Bsi bs au 237a 1993 (1999)

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[.]

1993

This Bri sh Stan ard, ha ing

b en pre ared u der the

directonof the Automo ile

Stan ards Policy Commi e ,

waspublished u der the

authoriyof the Stan ards

Bo rdan comes

into efect on

1 Se temb r1 9

© BSI0 -1 9

Fir t published as BS AU2 7-1,

Decemb r1 9

Secon edi on Se temb r1 9

The folowing BSI references

relate to the work on this

stan ard:

Commi e referenceAUE/9

Draft for comment9 /76 7 DC

The prep ration of this British Stand rd was entrusted b the Automobi e

Stand ards Pol cy Commit e ( AUE/-) to Tech ical Commit e AUE/9, upon

which the fol owing bod ies were represented :

Automobi e Association

Consumer Pol cy Commit e of BSI

Dep rtment of Trad e an Ind ustry ( Consumer Safety Unit, CA Div ision)

Dep rtment of Transport

Garag e Equipment Association

Institute of Tra ing Stand ards Administration

Motor Cy cle Ind ustry ’s Association of Great Britain Ltd

Petrol Pump Man facturer ’ Association

Roy al Automobie Club

Society of Motor Man facturer and Tra er Ltd

Am endm ents is ued sinc publ cation

Pag e

Annex C ( normativ e) Safety and operating instructions

Fig ure A.1 — Schematic d rawing of test cir uit for

Fig ure A.2 — Schematic drawing for ca le termination

Fig ure A.3 — Schematic drawing for flame retard ance

This British Stand ard has be n prep red u der the direction of the Automobie

Stand rds Pol cy Commit e to esta lsh a stand ard of per ormance for jumper

lea sets for automotiv e jump starting

BS AU23 a deals with req uirements for jumper lead sets for use when starting

an internal combustion eng ine f om a sup lementary b t ery Ex mples are

motor v ehicles, boats and other instal ations

The stand ard is a pl ca le to1 V v ehicle sy stems

This second edition of BS AU23 super edes BS AU23 -1:19 0 which is

withd rawn.It constitutes a tech ical rev ision u d ertaken to improv e and clarify

testing procedures arising fom the a plcation of the fir t ed ition for conformity

testing purposes At the same time the title of the stand rd has be n amended to

reflect the fact that Part2 for heav y domestic duty and Part3 for commer ial

v ehicles hav e not be n d ev eloped an the ne d for such Parts are no long er

considered neces ary

Pr od uct c r tifica tion User of this British Stand rd are ad v ised to consider the

d esira i ty ofthird p rty certification of product conformity with this British

Stand rd b sed on testing an contin ing product surv ei ance which ma be

coupled with as es ment of a sup l er’s q ualty sy stems ag ainst the a propriate

Part of BS5 5

Enquiries as to the av aia i ty of third p rty certification s hemes are forwarded

b BSI to the Association of Certification Bod ies I a third p rty certification

s heme do s not alrea y exist, user should consid er a proaching an a propriate

bod f om the lst ofAssociation member

A British Stand ard d oes not purport to includ e al the neces ary prov isions of a

contract User of British Stand rd s are responsible for their cor ect a plcation

Com pl anc with a British Standard does not ofitself confer im m unity

f om leg al o l g ations

Sum mary of pag es

This document comprises a f ont cov er, an insid e font cov er, p g esi andi ,

p g es1 to10, an inside b ck cov er and a b ck cov er

This stand rd has be n up ated ( se copy rig ht d ate) an ma hav e ha

amendments incorporated This wi l be indicated in the amendment ta le on the

inside f ont cov er

1 Scope

This British Stand ard specifies req uirements for

jumper lea sets for lg ht d omestic use when

starting an internal combustion eng ine f om a

sup lementary b t ery in env ironmental

temperatures down to–10°C It is restricted to

ma imum eng ine ca acity ,3.5lpetrol

and2.5ldiesel

Req uirements for the safe use of jumper lea sets for

jump starting are g iv en as safety and operating

instructions in Annex C

2 Ref r nces

2.1 Norm ative referenc s

This British Stand rd incorporates, b reference,

prov isions f om specific ed itions of other

publ cations These normativ e references are cited

at the a propriate points in the text and the

publ cations are lsted on the inside b ck cov er

Subseq uent amendments to, or rev isions of, any of

these publ cations a ply to this British Stand ard

only when incorporated in it b up ating or rev ision

2.2 Inform ative referenc s

This British Stand ard refer to other publ cations

that prov ide information or g uid ance Ed itions of

the publcations cur ent at the time of is ue of this

stand ard are l sted on the inside b ck cov er, but

reference should be mad e to the latest editions

3 Definitions

For the purposes of this British Stand rd, the

definitions g iv en in BS6 0 :19 5 a ply , tog ether

with the folowing

3.1

conductor

that portion of a ca le which has the specific

fu ction of conv ey ing cur ent

3.2

cl p

a d ev ice which makes a mechanical and electrical

con ection f om the cond uctor to the b t ery or

earth terminal of a v ehicle

3.3

jumper lea set

a set of two insulated flexible low-v oltag e conductor

and four insulated clps securely at ached to the

ends of the conductor

3.4

starter bat ery

a b t ery princip l y used for starting , lg hting and

ig nition on v ehicles or plant employ ing internal

combustion eng ines

3.5

jum p starting

a tech ique used for as isting the starting of an

internal combustion eng ine where a healthy and

reasona ly wel charg ed b t ery is con ected

temporari y in p ral el with an ai ing or dis harg ed

b t ery of the same nominal v oltag e to prov id e

a d itional c an ing power

4 Cable and construction

4.1 Jum per lea leng th

W hen measured betwe n the end s of the jaws of

each clp, the ov eral leng th of the jumper lead s as

shown in Fig ure 1 shal be not les than3m

4.2 Ca le construction

Any material used for ca le construction shal be of

a siz ca a le of car y ing10 A contin ously

4.3 Cable insulation

The ca le insulation shal be homog ene us an

shal me t the req uirements of ty pe TI1of

BS6 4 :19 0 an ofA.4 of this stand rd

The mean thick es of insulation shal be not les

than1.3mm, but it is permis ible for the thick es

at any one place to be les than1.3mm prov ided

that the d iference d oes not ex ce d0.1 mm +10% of

the v alue specified

Compl ance shal be checked using the method

d es ribed in8.1 of BS6 6 -1.1:19 2

4.4 Colour co ing

A clear d istinction shal be mad e betwe n the two

ca les in a jumper lea set b colour cod ing of the

ca les and clps The ca le an cl p insulation used

for a positiv e con ection shal be red, an that used

for the neg ativ e shal be black

4.5 Tem perature rang e

All ca les an conductor shal be d esig ned to

operate within a temperature rang e of–25°C

to+7 °C

W hen tested in ac ord nce with8.1 of

BS6 6 -1.4:19 2 at–25°C, the ca le insulation

shal show no c acking or rupture v isible to the

naked ey e, if neces ary cor ected to g iv e normal

v ision, of a trained observ er

5 Cl ps

5.1 Desig n

Clps consisting of a p ir of jaws, held tog ether b

and piv oted a out a hing ed point, shal be fit ed

with a spring clamping d ev ice to prov ide for e on the

jaw holding the cl p in a closed position

NOT Desig ns of clip are o tonal prov ided that the me t the

re uirements of this stan ard

5.2 Per orm anc

The clp shal be ca a le of clamping on and firmly

g rasping a horiz ntal plain stu of a diameter

of25mm which projects10mm f om a sur ounding

flat surace and shal be ca a le of resisting a

tensie for e eq ual to the weig ht of the jumper lea s

plus a further5 N±1N a pl ed in the d irection of

the ca le

The clp spring shal not deteriorate when tested in

ac ord nce withA.2 The v oltag e drop shal not

exce d0.5V and the measured temperatures shal

not exce d7 °C The test shal be repeated using

the two25mm×2 mm cop er b r des ribed

inA.2.3.5 Ag ain, the v oltag e drop shal not

exce d0.5V and the measured temperatures shal

not exce d7 °C

5.3 Ca le term inations

5.3.1 Ele trical

The clp shal be at ached b either of the folowing

methods

a) The cl p shal be clamped or c imped to the

conductor of the ca le

b) A ring termination shal be c imped to the

conductor and bolted to the cond ucting material

of the cl p

No portion of the insulation shal be within the z ne

of c imping or clamping

5.3.2 Me hanical

Some form of ca le strain rel ef shal be fit ed ov er

the ca le insulation to prev ent the joint being

strained The joint shal not break when tested in

ac ord nce withA.3 and , after completion ofA.2,

the v oltag e drop shal not exce d0.5V and the

measured temperature shal not exce d7 °C

5.4 Insulation of clp

The clps shal be insulated in such a wa that if a

dosed u at ached cl p touches a flat conducting

surace or another cl p there is no direct contact

betwe n l v e p rts

Asses ment shal be b v isual ex mination and a

simple electrical contin ity test

The cl ps shal me t the requirements of A.4

6 Resista nce to contamina tion

Jumper lea sets shal be comp tible with the

automotiv e fuels, lubricants an fluids g iv en in

Annex B

After remov al fom each fluid, the samples shal be

wiped d ry The samples shal me t the

requirements of the fir t p rag ra h of5.2

W hen tested in ac ord nce withA.2 the v oltag e

d rop for each lea shal not exce d0.5V and the

temperature shal not exce d7 °C

7 Ma rking

All jumper lead sets shal be marked either directly ,

or b at achment of a dura le non-cond ucting tag , in

a leg ible an ind el ble man er The marking shal

includ e the fol owing

a) Man facturer’s or d istributor’s name or trad e

mark

b) The n mber and d te of this British Stand ard,

i.e.BS AU23 a:19 3

1)

c) The stand ard sy mbols for warning and “ ead

instructions before use” in A.3.1 or

BS5 7 -3:19 2 and1.4.17 of BS3 41-1:19 1

( se Fig ure 2)

d) Con ect +to+then–to–

8 Container

Jumper lead sets shal be sup l ed in a dura le

container that shal be ca a le of re-ac ommod ting

the jumper lead set after use Operating and safety

instructions in ac ord nce with Annex C shal be

printed on the container in a leg ible and indelble

man er

1)

Marking BS AU2 7 :1 9 on or in relaton to a prod ct re resents a man facturer’s declaraton ofconformiy,i.e.a claim b

or on b halfof the man facturer that the prod ct me ts the re uirements of the stan ard.The acuracy f the claim is solely the

claimant’s resp nsibiliy S ch a declaraton is not to b confused wih third p rty certficaton of conformiy , which ma also b

desira le

F

Man atory sig n( A.3.1) of BS5 7 -3:1 8 ) Re d instructons b fore use ( 1.4.1 of BS3 4 -1:1 7 )

Fig ure 2 — Marking sym bols [se clause7c)]

Annex A (normative)

Tests for jum per lead sets

A.1 Samples

Unles stated otherwise within this stand ard a new

sample ma be used for each test

A.2 Ele trical tests

A.2.1 Principle

Cur ent is p s ed throug h a jumper lea which is

con ected betwe n two cop er conductor At the

completion of a set time, a v oltag e-drop rea ing is

taken ac os the jumper lea The jumper lea is

remov ed f om the cop er conductor immediately

the cur ent is switched of an recon ected after a

co lng -of period This remov al and recon ection

procedure is to d is ov er whether the clp spring has

deteriorated during the cur ent-car y ing period

A.2.2 Te t temperature

The tests shal be car ied out in an ambient

temperature of20 °C to25°C

A.2.3 Apparatus

A.2.3.1 A n a c sup ly ca pa ble o

sup lying10 A r m.s o a d c power sour ce

ca pa ble o sup lying10 A, for the req uired time

period

A.2.3.2 A mmeter , ca a le of rea ing10 A±1A

A.2.3.3 Volmeter , ca a le of rea ing a minimum

of0.5V±0.0 V

A.2.3.4 Single point ele tr ica l ther mometer pr obe

A.2.3.5 Two2 mm d ia meter cop er r od s, at

least5 mm long , and two25mm×2 mm cop er

b r at least5 mm long

A.2.4 Pr c dure

A.2.4.1 Suspen each jumper lea in fe air b its

clps betwe n the two25mm diameter cop er rod s

and ensure that it is not coi ed

A.2.4.2 Connect the a p ratus as shown in

Fig ure A.1 and ensure that the lead s to the

v oltmeter are as close as practica le to the clps of

the jumper lead s

A.2.4.3 For a period of6min p s a cur ent

of10 A ±2 A contin ously throug h the jumper

lea Record the temperature at the ca le/clp joint

after1min.Then after6min record the read ing s of

the v oltmeter, ammeter an ca le/ cl p joint

temperature

A.3 Ca le term ination test

In order to test the streng th of the con ection

betwe n the cl p and the ca le, ar ang e the ca le

clps in hold er ( se Fig ure A.2) such that the whole

ca le, measured f om the seat of the cl p, is a le to

hang v erticaly and fe ly as a lo p

Then heat the ca le tog ether with the holder

for1 h in a conv ection ty pe heating ca inet to a

temperature of7 °C ±2 °C Immed iately after

remov al fom the ov en g ently and careful y load the

ca le with a test mas to g iv e a for e of5 0N±10N

a pled b means of a pul ey of10 mm d iameter at

the bot om of the lo p and subject it to this loa

for5min Then remov e the ca le fom the

mechanical test rig and alow it to return to ambient

temperature before car y ing out the test procedure

inA.2

NOT If the samples are to long to fi in the o en,i is

p rmis ible to te the le ds in a lo se lo p/knot pro id ed the ful

weig ht is actng on the clips Unte any lo p/ knot b fore a plying

the test mas

A.4 Test for flam e retardanc

A complete clp with a piece of the insulated ca le,

a prox imately2 5mm in leng th, shal be

sup orted horiz ntaly

Subject the cl p insulation to a luminous “ batswing ”

flame which is 25mm wide ac os the tips and

a pled so that the long itudinal a is of the flame is

p ral el to and below the long itudinal a is of the cl p

for a period of5s ( se position1, Fig ure A.3)

Repeat the proces with the flame a pl ed to a

section of the ca le ( se position2, Fig ure A.3)

I the clp or ca le ig nites, it shal not contin e to

burn for more than6 s after the flame has be n

remov ed , an the burning shal not extend more

than25mm on each side of the portion of the cl p or

ca le which has be n subjected to the flame

Fig ure A.1 — Schematic drawing of test circuit for ele trical tests

Fig ure A.2 — Schem atic drawing for ca le term ination testing

Annex B (normative)

Test fluids and conditioning

B.1 Samples

A new lea set shal be used for each fluid A

complete lea set shal be submerg ed in each fluid

forB.2, B.3 andB.4

B.2 Lubricating oi

The oi consists of pure refined petroleum products

in which smal q uantities of ad ditiv es ma be

blend ed to me t the fol owing req uirements

NOT Lubricatng oils that are commerialy a aila le me t

these re uirements

Cond ition a complete lead set in oi for24h

at23°C±3 °C

B.3 Fuel oi

The oi is clas A.1 eng ine fuel as defined in

BS28 9-1:19 8 ( d iesel

Condition a complete lead set in fuel oi for24h

at23°C±3°C

B.4 Petrol

Two sep rate test fluids shal be used:

a) petrol in ac ord nce with

BS4 4 :19 8 ( 4 star);

b) petrol in ac ord nce with BS7 7 :19 8

( unlea ed)

Cond ition a complete lea set in each fluid for24h

at23°C±3°C

B.5 Bat ery ele trolyte

Bat ery acid in ac ord nce with BS3 31:19 2

d iluted with pure d isti ed water to a density

of1 28 kg /m

3

measured at a temperature of25°C

shal be used

Take a complete lea set an dip each clp and

a prox imately15 mm ofat ached ca le into the

test fluid at23°C ±3°C for5s, and hang to dry

for24h W ipe of remaining acid before proce ding

withA.2

Fig ure A.3 — Schem atic drawing for flame retardanc test

a)Vis osity at9 °C

18.8×10

– 6

m 2

/s min

2 15× 10

– 6

m 2

/ s ma

b)Vis osity index 9 min

d )Carbon resid ue

( Ramsbot om)

0.9 ma

e) Flash point ( open) 24 °C min

f) Total acid ity

( mg of KOH/ g of oi )

0.1 ma

g )Mineral acidity ni

h)Ash content 0.01% max

i Sa onification n mber

( 20g sample)

0.5ma