formula aha? YBRID @QAE Appendix G Wire Current Capacity (DC) oe j OLGA atin 64 ty Wire AN gauge | Wire Area Max. Fuse Copper (Thousands of | Continuous circular Mils) Rating 24 5 2 7 20 10 18 14 16 20 14 28 2 40 10 55 8 80 6 105 4 140 3 165 2 190 7 220 0 260 20 300 370 350) a0 405 250 455, 300 505: 16 (©2010 SAE Intemational, AIL Righs Reserved. Printed in USA. August 24,2010ze Conversion Table n Wire Gauge! Laws-) Dia Dia Cross Sectio1 Area (mm2 200 ag sits frost ooo ey 2 364827 eran 2 3249 bse ae eee 2 2576 fe 3.61 3 ae | 6.65 4 0.2043 5.19 1.14 5 0.1819 4.62 116.76 c jo162 aaa his 7 jo.14a3_ B67 ha. x ai IZ 13 ao l Ie tt \3 fl w oe ] 4 - 7Quick Reference: Wire Size/Type/Color per current Revised by: Josh Hickman 3/10/2012 Sizing Excerpt from Page 62 of the EcoCAR 2 Non-Year Specific Rules F-14.1.6 Connections Ai leetrical connections must be made with appropriate terminals, Terminals should be crimped or Fred. depending on the type of connection, and must be correct forthe wire size being inserted. Excerpt from Page 63 of the EcoCAR 2 Non-Spe: F-14.2.3 Automotive Standard Wiring ‘Al wiring, fusing and other components used in any low-voltage circuits must be rated for automotive use. ‘futomotive stranded copper wiring (such as GPT, TWP, HDT, GXL, SXL. or TXL) must be used and tect the manufacturers recommended current ratings. Note: Insulation on wire must be automotive rated. hn small electrical connections and parts (terminal strips, junctions, shunts, relays, ete,) should be contained in.an enclosed box, whenever practical. If the box is exposed to the outside, the enclosure should be Gesigned to seal out spills, rainwater, road dust, and debris. All wiring must be strain-telieved and Securely fastened throughout the vehicle to minimize movement. HEVT Policies Ampacities of copper wire, in free air at 30° C: -om/vol_ S/chpt_3/2.htm! EcoaeCan2 © Argonne HNT™Quick Reference: Wire Size/Type/Color per current Revised by: Josh Hickman 3/10/2012 Wires are sized so that the temperature of the conductor in the wire does not exceed the temperature ‘ating ofthe insulation. The continuous and peak currents flowing through the wire determine the temperature of the wire. Using the continuous current, the steady state temperature ofthe wire can be found. The steady state temperature is then used as the intial temperature in a transient wire temperature calculation. The peak current is used in the transient calculation for a pre-determined amount of time, Usually 10 seconds. The final temperature ofthe wire found inthe transient calculation is the hottest temperature that the wire should ever reach. Battery ‘SGT 08 - 4/0 SAE J-1127 = 40 to+ 806 Cable | stranded ‘SXL 20-06 SAE S128 -51t0+125C | high heat | stranded GX 20-06 SAE J-1728 ~51t0+125C | high heat | stranded ‘mail| stranded diameter, minimum, weight, TL 20-12 SAE J-1560 -51to+125C | high heat ‘general GPT 20-06 SAE J-1128 =40 to + 806 wiring | Sona Woodward: Harness construction: page 4 The following information has been supplied by Waytex:a supplier of electrical wiring supplies SGT- This multi-stranded bare copper battery cable is designed for general industrial, automotive or marine use, The tough PVC jacket is manufactured to SAE specifications J1127-SGT and is resistant to oil fuel, acids, grease and abrasion, SXL- Automotive wire with a chemically cross-linked Polyethylene jacket. SXL wire has standard wall thickness, and is resistant to moisture, grease, ol, gasoline and most solvents. Rated for 12 Volts. Rated between -49 F to 257 F or -45 Cto 125 C, Meets or exceeds SAE Specification J1128, GXL- Automotive wire with a chemically cross-linked Polyethylene jacket. GXL wire has a thin wall, and is resistant to moisture, grease, oil, gasoline and most solvents. Rated for 12 Volts. Rated between -49 F to 257 For-45 C to 125 C. Meets or exceeds SAE Specification J1128. EcoeCAR2 @ argone® ET”Quick Reference: Wire Size/Tyne/Color per current Revised by: Josh Hickman 3/10/2012 wire with a chemically cross-linked Polyethy lene jacket. TXL wire has a thin wall, and is resistant to moisture, grease, oil, gasoline and most solvents, Rated for 12 Volts. Rated between -49 F to 257 For -45 C to 125 C. Meets or exceeds SAE Specification 11128, GPT — Does not matter ~ DO NOT USE ~ single conductor Color of primary and stripe on wire High Voltage: Orange Cable or Black Cable with Orange Tape Standard for Low voltage wiring is currently in process Argonne HNT”Wire Type. Core Size (mmz) | Color [ Wax Temp Rating | Bend Radius (mm) Leoni HIVOCAR 150-16 16 150°C 49.5 Leoni HIVOCAR 150 5,0 15 150°C 18.18 AWGHI6, 600V 131 Yellow 105°C WA [awaw8, 6ov 0.82 Purple 105°C N/AQ> (fw) Bay” ete Pewee Bat * 1 D0Me Ohm, Fan Spe shack Lepweh * In Picci = OG “on 1) Nedain eshonnte Re sintlding /msher|ove 5a C inside of He cnelssure, + E55 fe eee . te Be ieee eee as i Tye = 94.45 (oro!) @ Tame of (Hed Arps er a Oe paeg 8k UO: Amps Te Bagg = Paatauniny 42S tenp tating, ed / © Twice = Wie mid & 50°"Eom © Cyt Aas? Powe * To” Tots ) ie J : A = Jos 3 aeceleation events Cr BE 5 : ( brew & boule ) be = Wes? ot Jew ~ eepesptisscpee %,90) b/,5 Diy = BBO. ODI ~ 2917 (incense kong) > °C (amoung op 9 Voakind = GI.LO or @ Tye, £ BO pgs Gigs Hoi se Cngh erin? @ Tp a HO bee Te = 922 E (etn AL) @ Tpeh # OAM 1 Te 7 BRATS UM SO MPM eel era eT,» ame, Tee 7 ZO = Vive Tded Ce 160°C__ Fe bow 1597S, 50 | (Sout HV vive ) Bind = 00394 Oh Ian qushet Leste ~ Im Thief coo Hanya Cee : Coe neds ttionae Tans of 09 Ay, + af 1D boys ee) Oe = Pnatoning YO" Tenp nbn -om ; eee 139. 93 Besps — We mtd @ 169°S e VataLeoni 150-S 5,0 ( Saw? pv yee) aus — {pensiontnGase Gr 8S Ke Ma o= es Ae = lex10° mt Rig 7.00304 > . 004 ( we ) Proe = 8.400 Mh ee ahah Ge Sg (yo 0) © Tyee 4 200M , T= Supt @ Tyr t RW Aps 6 T= 642 aS © Tye + 202 Amps , (ce isiebe OT. 7 Oo | Ty 7 ST Ths meets dye reguierronts ot the arpebhio>nGonpron Current Te Continvars =. HVAC Oey L2 Aeps CeStmnic Defoe G.L35% Amps ~ 6.3 Avps 1D eps (ears spe 29 DER yahaw oed case) Groute ) & a \to bwgs V3 Aeogs/ i> Daops PL itor (Sele sme) (Sue simiv ) 4 dale (726-3 dnrs ese PL cist cetwy porte Le praetor Liiewte ¥ Pres @ 305, 3 eectiembin fens K Lamibad by Fed evened Fuse ~ 160 AmysOe LSA F290 wt 40 A zqt.2 mnie oA 32. anit eto 15 = Seti Az Well (1) 24 mm % (3fo") 4S = 122.25 Im (1") 25.4 mm (g") 20 = 32.98The Quality Connection LEONILEONI Hivocar* Sos Sab thal 0c ouse Wy testo Due to diminishing fos fue reserves and the rapidly changing ‘imatc conditions caused by green house gases, teratve ivesin automotive applications are becoming more important Theteis evidence to suggest that diferent version of hybrid ‘ives wil sustain the industy during the transition period unt the market hunches wel-engineete electrical vehicles. In particular the innovative nature of hybridelectical vehicles aces a greater demand onthe cable aswell asthe cable harness 0 that they have mite silty to today’ vehicle harnesses With LEONI tocar cables, LEON offers a product family that hasbeen tailored to this make,Properties Limiting factors fr H cables ate tightinstalation space * high power transmission between 1 battery power electro nics andengine/generator "shielding against EMI caused by the power electronics The LEON! Hivocar® portfolio contain quale cables, available imelther single or mult-cor shielded solutions. epending on the design, the cables are capable of handing voltages upto 1000 which are needed in commercial vehicles or buses. Conductors Different conductor constructions an fexibities canbe ealsed according to customers requirements. Since weigh reduction is abo key facto future designs, LEONI can also provide aluminum conducts. Shielding Using a flee braided shield made up f copper tends, LEONI ivocar” provides an advanced emission shielding perfermance forthe wiing environment To support the diferent equi. ‘ments on performance LEONI offers multiple combintions of shield type. Excerpt fom our present product portfolio. Sexton Gade Tater icine ah tigre eatin WF ect aa sega |oftmedaper wie ghedictle omc ust [mune |e arn wage 95% Saks | Otro ith Hheatge cle EC He resi.LEONI Hivocar’ 150-5 25 Mesures lrg efectenes LED Hea” 150 55 feign) Material selection LEON uses selective ange of insulation and jacket materia LEON Hivoca” products take advantage of material specific Performance e. 9, mechanical r thermal esitance, leading to "echnical high arade cable solutions. z Mein ey 5 ety Noite Sa a res Woriaaaes—eabfon’ Tempetrsange Seaionier Sheath ar FCP °C HS *CBa0HN 15-30 Teorey o-cwens-caam0m) eo UTE Tw HO CHOOONLEONI Hivocar® For temperatures upto 150°C LEONI has developed an innovative cable type, named LEONI Hivacar* 150. Concerning ‘especially the thermal properties, LEON! Hivocat* 150 shows ‘an outstanding performance exceeding the typical automotive standard for class D (-40 to 150°C) materials, te osm omic is0 Termini DOC wER FONE Shentomgeg CHR amc eH bogtemasing 19 C38008 Cera This tesltsin longer service fe as well as greater safety ‘margin with respect to temperature peaks that may be caused by bret power peaks (Ghee a poty EO Her” 150Latest Development 200 C resistant cable for hybrid vehicles ‘ve particialy tothe high curents, conductor temperature ‘an dmb 1 200° and biety even beyond that. he cables then also have tobe lid in especialy exposed postions where ‘they can in winter be subjected to extreme col, there the addtional challenge offow-remperatre iby in case the ‘ables also need to be moveable under such conditions LEON offers abies that can cope with such extreme conditions and ae insulated wth special liane material which ably coversa temperature range from 50°C 10 4200°C Paid Tea ae Soren asia TOR DHA vonuamaary CHa CHEN The 200°C resistant high voltage cables are avaiable in single and muli-core versions. The Shielding consists of high fx brads made oftn ned copper wires in combination with ol shied. Reina esi ton hath Temperate ge 05-20 cousins 0% CORDLEONI Cable Inc. LEONI Kabel GmbH BU Automotive Cables 400 Water, Suite 202 Rochester Ml 48307 Usa Phone +1 (248)650-3328 fax 11 (248}650-3365, Email marydecookeonicom \worlcen-automative-cables.com StieberstaBe S 91154 Rath Germany Phone +49(0)9171-9042218 Fax +9 0)9171-8902232 Email cable infoteonicom \eon-automotive-cablescomLEONI Kabel GmbH DRAFT LEONI LEONI Part No: 76HO0128A_ LEONI Hivocar® 150-16/0,15/9,9MM 1. Leitungsaufbau/ Construction 1.1.Leitungsquerschnittszeichnung / Cross section drawing 1.2.Aufbaubeschreibung / Design characterization 1.2.1.Leiter / Conductor (1) Cu-Litze, blank, Cu ETP 1 gem. EN 13602 stranded copper wire, bare, CUETP I acc. to EN 13602 1.2.2.lsolierung / Insulation (2) XPE, Farbe: kundenspezifisch (s. auch 6,), nach ISO 6722 Klasse D APE, colour: customer speci (s. also 6), with [50 6722 cls. D compliant properties 1.2.3. Schirmung / Shield 1.Geflecht aus Cu-Drahten, verzinnt, Cu ETP 1 gem. EN 13602 (3) braid of tinned copper wires, Cu ETP 1 ace. to EN 13602 2) 1.2.4.Mantel | Sheath (5) TPE-U, Farbe: orange gem SAE J 1127, Folie unter dem Mantel TPE-U, colour. orange acc. SAEJ 1127, foll under the sheath 1.2.5. Kennzeichnung / Marking Bedruckung des Mantels/printing of the sheath ‘Text LR: LEONI Hivocar® 150-16 CAUTION! HIGH VOLTAGE! 76H00128A Text LS: LEONI Hivocar® 150-16 CAUTION! HIGH VOLTAGE! 305940 - ‘Auftragsnr.”LEONI Kabel GmbH DRAFT LEONI LEON! PartNo: 76HOO128A, 1.3. Aufbaudaten / Design data FR Teiteraufbau | Querschnitt Wandstirke | Ader a) ‘core | Conductor stranding| cross section wallthickness| cores ElementNo.} —jpal.xtom) Imm rm) [mm om) 12 126x040 16 32 0582 | 69 50,30 Schirmung Tafbow ‘Opt. Bedeckung Shim ‘shield design visual coverage shield @ Element No. [mm] ‘nom. (9) om) sa ‘Os oF 7502030 Mantel Wandstarke Aassen® sheath wall thickness ‘outer- 0 ee rin. ne [omit 5 O70 3902 03 Elektrische Eigenschaften / Electrical characteristics (20°C) 2.1. Leiterwiderstand bei 20°C max. 1,16 Ohm/km Conductor resistance at 20 (1) 2.2.Prafspannung 6KVIA) Testing voltage 2.3 Betriebsspannung OV DCIAC Operating voltage ‘Die Strombelastbarkeitrichtet sich nach den durch die Einbauverhaltnisse gegebenen Warmeableitbedingungen The current rate depends on heat dissipation conditions of the application ‘Mechanische Eigenschaften / Mechanical characteristics 3.1. Leitungsgewicht a. 237ka/km Cable weight 3.2. Biegeradius /Bending radius 3.2.1.Einfach /single 3.2.2.Mehrfach /muttipe (<10x) 15xd Chemische Bestindigkeit / Chemical resistance Fur die chemische Bestandigkeit der verwendeten Isolationswerkstoffe wenden Sie sch bitte unter Angaben der Chemikalie(n) direkt an das LEONI Produktmanagement The chemical resistance of the applied insulation materials is available on request Please ‘ndlcate the chemical) of interest to LEOM! Productmanagementi i LEONI Kabel GmbH DRAFT LEUNI LEONI Part No: 76HO0128A 5. Thermische Eigenschaften / Thermal characteristics Betriebstemperatur (3000 h) 40°C bis 150°C Operating temperature (3000 h) 6 Farben der Aderisolierungen / Colours of core-insuletions Die lsolationsfarben werden durch die neunte Stelle der LEONI Part No. (oben: Nummernzeichen #) bestimmt. Zur Auswahl einer Farbkombination des Nummemnzeichen durch einen Buchstaben aus folgender Tabelle ersetzen, The insulation colours are defined by the ninth digitof the LEONI Part No. (see above: numbersign #) For choosing a colour combination please replace the numbersign by a letter of the following table: Tabelle der Isolationsfarben / table of insulation colours Neunte Stelle der LEONI Part, No, x 9 digit of the LEONI Part No, Farben (1) Tatur7 7 7 colours natural 7. Normen /standards sim, 150 6722enonanes meqimsbomtey mud -0'5 5-051 o10NH NOT vortiszez:oeanon ae ea near mio mien | INO31 Haw paeH NOT INO31 awo regen mortINO31 909 pee nonWas WAYTEK Quality Electrica Wiring ne all eee > COMPETITIVE PRICES > QUALITY PRODUCTS > GREAT SERVICE KE] PRODUCT DETALS FOR TEM# WNi6-4 product search 0c veo TAP 3316 1452 our e-cataiog eee ae I ae xitennaceca ianeaies crag ee SINT pig Ger One Now — a ‘et Ses agen eat ay eee g Sone Ot Procte ae Mu Featured Products Bh New Products Come and creckextad WAYTE > COMPETITIVE PRICES > QUALITY PRODUCTS > GREAT SERVICE K 4 1, [Gj PRODUCTDETALS FOR MEMAWG1e7 product seareh {eA cer auromomvewne Bow ccnans Ser, BAR coe = [Uetctntecssone tng ‘te evan BO =—_ 1 tea Coverings ‘nae Sobe ot gee com 1 Goseorreacets ow 0 i Request catalog tae hae Bi contact Us j Featured Products Ge Now Products 3 ema sso ne150-16ANG + Io(S9-g 6,0