SAE J2576-2002 Blade Fuses-42 V System.pdf

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SURFACE VEHICLE 400 Commonwealth Drive, Warrendale, PA 15096-0001 RECOMMENDED PRACTICE J2576 ISSUED APR2002 Issued2002-04 Blade Fuses - 42 V System ForewordThis SAE Recommended Practice has been developed by: the Circuit Protection Task Force of the Circuit Protection and Switching Devices Committee. The objectives of the task force are to develop information reports, recommended practices, and standards concerned with the requirements, design, and testing of circuit protection components such as fuses, circuit breakers, or other devices of similar purpose that are intended for use in the electrical systems of vehicles. This document is intended as a guide toward the adoption of standard practices and is subject to change so as to keep pace with experience and technical advances. TABLE OF CONTENTS 1.Scope. 2 2.References. 2 2.1Applicable Documents2 2.1.1SAE Publications 2 2.1.2ASTM Publications . 2 2.1.3ISO Publications.2 2.2Related Publications. 3 2.2.1SAE Publication 3 2.2.2ISO Publication. 3 3.Definitions.3 4.Test Requirements. 7 4.1Test Equipment and Instrumentation 7 4.2General Conditions. 10 4.3Sample Sizes . 10 5.Test Procedures .10 5.1Electrical Testing 10 5.2Mechanical and Environmental Testing 11 6.Performance Requirements 13 6.1Electrical Test Requirements 13 6.2Mechanical and Environmental Test Requirements. 14 SAE J2576 Issued APR2002 -2- 7.General Requirements14 7.1Design Parameters .14 7.2Marking and Identification.15 7.3Testing Safety and Operational Advisory .15 8.Test Sequence Chart16 Figure 1Miniature Class Blade Fuse4 Figure 2Standard Class Blade Fuse5 Figure 3Time Lag Class Blade Fuse6 Figure 4Miniature Class Blade Fuse Test Slug7 Figure 5Standard Class Blade Fuse Test Slug8 FIgure 6Time Lag Class Blade Fuse Test Slug .9 Figure 7Transient Cycling Test Duty Cycle Format .11 Figure 8Blade Strength Test (Axis Orientation).12 Figure 9Test Sequence Chart16 Appendix A Example of Test Fixture Design17 Figure A1Test Fixture Component Reference Drawing18 1.ScopeThis SAE Recommended Practice defines the blade fuse styles, test conditions, procedures, and performance requirements for use in vehicle electrical power systems designed to the new motor vehicle industry 42 V architecture. The intent of this document is to provide a framework for 58 V Blade Fuse characteristics, serving the motor vehicle industry to establish standardization with respect to electrical performance and mechanical requirements. This standardization shall lend itself to safe application practices; e.g., prevention of 32 V devices utilized inappropriately in 42 V electrical systems. Both the performance and mechanical requirements expressed herein are for the advancement of mobility engineering and the development of safe application practices. They are not intended for the establishment of design exclusions, patent rights, or franchising that engenders restraint of trade. 2.References 2.1Applicable PublicationsThe following publications form a part of this specification to the extent specified herein. Unless otherwise specified, the latest issue of SAE publications shall apply. 2.1.1SAE PUBLICATIONSAvailable from SAE, 400 Commonwealth Drive, Warrendale, PA 15096-0001 SAE J1034Engine Coolant Concentrate - Ethylene-Glycol Type SAE J1284Blade Type Electric Fuses SAE J1888High Current Time Lag Electric Fuses SAE J2077Miniature Blade Type Electrical Fuses 2.1.2ASTM PUBLICATIONS (OR REFERENCED PROPERTIES)Available from ASTM, 100 Barr Harbor Drive, West Conshohocken, PA 19428-2959. ASTM B 117Method of Salt Spray (Fog) Testing ASTM No. 3 Oil 2.1.3ISO DOCUMENTSAvailable from ANSI, 25 West 43rd Street, New York, NY 10036-8002. ISO 1817 No. 1 Oil ISO 8820-3Road vehiclesFusesPart 3: Fuse-links with tabs (blade-type) SAE J2576 Issued APR2002 -3- 2.2Related PublicationsThe following publications are provided for information purposes only and are not a required part of this specification. 2.2.1SAE PUBLICATIONAvailable from SAE, 400 Commonwealth Drive, Warrendale, PA 15096-0001 SAE J726Air Cleaner Test Code 2.2.2ISO DOCUMENTAvailable from ANSI, 25 West 43rd Street, New York, NY 10036-8002. ISO 8820-1Road vehiclesFusesPart 1: Definitions and general test requirements 3.Definitions 3.1FuseA device designed to interrupt the electrical circuit when subjected to over-current. This action is to be nonreversible, and the fuse is intended for replacement after the circuit malfunction has been corrected. 3.2Fuse HolderAn electro-mechanical assembly capable of accepting or otherwise providing termination to a fuse device and providing termination capability to an electrical power source. 3.3Insulator BodyAn electrically non-conductive housing (e.g., plastic) that provides a supporting framework for the conductive sections of the fuse assembly. May provide in supplemental fashion, a mechanical design form to facilitate keying or other interface relationship with a fuse holder or other power distribution module assembly, which would serve to distinguish a 58 V fuse from a 32 V fuse. 3.4Fuse ElementThe section of the fuse conductive path that is by design the most susceptible area to overload current conditions and when subjected to overload current in sufficient amount and duration, becomes disrupted effectively interrupting the current path to a non-conducting state. A 58 V fuse element will provide for safe interruption of current under all conditions of overload. 3.5TerminalThe terminal is that part of the fuse construction that makes the electro-mechanical conductive connection for the fuse assembly to its respective fuse holder device. The terminals are those portions of the fuse extending from the insulator body on the respective fuse type footprint centerline. 3.6Rated CurrentThe rated current is the maximum continuous current the fuse is capable of passing for the minimum specified time as shown in the test procedures and performance requirements. It also serves to identify the fuse nominal rated current value. While being a performance and identification value, end use applications and circuit design factors may necessitate a continuous current rating less than the fuse rated current value. 3.7Rated VoltageThe rated voltage is the maximum voltage for which the fuse is designed. For this document, the rated voltage is 58 V. Rated voltage is not necessarily the same as operating voltage, which typically is less than the rated voltage in a vehicular electrical system. Rated voltage allows for the periodic voltage rise or transient voltage spikes that occur in vehicular electrical systems. 3.8Voltage DropThe voltage drop is the voltage measured across the fuse circuit path passing the full rated current after specified time duration and under specific conditions of test. 3.9Breaking CapacityThe breaking capacity is a value of the respective fault current that a fuse (fuse element) is capable of interrupting in accordance with a specific test condition and performance criteria. 3.10 Time/Current CharacteristicsThe relation of time for a fuse to operate (open) in proportion to a specific test current, typically expressed in graphical form to relate a time/current curve. SAE J2576 Issued APR2002 -4- 3.11 Operating TimesAn expression of time duration in minimum and maximum terms to indicate when a fuse should operate (open) at a specified value of current in excess of the rated current. 3.12 Miniature Class Blade FuseIndicates a 58 V rated fuse that generally corresponds to the class of fuse identified in SAE J2077 as a miniature blade type electrical fuse, however, it is mechanically coded to prevent the 32 V miniature blade type fuse from being interchanged in a 58 V application. Figure 1 depicts this class of fuse basic format without mechanical coding provision incorporated. FIGURE 1MINIATURE CLASS BLADE FUSE SAE J2576 Issued APR2002 -5- 3.13 Standard Class Blade FuseIndicates a 58 V rated fuse that generally corresponds to the class of fuse identified in SAE J1284 as a blade type electrical fuse, however, it is mechanically coded to prevent the 32 V version blade type fuse from being interchanged in a 58 V application. The term “standard” in this context is solely intended to indicate that this fuse size is the first and oldest in the family of blade fuses to gain wide use and acceptance in the automotive industry. Figure 2 depicts this class of fuse basic format without mechanical coding provision incorporated. FIGURE 2STANDARD CLASS BLADE FUSE SAE J2576 Issued APR2002 -6- 3.14 Time Lag Class Blade FuseIndicates a 58 V rated fuse that generally corresponds to the class of fuse identified in SAE J1888 as a high current time lag blade type electrical fuse, however, it is mechanically coded to prevent the 32 V high current time lag blade type fuse from being interchanged in a 58 V application. Figure 3 depicts this class of fuse basic format without mechanical coding provision incorporated. FIGURE 3TIME LAG CLASS BLADE FUSE SAE J2576 Issued APR2002 -7- 4.Test Requirements 4.1Test Equipment and Instrumentation 4.1.1POWER SUPPLYA regulated DC output power supply capable of delivering the current levels required for all tests shall be used. The supply voltage shall not exceed 58 V DC, have ripple not to exceed ±0.5 V, and a time constant of 2 ms or less. 4.1.2FUSE TEST SLUGSVerification of correct setup with the test holder shall require the use of test slugs constructed of silver plated copper alloy CA110 per the dimensions of Figures 4, 5, and 6. FIGURE 4MINIATURE CLASS BLADE FUSE TEST SLUG SAE J2576 Issued APR2002 -8- FIGURE 5STANDARD CLASS BLADE FUSE TEST SLUG SAE J2576 Issued APR2002 -9- FIGURE 6TIME LAG CLASS BLADE FUSE TEST SLUG 4.1.3CONNECTING CABLES FOR ELECTRICAL TESTSConnecting cables shall be of multiple stranded copper conductor design. The cable sizes are listed in Table 1. TABLE 1WIRE SIZES FOR TESTS Rated Current (Amps) Cross-Sectional Area (mm2)SAE Wire Size 1A thru 10 A0.3522 15 A0.5020 20 A0.75 0.8018 25 A1.016 30 A2.0 2.514 35 A 40 A3.0 4.012 50 A 60 A5.0 6.010 SAE J2576 Issued APR2002 -10- 4.2General Conditions 4.2.1Unless otherwise specified, tests are performed in still air at a room ambient environment of 23 °C ± 3 °C. 4.2.2Fuses that have been subjected to environmental testing where they are not installed in a test holder as part of the test and require post-environmental electrical testing shall have the terminal blades cleaned sufficiently to ensure proper electrical interface with the test holder. 4.2.3TEST HOLDER SETUP INSTRUCTIONSFuses shall be mounted horizontally unless otherwise noted. When testing two or more fuses in series, the fuses shall be mounted no less than 150 mm apart and with no less than 600 mm of interconnecting cable, unless otherwise noted. All electrical tests shall be made with matched wire size, as shown in Table 1 and a standardized test module as shown in Appendix A. The interface voltage drop (VCD VAB) of the fixture shall not exceed 15 mv per terminal (30 mV total). The voltage check shall be made using the test slugs as referred to in 4.1.2. 4.3Sample SizesTest sub-groups shall comply with the Test Sequence Chart shown in Section 8. 5.Test Procedures 5.1Electrical Testing 5.1.1VOLTAGE DROPUsing the test holder and sample requirement from Test Sequence Chart, apply 100% of rated current to the fuse under test and after 15 minutes elapsed time record the voltage drop. Repeat for all fuses in each amperage sample group. See Figures 1, 2, 3, and note. NOTE Measurement points are located on the fuse terminals at a centered distance from the bottom datum of the fuse body (1.5 mm) for all classes of fuse covered by this document. 5.1.2ISOLATION RESISTANCEAfter a fuse sample group has been subjected to an over-current during a test and the current path interrupted, the open-circuit resistance between the fuse terminals (blades) shall be measured using an appropriate volt/ohmmeter that is capable of performing the measurement at fuse rated voltage. 5.1.3TIME/CURRENT CHARACTERISTICSUsing the test holder and sample requirement from Test Sequence Chart for each level of test current required, apply current to the fuse under test per Table 2 and record the elapsed time for the fuse to interrupt the current. Repeat for all fuses in each amperage sample group. NOTE 100% and 110% tests are terminated after 100 hours of continuous operation assuming the fuse under test has not interrupted current flow. 100% and 110% tests may be performed at any convenient voltage up to rated voltage. All other tests to be performed at rated voltage. 5.1.4BREAKING CAPACITYUsing the test holder and sample requirement from Test Sequence Chart for each fuse rated current, apply a test current of 1000 +5/0% A with a rise time of 2.5 ms ± 0.5 ms at 58 V DC +5%/0% V. Hold voltage for 30 s after interrupt. TABLE 2TIME/CURRENT TEST LEVELS Miniature and Standard ClassTime Lag Class 110% In100% In 135% In135% In 200% In200% In 350% In350% In 600% In600% In SAE J2576 Issued APR2002 -11- 5.1.5TRANSIENT CYCLINGUsing the test holder and sample requirement from Test Sequence Chart, subject the fuses to a peak current at 460% to 500% of rated current for fuse ratings 5 A or less and 540% to 600% for fuses over 5 A in rating using the pulse cycle curve shown in Figure 7. This test shall be performed for a total of 50 000 cycles. 5.2Mechanical and Environmental Tests 5.2.1VIBRATIONUsing the sample requirement from the Test Sequence Chart, the fuses shall be placed in a suitable test fixture and subjected to a simple harmonic motion having amplitude of 0.75 mm (1.5 mm total excursion). The frequency shall be varied uniformly between the limits of 10 Hz to 55 Hz. The entire range of 10 Hz to 55 Hz shall be traversed in approximately 1 minute. The motion shall be applied for a period of 2hours in each of three mutually perpendicular planes for a total elapsed time of 6 hours. Vibration testing is performed without electrical current being passed through the fuses. FIGURE 7TRANSIENT CYCLING TEST DUTY CYCLE FORMAT SAE J2576 Issued APR2002 -12- 5.2.2STRENGTH OF BLADE FUSE TERMINALSUsing a suitable holding fixture for the test (refer to Figure 8) and sample requirement from the Te