ANSI UL 1839-2016 UL Standard for Safety Automotive Battery Booster Cables (Second Edition).pdf

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1、UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION OR DISTRIBUTION WITHOUT PERMISSION FROM UL UL 1839 Automotive Battery Booster Cables STANDARD FOR SAFETYUL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION OR DISTRIBUTION WITHOUT PERMISSION FROM ULUL COPYRIGHTED MATERIAL NO

2、T AUTHORIZED FOR FURTHER REPRODUCTION OR DISTRIBUTION WITHOUT PERMISSION FROM UL UL Standard for Safety for Automotive Battery Booster Cables, UL 1839 Second Edition, Dated August 31, 2016 Summary of Topics This new edition was issued to clarify the requirements for conductor materials. The revised

3、requirements are substantially in accordance with Proposal(s) on this subject dated January 23, 2015. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form by any means, electronic, mechanical photocopying, recording, or otherwis

4、e without prior permission of UL. UL provides this Standard as is without warranty of any kind, either expressed or implied, including but not limited to, the implied warranties of merchantability or tness for any purpose. In no event will UL be liable for any special, incidental, consequential, ind

5、irect or similar damages, including loss of prots, lost savings, loss of data, or any other damages arising out of the use of or the inability to use this Standard, even if UL or an authorized UL representative has been advised of the possibility of such damage. In no event shall ULs liability for a

6、ny damage ever exceed the price paid for this Standard, regardless of the form of the claim. Users of the electronic versions of ULs Standards for Safety agree to defend, indemnify, and hold UL harmless from and against any loss, expense, liability, damage, claim, or judgment (including reasonable a

7、ttorneys fees) resulting from any error or deviation introduced while purchaser is storing an electronic Standard on the purchasers computer system. AUGUST 31, 2016 UL 1839 tr1UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION OR DISTRIBUTION WITHOUT PERMISSION FROM UL AUGUST 31, 2016 U

8、L 1839 tr2 No Text on This PageUL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION OR DISTRIBUTION WITHOUT PERMISSION FROM UL AUGUST 31, 2016 1 UL 1839 Standard for Automotive Battery Booster Cables First Edition December, 2005 Second Edition August 31, 2016 This ANSI/UL Standard for Saf

9、ety consists of the Second Edition. The most recent designation of ANSI/UL 1839 as an American National Standard (ANSI) occurred on August 31, 2016. ANSI approval for a standard does not include the Cover Page, Transmittal Pages and Title Page. Comments or proposals for revisions on any part of the

10、Standard may be submitted to UL at any time. Proposals should be submitted via a Proposal Request in ULs On-Line Collaborative Standards Development System (CSDS) at http:/. ULs Standards for Safety are copyrighted by UL. Neither a printed nor electronic copy of a Standard should be altered in any w

11、ay. All of ULs Standards and all copyrights, ownerships, and rights regarding those Standards shall remain the sole and exclusive property of UL. COPYRIGHT 2016 UNDERWRITERS LABORATORIES INC. ANSI/UL 1839-2016UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION OR DISTRIBUTION WITHOUT PER

12、MISSION FROM UL AUGUST 31, 2016 AUTOMOTIVE BATTERY BOOSTER CABLES - UL 1839 2 No Text on This PageUL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION OR DISTRIBUTION WITHOUT PERMISSION FROM UL CONTENTS INTRODUCTION 1 Scope .5 2 Units of Measurement .5 3 Components 5 4 Undated References

13、6 5 Glossary .6 CONSTRUCTION 6 Cable 6 PERFORMANCE 7 Cable 7 7.1 Deformation test 7 7.2 Heat shock test .11 7.3 Cold bend test 12 7.4 Crushing resistance and abrasion test .13 7.5 Chemical exposure 16 7.6 Water absorption 16 7.7 Dielectric voltage-withstand test .17 7.8 Ampacity test .17 7.9 Cold im

14、pact test .18 7.10 Flame test .18 7.11 Temperature rating .18 8 Clamps .18 8.1 General 18 8.2 Cold drop .20 8.3 Aging 20 8.4 Water absorption 20 8.5 Acid exposure 21 8.6 Abrasion test .21 8.7 Water exposure .22 8.8 Dielectric voltage-withstand test .22 8.9 Clamp retention .22 9 Middle Connector (Whe

15、n Provided) 24 9.1 Crush test 24 9.2 Cold drop .24 9.3 Aging 24 9.4 Acid exposure 25 9.5 Water exposure .25 9.6 Dielectric voltage-withstand test .25 MANUFACTURING AND PRODUCTION TESTS 10 General 25 11 Polarity Test .25 MARKING AUGUST 31, 2016 AUTOMOTIVE BATTERY BOOSTER CABLES - UL 1839 3UL COPYRIGH

16、TED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION OR DISTRIBUTION WITHOUT PERMISSION FROM UL 12 General 26 13 Instructions 27 14 Packaging .28 AUGUST 31, 2016 AUTOMOTIVE BATTERY BOOSTER CABLES - UL 1839 4UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION OR DISTRIBUTION WITHOUT PERMI

17、SSION FROM UL INTRODUCTION 1 Scope 1.1 These requirements cover battery booster cable sets used for providing a temporary connection of a surface vehicle battery of up to 24 volts to another similar battery to provide emergency starting power when required. 1.2 These requirements do not cover wiring

18、 or cabling intended for connection of electrical systems in a vehicle or for wiring or cabling used in the recharging function of electric vehicle recharging equipment. 2 Units of Measurement 2.1 Values stated without parentheses are the requirement. Values in parentheses are explanatory or approxi

19、mate information. 3 Components 3.1 Except as indicated in 3.2, a component of a product covered by this standard shall comply with the requirements for that component. 3.2 A component is not required to comply with a specic requirement that: a) Involves a feature or characteristic not required in th

20、e application of the component in the product covered by this standard, or b) Is superseded by a requirement in this standard. 3.3 A component shall be used in accordance with its rating established for the intended conditions of use. 3.4 Specic components are incomplete in construction features or

21、restricted in performance capabilities. Such components are intended for use only under limited conditions, such as certain temperatures not exceeding specied limits, and shall be used only under those specic conditions. AUGUST 31, 2016 AUTOMOTIVE BATTERY BOOSTER CABLES - UL 1839 5UL COPYRIGHTED MAT

22、ERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION OR DISTRIBUTION WITHOUT PERMISSION FROM UL 4 Undated References 4.1 Any undated reference to a code or standard appearing in the requirements of this standard shall be interpreted as referring to the latest edition of that code or standard. 5 Glossary 5.

23、1 For the purpose of these requirements the following denitions apply. 5.2 CLAMP Device located at both ends of the booster cable which contains the jaw ends, connectors, and handles, which are used to make the connections to the battery. 5.3 CONDUCTORS Wiring used in the booster cable. 5.4 CONNECTO

24、RS Portion of the clamp that contacts the battery terminals. 5.5 INSULATION Protective covering of the conductors, cable, and clamps. 5.6 JAW END Portion of the clamp that opens in order to accommodate the battery terminals. 5.7 MIDDLE CONNECTOR A connector located in the middle of the cable that is

25、 disconnected prior to the clamps being connected to the vehicle batteries and then used to complete the connection once the clamps are connected to the respective battery terminals. CONSTRUCTION 6 Cable 6.1 Conductors shall be of copper per the Standard Specication for Soft or Annealed Copper Wire,

26、 ASTM B3; or the Standard Specication for Soft or Annealed Copper Wire for Electrical Purposes, ASTM B33; or copper clad aluminum per the Standard Specication for Copper-Clad Aluminum Wire, ASTM B566. The conductors shall comply with the specications in Table 6.1 and the applicable tests for cables

27、in Section 7. Table 6.1 Conductor constructions Minimum conductor area for nished cable Strand diameter SAE wire a size Metric wire b Size (mm 2 ) Cir. mil. (mm 2 ) No. strands/ gage in (mm) 10 (6) 9343 (4.65) 19/23 0.0226 (0.574) 8 (10) 14810 (7.23) 19/21 0.0285 (0.724) 6 (16) 24538 (12.1) 37/21 0.

28、0285 (0.724) 4 (25) 37360 (18.3) 61/22 0.0253 (0.643) 2 (35) 62450 (31.1) 127/23 0.0226 (0.574) 1 (50) 77790 (38.1) 127/22 0.0253 (0.643) 0 (50) 98980 (48.3) 127/21 0.0285 (0.724) 2/0 (70) 125100 (59.8) 127/20 0.0320 (0.813) 3/0 (95) 158600 (77.6) 259/22 0.0253 (0.643) 4/0 (120) 205500 (98.5) 427/23

29、 0.0226 (0.574) AUGUST 31, 2016 AUTOMOTIVE BATTERY BOOSTER CABLES - UL 1839 6 Table 6.1 Continued on Next PageUL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION OR DISTRIBUTION WITHOUT PERMISSION FROM UL Table 6.1 Continued Minimum conductor area for nished cable Strand diameter SAE wir

30、e a size Metric wire b Size (mm 2 ) Cir. mil. (mm 2 ) No. strands/ gage in (mm) a The SAE wire size number indicates that the cross sectional area of the conductors approximates the area of the American Wire Gage for equivalent sizes. b The metric wire size shown is the next larger standard metric w

31、ire size (except for the size shown for the 1/0) for the SAE wire size. Note that the mm 2 for each type is the same number as the metric wire size i.e., a metric wire size of 6 is 6 mm 2 . The metric dimensions are not the direct conversion from the circular mils. Note: Stranding other than those s

32、hown for SAE and metric wire sizes are not prohibited when they meet the minimum conductor area specications in Table 6.1. 6.2 The conductor insulation material shall be thermoplastic or a thermoset with a minimum average insulation thickness of not less than 1.5 mm (0.06 in) for 102A W G( 63 5m m 2

33、 ) wire and 2.0 mm (0.08 in) for 1 4/0 AWG (50 120 mm 2 ) wire. A separator shall be used between uncoated conductors and insulations with a sulfur cure. Separators are optional for other constructions. 6.3 The booster cable set shall not be less than 3700 mm (12 ft) in length, measured from jaw-end

34、 to jaw-end. 6.4 The conductors of a booster cable set employing parallel conductors shall be separated at each end to allow the jaw ends of the clamps to span a minimum distance of 920 mm (3 ft). 6.5 The cable insulation shall resist mechanical abuse that is encountered during use and storage. In a

35、ddition, the cables shall be capable of being exed under wide temperature uctuations. Cables shall be tested in accordance with Section 7. PERFORMANCE 7 Cable 7.1 Deformation test 7.1.1 Specimens of insulation from thermoplastic insulated cable are to be subjected to the load indicated in Table 7.1

36、while being maintained at a temperature of 121C 1.0C (249.8F 1.8F). Insulation thickness shall not be decreased more than 50 percent. AUGUST 31, 2016 AUTOMOTIVE BATTERY BOOSTER CABLES - UL 1839 7UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION OR DISTRIBUTION WITHOUT PERMISSION FROM U

37、L Table 7.1 Specimen loading Load exerted on a specimen by pressor foot a Size of conductor grams-Force N 10 500 4.90 8 1 750 7.36 1/0 4/0 1000 9.81 a The specied load is the weight of the spindle and the added weight to the spindle. 7.1.2 For the 10 4/0 AWG sizes of thermoplastic-insulated, thermos

38、et-insulated, or other wire, the insulation thickness T 1 is to be determined from measurements made at a marked position on a 25 mm (1 in) length of the nished, insulated conductor. The diameter D 1 over the insulation is to be measured to the nearest 0.01 mm (0.001 in) by means of a dead-weight di

39、al micrometer whose presser foot puts a load of 0.84 0 . 0 2No r8 5 2 gf on the specimen. The presser foot is to have a at, round face whose diameter is 6.4 0.2 mm (0.250 0.010 in). The anvil of the instrument is to be round, at least 38 mm (1.5 in) in diameter, and is to be parallel to the face of

40、the presser foot. The diameter d over the conductor, or over the separator, is to be measured by means of the same dial micrometer. The thickness T 1 is then calculated to the nearest 0.01 mm (0.001 in) from the formula: 7.1.3 The insulated conductors of a parallel cord are to be separated. The insu

41、lation thickness T 1 of an insulated conductor from a parallel or jacketed cord or from a xture wire is to be determined as indicated in 7.1.2 from measurements made at a marked position on a 25 mm (1 in) length of insulated conductor from the nished exible cord or xture wire. 7.1.4 The apparatus fo

42、r this test is illustrated in Figure 7.1. The apparatus is to be of brass and is to consist of three rods that are free to move vertically in a support frame. The assembly is to be constructed for use in a heated oven. Each rod is to be straight and 19.0 0.2 mm (0.75 0.010 in) in diameter. The weigh

43、t of each rod is to be 250 g (8.8 oz). The lower end of each rod is to be reduced in diameter to 9.5 0.2 mm (0.375 0.010 in) or for the nal 19 mm (3/4 in) or length of the rod. The lower end of the reduced-diameter section is to be at, round, without sharp edges, and both concentric with and perpend

44、icular to the longitudinal axis of the rod. The lower end of the reduced section is to serve as the foot that presses on a specimen during a test. The force on the specimen is to be the sum of the force exerted by the rod (2.45 N or 250 gf) plus that of any weight to be placed on the upper end of th

45、e rod to make the total force equal the load specied in Table 7.1. Each weight is to be indent stamped with its exact weight. This is generated text for gtxt. AUGUST 31, 2016 AUTOMOTIVE BATTERY BOOSTER CABLES - UL 1839 8UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION OR DISTRIBUTION

46、WITHOUT PERMISSION FROM UL Figure 7.1 Deformation test apparatus with specimens in place Added weights are not shown AUGUST 31, 2016 AUTOMOTIVE BATTERY BOOSTER CABLES - UL 1839 9UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION OR DISTRIBUTION WITHOUT PERMISSION FROM UL 7.1.5 The frame

47、 is to consist of three at, rectangular plates spaced 57 mm (2-1/4 in) apart (vertical separation) and parallel to one another in a rigid assembly. The dimensions of the plates are to be the same (plates measuring 216 by 70 by 6 mm (8-1/2 by 2-3/4 by 1/4 in) are typical). The upper surface of the lo

48、wer plate is to be the surface against which each rod presses a specimen during a test. That surface is to be horizontal during a test. That surface is to be smooth (the surface is to be renished when repeated testing indents the surface or makes it rough to the touch). Identically located holes are

49、 to be provided through the center and upper plates to serve as guides and supports for the rods, which are to be free to move vertically and not otherwise. The diameter of each hole is to be larger than the 19 mm (3/4 in) diameter or diameter portion of a rod for clearance of vertical movement of a rod in the hole. Horizontal separation between the rods is to enable weights to be in place on all three rods at the same time with a clearance between the weights.