SURFACE solo rev. c ___,. VEHICLE | ee SAE International’ stanDARD Rewed 200704 Superseding _J240 0CT2002 Life Test for Automotive Storage Batteries RATIONALE ‘The test procedure has been modified as a result of 2 study completed {o evaluate the correletion of this test to fiel failure modes and life for a broad range of current 12 V Automotive Lead-Acid Storage Battery manufacturing technology This test was found to have an insufficient corelation fo be used as a universal test. INTRODUCTION To shorten product development tme and to support contnucus improvement, the automotive industry require accelerated testing methodology that allows reliable evaluation of changes in component design and technology. Thy designs of today's automobiles have significantly higher under hood temperatures at which the automotive storage better must operate. The original J240 was established in 1971 and was later modified with an increased discharge duration t becoma J240b in 1982. In 2002, paragraph 3.11 was included to increase the test condition temperature (41 °( Increased to 75 °C) to improve the correlation of failure modes observed in both the laboratory and the field. In the current format the test is written with test conditions at75 °C, with the opton to be sun at 41 °C. TABLE OF CONTENTS 1. 14 244 i 22 Related Publications. Si 224 ‘SAE Publications........ 3. ‘TESTING PROCEDURE 4. NOTES... 44 Key WOrdS..cesen abner 42 Marginal indicia ‘SAE Tectrical Standards Boar Res provi that. “This rope i published by SAF to vance the sat of lchncal and ergnwoing sence. Tha usa of is report sly vauria, arts epic and sulay ay pate use, nang ay daw Irtingetnent asa swreory fe So esporsbily of use” ‘SAE ravens each techricalroportatlasst every fv years wich te maybe reermed, esd, or cancolkd. SAE inv your wean conor and suggestions, CCopright © 2007 SAE Intemational [Al gts esered. No part ofthis pubaton ma) be reproduced, stad in 2 rerioval eyiem or tranamied, fv any form or by any means, elackonc, mectenice Photeopying, rocarng. cr etarwse whet ha ror wrton armisson f SRE ‘TOPLACEADOCUMENT ORDER: Tol: 87-606-7319(inalde USA and Canads} Tat Yaurres7a outta USA) Fax 7247764780SAE J240 Revised APR2007 = 4. SCOPE This SAE Standard epplies to 12, flooded lead acid automotive storage batteries of 180 minutes or less reserv capacity using cast positive grid technology only. This life test simulates automotive service when the battery operatas i a voltage regulated charging system. It subjects the battery to charge and discharge cycles comparable to thos encountered in automotive service. Other performance and dimensional information is contained in the latest issue ¢ SAE J597. This document is intended as 2 guide toward standerd practice, but may be subject to change to keap pace wit experience and technical advances. 4.1 Purpose ‘This lif tast simulates high-heat automotive service when the battery operates in a voltage-ragulated charging systerr The test subjects the battary to charge and discharge cycles to produce failure modes similar to those found in battario. installed in high temperature applications. NOTE: Caution must be exercised when using this lest 2s a means to provide an absolute value for battery life Recommendalions for sample size are not coniained in this procedure. Increasing the sample size will provid higher confidence in the lest results; therefore, standard statistical practices should be incorporated with this tes procedure. 2, REFERENCES 2.1 Applicable Publication ‘The folowing publication forms a part of this specification to the extent specified herein. Unless otherwise specified, th latest issue of SAE publications shall apply. 2.1.4 SAE Publication Available from SAE, 400 Commonweatth Drive, Warrendale, PA 15096-0001, Tel: 877-606-7323 (inside USA an Canada) oF 724-776-4970 (outside USA), ww.sa.01. SAE J537 ‘Storage Batteries 2.2 Related Publications The following publications are provided for information purposes only and are not a required part of this document. 2.24 SAE Publications Available from SAE, 400 Commonweath Drive, Warrendale, PA 15096-0001, Tel: 877-608-7323 (inside USA an Canada) of 724-776-4970 (outside USA), www.sa0.0rg, SAE 1999-01-1084 Hot Application Cycle Life Test for Automotive Storage Batteries ‘SAE 2007-01-0637 High Temperature Application Accelerated Cycle Lite Test for 12 Volt Lead-Acid SLI Automotiv Storage Battarias 3, TESTING PROCEDURE 3.1 Cycle life testing shall begin within sixty days of the final nondestructive test as shown in 3.3 of SAE J537 (Table 1) 3.2 The battery is tested in a water bath maintained at 75 °C + 3 °C (167 °F +5 °F). 3.3. Water level of the bath specified in 3.2 is to be maintained at a height equal to or greater than 75% of the overa height of the battery container or within 12 mm (1/2 in) of the metal bushing of side terminal batteries,SAE J240 Revised APR2007 -3 3.4 The test cycle is performed as follows: Discharge: 4 min #1 sat 25A20.1A Charge: 2, Maximum voltage (at bettery cable terminals): 14,8 V+0.03 V b. Maximum rate: 25 A+ 0.1 A , Time: 10 mint 3s 3.5 Battery is continuously cycled for 100 (+10, -0) h (example: Monday noon until 4:00 p.m. Frday). A switching dela of not more than 10 s is permitted from termination of charge to stat of discharge and termination of discharge ti startof charge. 3.6 The battery is given a 60 to 72h stand on open circuitin the 75 °C + 3 °C (167 “F + § °F) water bath, 3.7 With the battery at the temperature obtained in 3.6, discharge at a rate equal to its -18 'C (0 °F) cold cranking rati in amperes (see SAE J537) to 7.2 V, or a minimum discharge time of 30 s, whichover occurs first. 3.8 Replace battery on the life test without a separate recharge. Starton the ‘cherge" portion of the cycle. 3.9 The life test shall be considered complete when the battery fails to maintain 7.2 V for a minimum of 30s on thy manual discharge (3.7) for two consecutive 100 to 110 h test periods. 3.10. Water should be added to the electrolyte as required during the cycling portion of the test except to those batterie: described as maintenance free, 3.11 Optionally, this test may be conducted with the water bath temperature maintained at 41°C 43°C (105 “F #5 °F ‘when high temperature operation is not a concen. Lengthening of time end of number of cycles to failure point cat be expected. This lest option may change the types and distribution of failure modes depending on the better design technology. The battery supplier and the automotive user should concur that this ‘est option will product failure modes that correlate with application life and the temperature tequired to produce these failure modes. 4, NOTES 41 Key Words Life Test, Storage Battery, High Heat, 12V. 4.2 Marginal Indicia ‘The change bar (!) located in the left margin is for the convenience of the user in locating areas where technical revision hrave been made lo the previous issue of the reporl. An (R) symbol lo the lefLof the document tile indicates @ complet revision of the report. PREPARED BY THE SAE STORAGE BATTERY STANDARDS COMMITTEE