SAE J1127 Low Voltage Battery Cable

The standard "SAE J1127 Low voltage battery cable" developed by SAE International describes the requirements for low voltage battery cables designed for use at a nominal system voltage of 60 Volts direct current (25 Volts alternating current) or less in surface vehicle electrical systems. The tests are intended to qualify the cables for normal applications that include limited exposure to liquids and physical abuse.

For the purposes of this standard, the following terms and definitions apply:

• Coated wire refers to wire formed by coating a given metal with a relatively thin coating of a different metal (ASTM B354-23 Standard Terminology for Uninsulated Metallic Electrical Conductors).
• Cable family refers to a group of multiple conductor sizes with the same conductor wire coating, insulation formula, and wall thickness type.
• Conductor refers to a wire or combination of wires that are not insulated from each other and are suitable for carrying electric current (ASTM B354-23).
• Core refers to one of the components in an assembly. A component can be an uninsulated conductor, insulated conductor, twisted pair, shielded assembly, coaxial cable, or any finished cable.
• Liquid compatibility refers to a cable's ability to resist the effects of various liquids found in surface vehicles.
• Low voltage (low tension) is generally considered to be 60 Volts direct current (25 Volts alternating current).
• Minimum wall (thickness) refers to the lowest insulation thickness allowed at any point.
• Nominal refers to a convenient approximation used to specify or describe a component.
• Plastics refer to any of a large number of polymeric materials that are usually thermoplastic or thermoset, have a high molecular weight, and can be molded, cast, extruded, drawn, laminated, or otherwise formed into objects, powder, beads, films, filaments, fibers, or other shapes.
• The primary cable is a single or stranded, single-conductor, insulated cable used to carry electric current by connecting it to the low-voltage side of an ignition coil in surface vehicles.
• Ozone resistance is the ability of a material to withstand the degradative effects of ozone (surface cracking).
• SAE conductor size is a system that indicates the cross-sectional area of ​​the conductor.
• A separator is a thin layer used as a barrier to prevent mutually harmful effects between different components of the cable, for example between the conductor and the insulation or between the insulation and the sheath.
• Strip force is the maximum axial force required to overcome the adhesion between the conductor and the insulation.
• The temperature class rating is a class designation based on retention of mechanical properties (tensile and elongation) after 30 hours of thermal aging at 168 degrees above the temperature class rating.
• Thermoplastic refers to a plastic that can be softened by heating and hardened by cooling within a temperature range characteristic of the plastic, and can be repeatedly shaped by flowing into substances by molding, extrusion or shaping in a softened state.

In this standard, cable types are defined as follows:

• Type STT: Start or ground, thin wall, thermoplastic insulated
• Type SGT: Start or ground, general purpose, thermoplastic insulated
• Type STR: Start or ground, thin wall, thermoset elastomer (synthetic rubber) insulated
• Type SGR: Starter or ground, general purpose, thermoset elastomer (synthetic rubber) insulated
• Type STX: Start or ground, thin wall, cross (x) connected polyolefin insulated
• Type SGX: Start or ground, general purpose, cross (x) connected polyolefin insulated

In this standard, the requirements are defined as follows:

• General test conditions: Test samples should be preconditioned at room temperature (16°C plus/minus 23°C) for at least 5 hours. All tests should be carried out at the same temperature unless otherwise stated.
• Ovens: Unless otherwise specified, when a furnace is required, it shall be a hot air furnace conforming to Type II of “ASTM E145-94 Standard Specification for Gravity-Convection and Forced-Vent Ovens.” The air in the furnace shall be completely replaced at least 100 times per hour, but not more than 200 times, at the specified temperature.
• Tolerances: Unless otherwise stated, all values ​​are considered approximate.
• Representative conductor sizes for testing: When a test is required, all combinations of conductor size, wall thickness, and insulation formulation must meet the appropriate requirements. However, if testing of a representative conductor size is permissible, compliance for a cable family can only be demonstrated by testing samples of the major and minor conductor sizes. Permission to demonstrate compliance by testing representative conductor sizes for a cable family is granted by agreement between the customer and the supplier.

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