BRITISH STANDARD BS AU 237a 1993 Specification for Light domestic duty jumper lead sets for automotive starting BS AU 237a 1993 This British Standard, having been prepared under the direction of the A[.]
BRITISH STANDARD Specification for Light domestic duty jumper lead sets for automotive starting BS AU 237a: 1993 BS AU 237a:1993 Committees responsible for this British Standard The preparation of this British Standard was entrusted by the Automobile Standards Policy Committee (AUE/- ) to Technical Committee AUE/9, upon which the following bodies were represented: Automobile Association Consumer Policy Committee of BSI Department of Trade and Industry (Consumer Safety Unit, CA Division) Department of Transport Garage Equipment Association Institute of Trading Standards Administration Motor Cycle Industry’s Association of Great Britain Ltd Petrol Pump Manufacturers’ Association Royal Automobile Club Society of Motor Manufacturers and Traders Ltd This British Standard, having been prepared under the direction of the Automobile Standards Policy Committee, was published under the authority of the Standards Board and comes into effect on September 993 © BSI 07- 999 First published as BS AU 237- , December 990 Second edition September 993 The following BSI references relate to the work on this standard: Committee reference AUE/9 Draft for comment 92/76371 DC ISBN 580 22432 Amendments issued since publication Amd No Date Comments BS AU 237a:1993 Contents Page Committees responsible Foreword Inside front cover ii Scope References 1 Definitions Cable and construction Clips Resistance to contamination Marking Container Annex A (normative) Tests for j umper lead sets Annex B (normative) Test fluids and conditioning Annex C (normative) Safety and operating instructions for the use of j umper leads Figure — Typical j umper lead Figure — Marking symbols Figure A — Schematic drawing of test circuit for electrical tests Figure A — Schematic drawing for cable termination testing Figure A — Schematic drawing for flame retardance test List of references © BSI 07- 999 Inside back cover i BS AU 7a: 993 Fore word This British Standard has been prepared under the direction of the Automobile Standards Policy Committee to establish a standard of performance for j umper lead sets for automotive j ump starting BS AU 237a deals with requirements for j umper lead sets for use when starting an internal combustion engine from a supplementary battery Examples are motor vehicles, boats and other installations The standard is applicable to V vehicle systems This second edition of BS AU 237 supersedes BS AU 237- : 990 which is withdrawn It constitutes a technical revision undertaken to improve and clarify testing procedures arising from the application of the first edition for conformity testing purposes At the same time the title of the standard has been amended to reflect the fact that Part for heavy domestic duty and Part for commercial vehicles have not been developed and the need for such Parts are no longer considered necessary Product certification Users of this British Standard are advised to consider the desirability of third party certification of product conformity with this British Standard based on testing and continuing product surveillance which may be coupled with assessment of a supplier’s quality systems against the appropriate Part of BS 5750 Enquiries as to the availability of third party certification schemes are forwarded by BSI to the Association of Certification Bodies If a third party certification scheme does not already exist, users should consider approaching an appropriate body from the list of Association members A British Standard does not purport to include all the necessary provisions of a contract Users of British Standards are responsible for their correct application C omp liance with a British S tand ard d oe s no t of itse lf confe r immunity from le gal ob ligatio ns S ummary of p age s This document comprises a front cover, an inside front cover, pages i and ii, pages to 0, an inside back cover and a back cover This standard has been updated (see copyright date) and may have had amendments incorporated This will be indicated in the amendment table on the inside front cover ii © BSI 07- 999 BS AU a: 993 S cop e This British Standard specifies requirements for jumper lead sets for light domestic use when starting an internal combustion engine from a supplementary battery in environmental temperatures down to – 10 °C It is restricted to maximum engine capacity, 3.5 l petrol and 2.5 l diesel Requirements for the safe use of jumper lead sets for jump starting are given as safety and operating instructions in Annex C Re fe re nce s Normative re fe re nce s This British Standard incorporates, by reference, provisions from specific editions of other publications These normative references are cited at the appropriate points in the text and the publications are listed on the inside back cover Subsequent amendments to, or revisions of, any of these publications apply to this British Standard only when incorporated in it by updating or revision Informative re fe re nce s This British Standard refers to other publications that provide information or guidance Editions of the publications current at the time of issue of this standard are listed on the inside back cover, but reference should be made to the latest editions 3.5 j ump starting a technique used for assisting the starting of an internal combustion engine where a healthy and reasonably well-charged battery is connected temporarily in parallel with an ailing or discharged battery of the same nominal voltage to provide additional cranking power C ab le and construction Jump e r le ad le ngth When measured between the ends of the jaws of each clip, the overall length of the jumper leads as shown in Figure shall be not less than m C ab le constructio n Any material used for cable construction shall be of a size capable of carrying 100 A continuously C ab le insulation The cable insulation shall be homogeneous and shall meet the requirements of type TI of BS 6746:1990 and of of this standard The mean thickness of insulation shall be not less than 1.3 mm, but it is permissible for the thickness at any one place to be less than 1.3 mm provided that the difference does not exceed 0.1 mm + 10 % of the value specified Compliance shall be checked using the method described in of BS 6469-1.1:1992 A D e finitions For the purposes of this British Standard, the definitions given in BS 6604:1985 apply, together with the following 3.1 conductor that portion of a cable which has the specific function of conveying current 3.2 clip a device which makes a mechanical and electrical connection from the conductor to the battery or earth terminal of a vehicle 3.3 j ump e r le ad se t a set of two insulated flexible low-voltage conductors and four insulated clips securely attached to the ends of the conductors C o lo ur co ding A clear distinction shall be made between the two cables in a jumper lead set by colour coding of the cables and clips The cable and clip insulation used for a positive connection shall be red, and that used for the negative shall be black Te mp e rature range All cables and conductors shall be designed to operate within a temperature range of – 25 °C to + 70 °C When tested in accordance with of BS 6469-1.4:1992 at – 25 °C, the cable insulation shall show no cracking or rupture visible to the naked eye, if necessary corrected to give normal vision, of a trained observer C lip s D e sign Clips consisting of a pair of jaws, held together by and pivoted about a hinged point, shall be fitted with a spring clamping device to provide force on the a battery principally used for starting, lighting and jaw holding the clip in a closed position ignition on vehicles or plant employing internal NOTE Designs of clip are optional provided that they meet the combustion engines requirements of this standard 3.4 starte r b atte ry © BSI 07-1999 BS AU 7a: 993 Assessment shall be by visual examination and a Pe rformance The clip shall be capable of clamping on and firmly grasping a horizontal plain stud of a diameter simple electrical continuity test The clips shall meet the requirements of A of 25 mm which proj ects mm from a surrounding flat surface and shall be capable of resisting a tensile force equal to the weight of the j umper leads plus a further 50 N ± N applied in the direction of the cable accordance with A The voltage drop shall not exceed V and the measured temperatures shall not exceed 70 °C The test shall be repeated using the two 25 mm × mm copper bars described A Jumper lead sets shall be compatible with the automotive fuels, lubricants and fluids given in Annex B The clip spring shall not deteriorate when tested in in Re sistance to contamination Again, the voltage drop shall not exceed V and the measured temperatures shall not exceed 70 °C After removal from each fluid, the samples shall be wiped dry The samples shall meet the requirements of the first paragraph of When tested in accordance with A 5.2 the voltage drop for each lead shall not exceed V and the temperature shall not exceed 70 °C Marking C ab le te rminations 5.3.1 Electrical All j umper lead sets shall be marked either directly, or by attachment of a durable non- conducting tag, in The clip shall be attached by either of the following a legible and indelible manner The marking shall methods include the following a) The clip shall be clamped or crimped to the a) Manufacturer’s or distributor’s name or trade conductor of the cable mark b) A ring termination shall be crimped to the b) The number and date of this British Standard, conductor and bolted to the conducting material i e BS AU 237a: 993 of the clip 1) c) The standard symbols for warning and “read No portion of the insulation shall be within the zone instructions before use” in of crimping or clamping BS 5378- 3: 982 and 5.3.2 Mechanical the cable insulation to prevent the j oint being strained The j oint shall not break when tested in A A or of BS 3641 - : 971 (see Figure 2) Some form of cable strain relief shall be fitted over accordance with and, after completion of A , d) Connect + to + then – to – C ontaine r Jumper lead sets shall be supplied in a durable the voltage drop shall not exceed V and the container that shall be capable of re- accommodating measured temperature shall not exceed 70 °C the j umper lead set after use Operating and safety Insulation of clip The clips shall be insulated in such a way that if a dosed unattached clip touches a flat conducting instructions in accordance with Annex C shall be printed on the container in a legible and indelible manner surface or another clip there is no direct contact between live parts 1) Marking BS AU 237a: 993 on or in relation to a product represents a manufacturer’s declaration of conformity, i e a claim by or on behalf of the manufacturer that the product meets the requirements of the standard The accuracy of the claim is solely the claimant’s responsibility Such a declaration is not to be confused with third party certification of conformity, which may also be desirable © BSI 07- 999 Figure — Typical jumper lead BS AU 237a:1993 © BSI 07- 999 BS AU 7a: 993 Mandatory sign (A ) of BS 5378- 3: 982) Read instructions before use (1 of BS 3641 - : 971 ) Figure — Marking symb ols [see clause c)] © BSI 07- 999 BS AU 237a:1 993 Annex A (normative) Tests for j umper lead sets A.2.4.3 For a period of pass a current of 00 A ± A continuously through the j umper lead Record the temperature at the cable/clip j oint after Then after record the readings of A.1 Samples Unless stated otherwise within this standard a new sample may be used for each test A.3 Cable termination test A.2 Electrical tests A.2.1 Principle In order to test the strength of the connection Current is passed through a j umper lead which is connected between two copper conductors At the completion of a set time, a voltage- drop reading is taken across the j umper lead The j umper lead is removed from the copper conductors immediately the current is switched off and reconnected after a cooling- off period This removal and reconnection procedure is to discover whether the clip spring has deteriorated during the current- carrying period A.2.2 the voltmeter, ammeter and cable/clip j oint temperature Test temperature between the clip and the cable, arrange the cable clips in holders (see Figure A 2) such that the whole cable, measured from the seat of the clip, is able to hang vertically and freely as a loop Then heat the cable together with the holders for h in a convection type heating cabinet to a temperature of 70 °C ± °C Immediately after removal from the oven gently and carefully load the cable with a test mass to give a force of 500 N ± N applied by means of a pulley of 00 mm diameter at the bottom of the loop and subj ect it to this load The tests shall be carried out in an ambient for Then remove the cable from the temperature of 20 °C to 25 °C mechanical test rig and allow it to return to ambient A.2.3 temperature before carrying out the test procedure Apparatus A.2.3.1 An a c in A.2 sup p ly cap ab le of s up p lying 00 A r m s , cap ab le of sup p lying o r a d c p ow er so urce 00 A, for the required time period If the samples are too long to fit in the oven, it is weight is acting on the clips Untie any loop/knot before applying the test mass A.2.3.2 Am m eter, A.2.3.3 Voltm eter, capable of reading 00 A ± A capable of reading a minimum A.2.3.4 Single p oint electrical therm om eter p ro b e A.2.3.5 Tw o 25 mm diam eter cop p er ro ds, at least 50 mm long, and two 25 mm × mm copper bars at least 50 mm long Procedure A.2.4.1 Suspend each j umper lead in free air by its clips between the two 25 mm diameter copper rods and ensure that it is not coiled A.2.4.2 Connect the apparatus as shown in Figure A and ensure that the leads to the voltmeter are as close as practicable to the clips of the j umper leads © BSI 07- 999 A.4 Test for flame retardance A complete clip with a piece of the insulated cable, approximately 225 mm in length, shall be of V ± 05 V A.2.4 NOTE permissible to tie the leads in a loose loop/knot provided the full supported horizontally Subj ect the clip insulation to a luminous “batswing” flame which is 25 mm wide across the tips and applied so that the longitudinal axis of the flame is parallel to and below the longitudinal axis of the clip for a period of s (see position , Figure A 3) Repeat the process with the flame applied to a section of the cable (see position 2, Figure A 3) If the clip or cable ignites, it shall not continue to burn for more than 60 s after the flame has been removed, and the burning shall not extend more than 25 mm on each side of the portion of the clip or cable which has been subj ected to the flame BS AU 7a: 993 Figure A — S che matic draw ing o f te st circuit fo r e le ctrical te sts © BSI 07- 999 BS AU a: 993 Figure A — S che mati c draw ing fo r cab le te rmination te sting © BSI 07- 999 BS AU 237a:1 993 Figure A.3 — Schematic drawing for flame retardance test Annex B (normative) Test fluids and conditioning Condition a complete lead set in oil for 24 h at 23 °C ± °C B.3 Fuel oil B.1 Samples A new lead set shall be used for each fluid A complete lead set shall be submerged in each fluid for B.2 , B.3 and B.4 B.2 Lubricating oil The oil consists of pure refined petroleum products in which small quantities of additives may be blended to meet the following requirements a) Viscosity at 99 °C 18.8 × 10–6 m2 /s 21.15 × 10–6 m2 /s max b) Viscosity index 95 c) Pour point – 12 °C max d) Carbon residue 0.95 max (Ramsbottom) e) Flash point (open) 240 °C f) Total acidity 0.1 max (mg of KOH/g of oil) g) Mineral acidity nil h) Ash content 0.01 % max i) Saponification number 0.5 max (20 g sample) NOTE Lubricating oils that are commercially available meet these requirements The oil is class A.1 engine fuel as defined in BS 2869-1:1988 (diesel) Condition a complete lead set in fuel oil for 24 h at 23 °C ± °C B.4 Petrol Two separate test fluids shall be used: a) petrol in accordance with BS 4040:1988 (4 star); b) petrol in accordance with BS 7070:1988 (unleaded) Condition a complete lead set in each fluid for 24 h at 23 °C ± °C B.5 Battery electrolyte Battery acid in accordance with BS 3031:1972 diluted with pure distilled water to a density of 280 kg/m measured at a temperature of 25 °C shall be used Take a complete lead set and dip each clip and approximately 150 mm of attached cable into the test fluid at 23 °C ± °C for s, and hang to dry for 24 h Wipe off remaining acid before proceeding with A.2 © BSI 07-1999 BS AU 237a:1 993 Annex C (normative) Safety and operating instructions for the use of j umper leads C.1 General NOTE It is recommended that the instructions produced by e) If the above procedure is followed correctly, the fourth and final connection made will be the negative/earth connection to the discharged battery If the discharged battery uses the normal negative earth return, this final connection is made to a good earth point remote from the manufacturers to be included with a j umper lead set should be discharged battery terminal post A suitable compiled with reference to the Department of Trade and Industry earth point may be an engine mounting, chassis document Instructions for Consumer Products (subtitled Guidelines for better instructions and safety information for consumer products) [1 ] Instructions shall also contain the following warnings and procedures as a minimum member, engine block or any other unpainted surface remote from the battery and away from fuel and brake lines C.3 Procedure for starting WARNING READ THESE INSTRUCTIONS IN Jumper lead sets shall contain the following FULL BEFORE ATTEMPTING TO USE THE instructions JUMPER LEAD SET AND RETAIN FOR FUTURE a) Start the engine on the donor vehicle and run USE it for about at a fast tick- over; in sub- zero Before connecting the j umper leads ensure that the temperatures this time should be extended following safety measures are adhered to to or a) Batteries give off flammable gases — not b) With the engine of the donor vehicle still smoke nor use naked flames; ensure that the area running attempt to start the vehicle with the is properly ventilated b) Ensure that both batteries are of the same nominal voltage Battery or charging system discharged battery If nothing happens switch off the ignition on both vehicles and recheck all connections damage or explosion can result if j ump starting is c) After starting the vehicle with the discharged attempted with batteries of different voltage battery run this engine at fast tick- over for c) Ensure that the two vehicles are not touching several minutes to warm- up then allow to idle each other; sparks and vehicle damage could Do not disconnect the j ump leads with the engine of result if they are either vehicle running at above idle speed: this can d) Ensure that the j ump leads are in good condition; breaks in the conductor or poor crimp connections make starting difficult and can cause cause damage to the charging circuits and to other electronic equipment C.4 Procedure for disconnecting the leads overheating and fire Jumper lead sets shall contain the following e) Ensure that the ignition switches of both instructions vehicles are in the off position and that both a) Detach the clip connected to the earth point on handbrakes are applied If the j ump leads are the vehicle that had the discharged battery then connected whilst the ignition is switched on disconnect the other end of this lead from the sparks and fire could result donor battery f) Always connect the batteries positive to b) Disconnect the second lead, first from the positive and negative to negative irrespective of vehicle that had the discharged battery and then the vehicles’ earth terminations from the donor vehicle C.2 Procedure for connecting j ump leads Jumper lead sets shall contain the following instructions a) Connect the j ump leads one at a time b) Connect the positive lead (red) first c) Always attach each j ump lead to the charged/donor battery first d) Complete both connections of the first lead before making the first connection, with the second lead © BSI 07- 999 10 blank BS AU 237a:1993 List of references (see clause 2) Normative references BSI standards publications BRITISH STANDARDS INSTITUTION, London BS 2869, Fuel oils for non-marine use BS 2869- : 988, BS 3031 : 972, BS 3641 , Symbols for machine tools BS 3641 - : 971 , BS 4040: 988, BS 5378, Specification for automotive diesel fuel (class A1) Specification for sulphuric acid for use in lead-acid batteries General symbols Specification for leaded petrol (gasoline) for motor vehicles Safety signs and colours BS 5378- : 980, Specification for colour and design BS 5378- 3: 982, Specification for additional signs to those given in BS 5378-1 BS 6469, Common test methods for insulating and sheathing materials of electric cables BS 6469- , Methods for general application BS 6469- : 992, Measurement of thickness and overall dimensions — Tests for determining the mechanical properties BS 6469- 4: 992, Tests at low temperature BS 6604: 985, Code of practice for safe operation of starter batteries BS 6746: 990, Specification for PVC insulation and sheath of electric cables BS 7070: 988, Specification for unleaded petrol (gasoline) for motor vehicles Informative references BSI standards publication BRITISH STANDARDS INSTITUTION, London BS 5750, Quality systems 2) Other reference Instructions for Consumer Products (Guidelines for better instructions and safety information for consumer products) Department of Trade and Industry, 988 Available from HMSO [1 ] 2) Referred to in the foreword only © BSI 07- 999 BS AU 237a: 1993 BSI — British Standards Institution BS I is the indep endent national b ody res p ons ib le for p rep aring Britis h S tandards It p res ents the UK view on s tandards in E urop e and at the international level It is incorp orated b y Royal C harter 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