuit. See Figure 1 Current Rating Test Circuit. 4.1.1.2 Storage batteries specified in Table 1 shall be used as the power supply for 4.2.6 Interrupt Test. Open

34、circuit voltage as specified shall be maintained by a battery charger or power supply with voltage regulated per Table 1 and charging current output restricted per Table 1. TABLE 1STORAGE BATTERIES Current Rating Voltage Rating Cold Cranking Amperage (CCA) Open Circuit Voltage Maximum Charging Curre

35、nt 0-50A 12 V 575 min / 750 max 14.0 0.5V DC 30A 0-50A 24 V(1)28.0 1.0 V DC 30A 50-200A 12 V 1100 min / 1200 max 14.0 0.5V DC 100A 50-200A 24 V(1) 28.0 1.0 V DC 100A 1. Two 12 V batteries connected in series. NOTE: For all tests, it shall be alternatively acceptable for users to utilize storage batt

36、eries per Paragraph 4.1.1.2, battery charger to maintain open circuit voltage requirements per Table 1, and test circuit with resistor load as is shown in Figure 1 Current Rating Test Circuit, except that the power supply is replaced with a storage battery and suitable SAE INTERNATIONAL J553 JUL2016

37、 Page 5 of 32 battery charger. It shall be necessary, however, to ensure that essential control mechanisms and test current adjustability is achieved to attain accuracy and repeatability of testing. 4.1.2 Voltmeter 0 to 30 VDC maximum range, accuracy 1/2%. NOTE: A digital meter having at least 3-1/2

38、 digits readout with an accuracy of 1% plus 1 digit is recommended for millivolt readings. 4.1.3 Ammeter Capable of displaying full load current with an accuracy of 1%. A calibrated shunt shall be used in series with the test circuit to minimize circuit resistance (use of an inductive ammeter is per

39、missible in lieu of an ammeter/shunt set-up, provided accuracy and stability of load current reading is demonstrated). NOTE: A digital voltmeter having at least a 3-1/2 digit readout with an accuracy of 1% plus 1 digit is recommended for amperage readings when used in conjunction with a millivolt ou

40、tput calibrated shunt. 4.1.4 Digital Oscilloscope Capable of triggering on and displaying voltage waveforms is recommended to verify instantaneous applied currents during interrupt, endurance and transient current cycling tests. Used with the millivolt calibrated current shunt. 4.1.5 Current Shunt S

41、hould be rated at approximately twice the applied current, to assure accuracy, and prevent thermal damage to the shunt. The current shunt is used in conjunction with the voltmeter and/or oscilloscope to observe current through the circuit. 4.1.6 High-Voltage Breakdown Tester Capable of providing 500

42、 VAC RMS - 60 Hz, accuracy 5%. 4.1.7 Thermocouple and Meter 0 to 150 C minimum range, accuracy 2%, maximum thermocouple wire size 0.22 mm2(24 AWG). NOTE: A digital thermometer with thermocouple input is recommended, with an accuracy of 1C. 4.1.7.1 Two ambient observations are necessary during test c

43、ycles: ambient of test room and ambient of test chamber containing breakers under test. 4.1.7.2 Delta heat rise of terminations shall be calculated during 4.2.1.1 testing (at the testers discretion). 4.1.8 Oven Variable controlled temperature oven able to vary temperature at a rate of 1 C per min an

44、d control temperature 1 C of set point accurate to 2 C. 4.1.9 Test Load Any combination of fixed and/or variable resistor(s) capable of varying circuit load to specified test requirements in conjunction with a power supply. A test circuit by-pass may be employed during circuit set-up. Current throug

45、h the unit under test shall be monitored and controlled during the test 4.1.9.1 When performing transient current cycling tests, 12 V DC automotive lamps (original equipment or aftermarket, sealed beams or halogen bulbs) shall be used in sufficient total wattage and quantity to meet test load requir

46、ements of 4.2.5.4. SAE INTERNATIONAL J553 JUL2016 Page 6 of 32 4.1.9.2 Unless otherwise specified, the test loads required in rating tests shall have a tolerance of +/- 1.5%. 4.1.10 Test Leads Circuit breakers shall be tested using copper stranded wire sizes listed in Table 2 that conform to wire sp

47、ecifications as found in SAE J1128 or J1127. The wire length shall be 1.22 m (48.0 in) for all voltages tested and insulation shall be rated 105 C or above . TABLE 2 - TEST LEAD SIZES Rated Current SAE Wire Size No. ISO Cable Size mm25A to 10A # 18 0.8 mm210A to 15A # 16 1 mm215A to 20A # 14 2 mm220

48、A to 30A #12 3 mm230A to 40A # 10 5 mm240A to 50A # 8 8 mm250A to 60A # 6 13mm2 60A to 90A # 4 19 mm2 90A to 120A # 2 32 mm2 120A to 150A # 0 50 mm2 150A to 200A # 00 62 mm2 NOTE: ISO metric cable sizes are not exact equivalents to the SAE wire sizes. Tests and requirements in this Standard are base

49、d on SAE wire. Use of ISO metric cable may require shortening of the test leads from 1.22 m in length for SAE wire to between 500 mm and 1.0 m in length for resistive and thermal compensation. 4.1.10.1 Termination of Test Leads All test leads shall use standard commercially available terminals; ring terminals for threaded studs or screw type terminals, quick connect terminals f