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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 therefr
2、om, is the sole responsibility of the user.” SAE reviews each technical report at least every five years at which time it may be reaffirmed, revised, or cancelled. SAE invites your written comments and suggestions. QUESTIONS REGARDING THIS DOCUMENT: (724) 772-8512 FAX: (724) 776-0243 TO PLACE A DOCU
3、MENT ORDER; (724) 776-4970 FAX: (724) 776-0790 SAE WEB ADDRESS http:/www.sae.org Copyright 1996 Society of Automotive Engineers, Inc. All rights reserved.Printed in U.S.A. SURFACE VEHICLE 400 Commonwealth Drive, Warrendale, PA 15096-0001 RECOMMENDED PRACTICE Submitted for recognition as an American
4、National Standard J1625 REV. APR96 Issued1993-07 Revised1996-04 Superseding J1625 JUL93 (R) HEAVY-DUTY CIRCUIT BREAKERS ForewordThis Document has also changed to comply with the new SAE Technical Standards Board format. 1.ScopeThis SAE Recommended Practice defines the test conditions, procedures, an
5、d performance requirements for circuit breakers in ratings from 50 to 200 A. The document covers externally mounted automatic reset and manually reset types of circuit breakers for low voltage DC operation (typically 50 V or less). 2.References 2.1Applicable PublicationsThe following publications fo
6、rm a part of the specification to the extent specified herein. Unless otherwise indicated the latest revision of SAE publications shall apply. 2.1.1SAE PUBLICATIONSAvailable from SAE, 400 Commonwealth Drive, Warrendale, PA 15096-0001. SAE J537Storage Batteries SAE J1171External Ignition Protection o
7、f Marine Electrical Devices SAE J1428Marine Circuit Breakers SAE J1455Joint SAE/TMC Recommended Environmental Practices for Electronic Equipment Design (Heavy-Duty Trucks) 2.2Related PublicationsThe following publications are provided for information purposes only and are not a required part of this
8、 document. 2.2.1SAE PUBLICATIONSAvailable from SAE, 400 Commonwealth Drive, Warrendale, PA 15096-0001. SAE J553Circuit Breakers SAE J1888High Current Time Lag Electric Fuses SAE TSB 002Preparation of SAE Technical Reports 2.2.2CSA PUBLICATIONSAvailable from CSA Sales Department, 178 Rexdale Boulevar
9、d, Etobtcoke, Ontario, M9W 1R3. CSA C22.2 No. 14-M1987Industrial Control Equipment CSA C22.2 No. 235-M89Supplementary Protectors SAE J1625 Revised APR96 -2- 2.2.3U.S. GOVERNMENT PUBLICATIONU. S. Government, DOD SSP, Subscription Service Division, Building 4D, 700 Robbins Avenue, Philadelphia, PA 191
10、11-5094 MIL-STD-202FTest Method for Electronic heavy-gage ring terminals for threaded studs or screw type terminals, or screw type pressure connectors or box connectors for use with stripped wire leads. To avoid secondary heat generation and/or adverse millivolt drop, it is recommended that test lea
11、d terminals be crimped and soldered (when appropriate); also, connections to breakers must be repeatable and uniform. Terminals shall be attached to breakers with screw threads to a specified torque value that is generally recommended for the particular thread size. Secureness values shall be obtain
12、ed from the terminal manufacturer. For custom terminations, consult the circuit breaker manufacturer. 4.1.9TEST ENCLOSUREProvide for a draft and convection air current free test chamber with volume of approximately 7.08x104 cm3 (2.5 ft3). Chamber must allow for test lead access, internal chamber tem
13、perature monitoring, and indirect venting if needed to ensure requirements of 4.2.1 are met. 4.2Test Procedures 4.2.1AMBIENT CONDITIONSEnvironmental conditions have been selected for this document to help insure satisfactory operation under general customer use conditions. Circuit breakers shall be
14、tested in still air at the temperatures indicated and allowed a 30 min soak without electrical load before testing (and repeated 30 min soaks for individual breakers that are involved in more than one test condition). Equipment listed in 4.1.9 fulfills the still air requirement. Where not otherwise
15、specified, tests are to be run at 25 C 2 C (77 F 3 F). 4.2.1.1Test leads and terminations subject to thermal rise from test operations shall be allowed to restabilize to ambient conditions before starting a new test. Alternating between duplicate sets of leads is suggested. 4.2.2CURRENT RATING TEST
16、PROCEDUREThe circuit breaker shall be electrically connected with a pair of test leads described in 4.1.8 in series with the power supply as described in 4.1.1.1, a shunt with ammeter as described in 4.1.3, and an appropriate test load as described in 4.1.7 to provide the required current pass throu
17、gh the circuit breaker. Refer to Figure 1A for all tests except 4.2.5 and 4.2.6. Refer to Figure 1B for 4.2.5 and 4.2.6 only. 4.2.2.1Maximum Voltage Drop Test ProcedureWith the circuit breaker connected as described in 4.2.2, the voltage drop across the circuit breaker shall be measured while the br
18、eaker is passing full rated current and has achieved equilibrium (typically after 20 min of continuous operation at 100% of rated current, exhibited by no appreciable increase in voltage drop). Continue operation at 100% of rated current until 1 h elapses. If equilibrium was not attained in first 20
19、 min, continue monitoring voltage drop until equilibrium has been attained or unit exceeds voltage drop limits and/or trips out. TABLE 2TEST LEAD SIZES Rated CurrentSAE Metric Cable Size SAE Wire Size 50 to 60 A 13 mm2 # 6 Greater than 60 to 90 A 19 mm2 # 4 Greater than 90 to 120 A 32 mm2 # 2 Greate
20、r than 120 to 150 A 50 mm2 # 0 Greater than 150 to 200 A 62 mm2 # 0 0 SAE J1625 Revised APR96 -5- FIGURE 1ACURRENT RATING TEST CIRCUIT SAE J1625 Revised APR96 -6- FIGURE 1BENDURANCE AND INTERRUPT CYCLING TEST CIRCUIT NOTEFor applications sensitive to heat-rise at the circuit breaker terminations, th
21、ermocouple leads may be affixed to the terminations. General practice is to place the thermocouple lead on that portion of the terminal that is likely to come in contact with the wire lead insulation. Benchmark maximum values for delta heat rise (observed thermocouple temperature minus ambient tempe
22、rature) at 65 C delta for factory wired terminations and 50 C delta for field wired terminations. Additionally, external surfaces of metal or phenolic compounds may be checked for maximum temperatures, which typically should not exceed 125 C. However, higher heat-resistant materials may be employed.
23、 Therefore, consult the manufacturer for specifications. Results of this testing will assist the user with circuit design and proximity considerations for breaker installation. 4.2.2.2Overoad Trip Rating TestAfter a 30 min soak, reconnect the breaker as described in 4.2.2. Operate at 135% of rated c
24、urrent and record the elapsed time in seconds for the breaker to trip. If breaker has not opened after 1 h, discontinue the test. Repeat 30 min soak, operate at 200% of rated current and record elapsed time for the breaker to trip. If breaker has not opened after 2 min, discontinue the test. 4.2.3VO
25、LTAGE BREAKDOWN TEST PROCEDURE 4.2.3.1With the circuit breaker connected as described in 4.2.2, adjust the current to 400% of the circuit breaker rating and allow the breaker to cycle. At the end of 10 min, check the continuity at 500 VAC between each terminal of the circuit breaker individually and
26、 the cover of the breaker (if cover is metallic) with the breaker in both an open and closed circuit condition. 4.2.4HIGH AMBIENT DERATING TEST SAE J1625 Revised APR96 -7- 4.2.4.1With the circuit breaker connected as described in 4.2.2, place the circuit breaker in a temperature- controlled environm
27、ental chamber heated to 82 C 2 C with 30.5 cm (1 ft) of each lead inside the chamber along with the breaker. Apply 70% of rated current continuously for 1 h. End the test when 1 h is attained or if the breaker opens. 4.2.5ENDURANCE TEST PROCEDURE 4.2.5.1Test current for endurance tests shall be 600%
28、 of rated current, except where specified otherwise. Use Figure 1B test circuit and variable resistor load. 4.2.5.2With the circuit breaker connected as described in 4.2.2, Type I externally mounted circuit breakers shall be cycled for 60 min. The circuit breaker shall then be capable of passing 80%
29、 of rated current for 1 h, without tripping. 4.2.5.3Using the circuit breaker from 4.2.5.2 (assuming 4.2.5.2 requirements were met), reconnect as described in 4.2.2 and cycle Type I breaker until failure as defined in 4.5.2. NOTEAt testers discretion, or as published by the manufacturer, an arbitrar
30、y minimum cycle time may be established as a milestone threshold for termination of the test (e.g., 8 h, 12 h, etc.), to aid in test throughput. 4.2.5.4With the circuit breaker connected as described in 4.2.2, Type III circuit breakers shall be cycled for 100 on-off cycles using the trip indicating/
31、reset mechanism of the breaker. Means shall be provided to detect when the breaker is capable of resetting to initiate the next cycle. The circuit breaker shall then be capable of passing 80% of rated current for 1 h. 4.2.5.5Cycling Endurance Test for Switchable Type III Circuit Breakers (as defined
32、 by 3.4.3) At the option of the tester, a cycling endurance test shall be performed as is described herein. With the circuit breaker connected as described in 4.2.2 and using Figure 1A test circuit, apply a current cycling waveform as shown in Figure 2 through the breaker for 3000 cycles. NOTEConstr
33、uction of an electromechanical apparatus to facilitate consistent cycling action is recommended. Precautions should be taken to avoid the application of excessive forces to the breaker mechanisms beyond what could be expected by hand operation. FIGURE 2CYCLING ENDURANCE WAVEFORM SAE J1625 Revised AP
34、R96 -8- 4.2.6INTERRUPT TEST PROCEDURE 4.2.6.1Using the power source described in 4.1.1.2, test current shall be according to Table 3. Refer to Figure 3 for interrupt cycle definition and Figure 1B test circuit. FIGURE 3INTERRUPT CYCLE DEFINITION 4.2.6.2With the circuit breaker connected as described
35、 in 4.2.2 (using 4.1.1.2 power source), Type I circuit breakers shall be subjected to 1-1/2 cycles of interrupt current. 4.2.6.3With the circuit breaker connected as described in 4.2.2 (using 4.1.1.2 power source), Type III circuit breakers shall be subjected to 1-1/2 cycles of interrupt current. Pr
36、ocedure shall be to apply fault current for first 1/2 cycle. Next 1/2 cycle shall consist of allowing the unit to come into the ready to reset mode. As soon as reset capability is enabled, the reset mechanism shall be activated to restore the circuit, at which time the last 1/2 cycle of interrupt cu
37、rrent will be present. 4.2.7ENVIRONMENTAL TESTS 4.2.7.1Since end use applications may differ, the following tests are recommended, but not mandatory to determine general suitability of components. All tests shall follow the guidelines as set forth in SAE J1455 unless otherwise specified. 4.2.7.1.1Te
38、mperature TestPerform per SAE J1455, 4.1.3. Test as described for temperature cycling, thermal shock, and thermal stress at the specified test temperatures and according to the temperature transition charts. 4.2.7.1.2Humidity TestPerform per SAE J1455, 4.2.3 according to recommended test procedures
39、and environmental conditions. TABLE 3INTERRUPT TEST CURRENT REQUIREMENTS Rated Current 12 VDC Amps 50 to 70 A 900 Greater than 70 to 90 A1200 Greater than 90 to 110 A1500 Greater than 110 to 130 A1800 Greater than 130 to 150 A2100 Greater than 150 to 175 A2500 Greater than 175 to 200 A3000 SAE J1625
40、 Revised APR96 -9- 4.2.7.1.3Salt Fog TestPerform per SAE J1455, 4.3.3. Time duration may vary, from 24 to 96 h, depending on anticipated location of breaker and potential for exposure to saline solutions. 4.2.7.1.4Immersion and Splash TestFor general guidelines refer to SAE J1455, 4.4. NOTE 1Immersi
41、on testing shall apply only to devices that are stated as being waterproof, sealed, watertight, etc. Test procedures per SAE J1171, Section 5 may be followed for basic test requirements. NOTE 2Splash testing shall apply only to devices that are stated as being splashproof, water resistant, weatherpr
42、oof, etc. Test procedure in SAE J1428, 5.1.3 may be used. Devices passing immersion testing do not require splash testing. NOTE 3Chemicals used for testing shall be restricted to tap water for immersion and splash. Evaluation of external identification marking shall be conducted by splash testing us
43、ing commonly encountered chemicals that shall include: engine oil, power steering fluid, windshield washer solvent, gasoline, diesel fuel, anti-freeze, steam, and salt water. 4.2.7.1.5Mechanical Vibration TestPerform per SAE J1455, 4.9.4. Test shall be for 1 h in each of three mutually perpendicular
44、 primary axes using the suggested current practice per SAE J1455. 4.2.7.1.6Drop TestPerform per SAE J1455, 4.10.3.1. 5.Performance Requirements 5.1Current RatingWith the circuit breaker connected as described in 3.2.2, all circuit breakers shall pass 100% +1.5%, -0.0% of rated current continuously f
45、or a minimum of 1 h, shall open at 135% +1.5% maximum of rated current within 1 h, and shall open at 200% +1.5% of rated current within 2 min. 5.2Maximum Voltage DropUsing the procedure described in 4.2.3, the maximum voltage drop across the circuit breaker shall be within the limits provided by the
46、 manufacturer. 5.3Voltage BreakdownUsing the test procedure described in 4.2.4, there shall be no continuity between either terminal of the circuit breaker and the cover. 5.4High Ambient Derating TestUsing the procedure described in 4.2.4, all circuit breakers shall pass 70% of rated current for 1 h
47、 without opening. NOTERecognizing device design variations, it is recommended that manufacturers temperature derating curves be consulted for application considerations. Consequently, the test procedure of 4.2.4 and performance requirements of 5.4 may, at the testers discretion, be omitted from the
48、test program. 5.5Endurance Test 5.5.1Type I externally mounted circuit breakers shall be tested as described in 4.2.5.2 and then shall continuously pass 80% 1.5% of rated current for 1 h. The voltage drop at 80% of rated current shall be within the limits specified by the manufacturer. 5.5.2If failu
49、re occurs with the circuit breaker connected as described in 4.2.5.3, the ultimate failure of all circuit breakers shall result in an open circuit in the circuit breaker, and there shall be no damage to the associated wiring. Failure falls into three general categories: SAE J1625 Revised APR96 -10- a.Catastrophic FailurePart of the electrical contacts and/or thermostatic material burns up and the circuit path is broken (contained within breaker housing or no external manifestations). b.Operational FatigueThermos