FORD WSS-M22P6-A3-2014 CABLE PRIMARY LOW TENSION 0 15 MM WALL 125 C TO BE USED WITH FORD WSS-M99P1111-A (Shown on FORD WSS-M22P6-A1).pdf

1、 ENGINEERING MATERIAL SPECIFICATION Material Name Specification Number Date Action Changes 2014 06 11 N Status No replacement named L. Sinclair, NA 1997 04 02 Revised Revised Table 3 Column 3 Heading R.J. Patel 1997 03 12 Activated R.J. Patel WP 3948-a Page 1 of 9 CABLE, PRIMARY LOW TENSION, 0.15 MM

2、 WALL, 85 C WSS-M22P6-A1 CABLE, PRIMARY LOW TENSION, 0.15 MM WALL, 100 C WSS-M22P6-A2 CABLE, PRIMARY LOW TENSION, 0.15 MM WALL, 125 C WSS-M22P6-A3 CABLE, PRIMARY LOW TENSION, 0.15 MM WALL, 150 C WSS-M22P6-A4 CABLE, PRIMARY LOW TENSION, 0.15 MM WALL, WSS-M22P6-A5 Ni PLATED, 175 C CABLE, PRIMARY LOW T

3、ENSION, 0.15 MM WALL, WSS-M22P6-A6 Ni PLATED, 200 C NOT TO BE USED FOR NEW DESIGN 1. SCOPE The products defined by these specifications are low tension stranded and insulated cables. The cables are similar to that described in ISO 6722, with 0.15 mm insulation thickness. This specification includes

4、different temperature ratings and different conductor types i.e. plain copper, nickel plated, and copper alloy. 2. APPLICATION These cable specifications were originally released for use at a nominal system voltage of 50 V rms or less in automotive electrical harnesses. 3. REQUIREMENTS 3.1 QUALITY S

5、YSTEM REQUIREMENTS Material suppliers and part producers must conform to Quality System Requirements, QS-9000. Material specification requirements are to be used for initial qualification of materials. A Control Plan for ongoing production verification is required. This plan must be reviewed and app

6、roved by the relevant Ford Materials activity and/or Ford Supplier Technical Assistance (STA) prior to production parts submission. Appropriate statistical tools must be used to analyze process/product data and assure consistent processing of the materials. Part producers using this material in thei

7、r products, must use Ford approved materials and must conform to a process control plan which has been approved by STA and/or the relevant Materials Activity. 3.2 INFRARED SPECTROPHOTOMETRY AND/OR THERMAL ANALYSIS ENGINEERING MATERIAL SPECIFICATION WSS-M22P6-A1/A2/A3/A4/A5/A6 WP 3948-b Page 2 of 9 F

8、ord Motor Company, at its option, may conduct infrared and/or thermal analysis of material/parts supplied to this specification. The IR spectra and thermograms established for initial approval shall constitute the reference standard and shall be kept on file at the designated material laboratory. Al

9、l samples shall produce IR spectra and thermograms that correspond to the reference standard when tested under the same conditions. 3.3 CONDITIONING AND TEST CONDITIONS All test values indicated herein are based on material conditioned in a controlled atmosphere of 23 +/- 2 C for not less than 24 h

10、prior to testing and tested under the same conditions unless otherwise specified. 3.4 CABLE TEMPERATURE CLASS Depending upon the service conditions, the cables shall be made to belong to one of the following six classes of temperature: Class A - 40 to + 85 C Class B - 40 to + 100 C Class C - 40 to +

11、 125 C Class D - 40 to + 150 C Class E - 40 to + 175 C Class F - 40 to + 200 C 3.5 CABLE OUTSIDE DIAMETER (ISO 6722) No single value shall be outside the acceptable range of diameter as specified in Table 2. 3.6 CONDUCTOR (ASTM B 1, ASTM B 3, ASTM B 174, ASTM E 8, ISO 6722) 3.6.1 The individual stra

12、nds of the conductor shall be soft or annealed copper per ASTM B 3. Conductors of 0.35 mm2 size and smaller may use hard copper strands per ASTM B 1 or copper alloy strands. Annealed copper strand elongation shall conform to ASTM B 174. Hard copper strand shall meet the elongation requirements of AS

13、TM B 1. Compressed, compacted, or combination stranded cores may be used. Minimum conductor strand count shall comply with Table 1 of this specification. Missing strands are not allowed. 3.6.2 The conductor diameter and electrical resistance shall be determined in accordance with ISO 6722. The Condu

14、ctor Breaking Load Test shall be conducted in accordance with ASTM E 8. The values are specified in Table 1. 3.7 INSULATION (ISO 6722) ENGINEERING MATERIAL SPECIFICATION WSS-M22P6-A1/A2/A3/A4/A5/A6 WP 3948-b Page 3 of 9 3.7.1 The color of the insulation shall be specified on engineering drawing. Bas

15、e, stripe, and band marking color codes shall correspond to Table 4. Where striping is specified, the stripe shall be a minimum of 0.3 mm wide, but not more than 15 % of the circumference of the wire. The stripe shall be of the same class of material as the insulation. Where band marking is specifie

16、d (for sizes 0.13 and 0.22 mm2), the band mark shall be 3 mm +/- 1 mm wide with a 25 mm +/- 5 mm pitch. If the insulation is dyed or painted, the Durability of Cable Marking Test must be performed on the finished product. 3.7.2 The material shall adhere closely to, but strip readily from the conduct

17、ors, leaving them free of insulation and in suitable condition for applying terminals. Water soluble stripping agents shall not be used. The insulation thickness shall be determined in accordance with ISO 6722. The insulation thickness shall comply with the values listed in Table 2. 3.8 CABLE QUALIT

18、Y (TESTS) Withstand Voltage, Thermal Overload, Winding Test at Low Temperature (mandrel sizes per Table 5), Pressure at High Temperature, and Heat Shrinkage Tests shall all be conducted in accordance with ISO 6722. Ozone Resistance Test shall be conducted in accordance with SAE J1128. Note: The foll

19、owing tests, 3.8.1, 3.8.2, 3.8.3, 3.8.4, and 3.8.5, shall be tested in accordance with ISO 6722, but with exceptions to the requirements as indicated. 3.8.1 Test for Insulation Faults (In Process Testing) The test voltage shall be: 0.13 - 1.5 mm2 2 KV 3.8.2 Short Term Heat Aging (ISO 6722) During Wi

20、thstand Voltage Test, the voltage shall be applied immediately after immersion for 1 minute. Mandrel sizes are specified in Table 5. 3.8.3 Long Term Heat Aging (For Initial Qualification Only) (ISO 6722) During Withstand Voltage Test, the voltage shall be applied immediately after immersion for 1 mi

21、nute. The test temperatures are specified in the para 3.4. Mandrel sizes are specified in Table 5. 3.8.4 Resistance to Flame Propagation (ISO 6722) ENGINEERING MATERIAL SPECIFICATION WSS-M22P6-A1/A2/A3/A4/A5/A6 WP 3948-b Page 4 of 9 Any combustion flame of insulating material shall extinguish within

22、 70 seconds. 3.8.5 Fluid Resistance (ISO 6722) The fluids and the requirements are specified in Table 6. 3.8.6 Sandpaper Abrasion Resistance (SAE J1128) The sandpaper abrasion resistance shall meet the minimum abrasion requirements in Table 3. 3.8.7 Fogging Test (For Initial Qualification Only) (IEC

23、 540, para 7 (7d) at 100 +/- 2 C) This test is required for wire size of 0.75 mm2. Note: Anti-Fogging is required for all wiring passing through the body shell luggage or passenger compartments. Wiring used exclusively in the engine compartment is excluded. 3.8.8 Durability of Cable Marking 3.8.8.1

24、Procedure Prepare three test samples of approximately 600 mm. The apparatus shall consist of two pieces of felt without dressing, having a minimum wool content of 75 %, and with a packing density of 0.171 to 0.191 g/cm3 (approximate dimensions 50 x 50 x 3 mm) and a vessel containing ISO 1817, No. 1

25、Oil at 90 +/- 2 C. Immerse the test sample in the oil for 48 h with the cable ends emerging approximately 50 mm above the surface of the liquid. Remove the test sample from the oil and allow it to drain at room temperature for approximately 30 minutes. Position the test sample between two pieces of

26、felt and apply a pressure of 10 +/- 1 N while pulling the test sample from between the felt. Visually inspect the cable. Note: This test is required only for marked cables. 3.8.8.2 Requirements The insulation and the color shall show no evidence of peeling or cracking, and the markings shall remain

27、legible. 3.8.9 Hydrolysis Test (For Initial Qualification Only) 3.8.9.1 Procedure ENGINEERING MATERIAL SPECIFICATION WSS-M22P6-A1/A2/A3/A4/A5/A6 WP 3948-b Page 5 of 9 Prepare a test sample with approximate length of 2000 mm. Wind the cable on a mandrel (mandrel diameter per Table 5, Winding Test at

28、low temperature). Lay the windings next to each other. Put the prepared specimen (cable wounded on the mandrel) in the water, and keep the cable ends outside the water. Connect one end of the cable to the positive terminal of a 48 V DC power source, and the water bath to the negative terminal. Allow

29、 the cable to age in water for 21 days (504 h) at 80 C +/- 2 C. The specific volume resistance of the insulation must be measured immediately after immersion and every three days thereafter. The specimen shall be subjected to the Visual Inspection and Withstand Voltage Test after 21 days. 3.8.9.2 Re

30、quirements Specific volume resistivity of the insulation shall be 10e8 Ohm.cm. A visual inspection shall show neither cracks, fractures or other defects. During Withstand Voltage Test, breakdown shall not occur. The conductor shall not show any corrosion (some discoloration of the conductor is accep

31、ted). 3.8.10 Column Strength 3.8.10.1 Procedure Test shall be conducted by the use of a tensile test machine and the test fixture described in Figure 1. Note: This test is for the wire sizes 0.35 and 0.5 mm2. Smaller sizes are applicable only for terminals with insulation displacement. Therefore, co

32、lumn strength test is not required for smaller sizes. Do not bend the wire prior to testing. Prepare twenty-five (25) test samples of 40 mm +/- 0.5 mm long. Insert the test wire in the appropriate cavities of the test fixture. The hole diameter shall not exceed the maximum cable diameter for a speci

33、fic wire size by more than +/- 0.03 mm. Insure ENGINEERING MATERIAL SPECIFICATION WSS-M22P6-A1/A2/A3/A4/A5/A6 WP 3948-b Page 6 of 9 that the fixture and the wire are vertically aligned with each other. Apply a compressive force at the constant speed of 50 +/- 0.5 mm/minute and record the highest for

34、ce attained as the wire is being compressed. This force shall be high than the values specified in the requirements. 3.8.8.2 Requirements Wire Size Min Force 0.35 mm2 15 N 0.5 mm2 15 N 4. SUPPLIERS RESPONSIBILITY All materials supplied to this specification must be equivalent in all characteristics

35、to the material upon which approval was originally granted. Prior to making any change in the properties, composition, construction, ENGINEERING MATERIAL SPECIFICATION WSS-M22P6-A1/A2/A3/A4/A5/A6 WP 3948-b Page 7 of 9 color, processing or labeling of the material originally approved under this speci

36、fication, whether or not such changes affect the materials ability to meet the specification requirements, the Supplier shall notify Purchasing, Toxicology and the affected Materials Engineering activity of the proposed changes and obtain the written approval of the Materials Engineering activity. T

37、est data, test samples and a new code identification are to be submitted with the request. Substance restrictions imposed by law, regulations or Ford, apply to the materials addressed by this document. The restrictions are defined in Engineering Materials Specification WSS-M99P9999-A1. 5. APPROVAL O

38、F MATERIALS Materials defined by this specification must have prior approval by the responsible Materials Engineering activity. Suppliers desiring approval of their materials shall first obtain an expression of interest from the affected Purchasing, Design and Materials Engineering activity. Upon re

39、quest, the Supplier shall submit to the affected Materials Engineering activity a completed copy of their laboratory test reports, signed by a qualified and authorized representative of the test facility, demonstrating full compliance with all the requirements of this specification (test results, no

40、t nominal values), the material designation and code number, and test specimens for Ford evaluation. Fords engineering approval of a material will be based on its performance to this specification and on an assessment of suitability for intended processes and/or applications. Upon approval, the mate

41、rial will be added to the Engineering Material Approved Source List. Table 1 CONDUCTOR ISO Wire Size (mm2) Min No. of Strands Max Conductor Diameter (mm) Conductor Area (mm2) Minimum Conductor Breaking Load (N) Maximum Conductor Resistance mOhm/m at 20 C Min Max Plain Copper Ni Plated Copper Copper

42、Alloy 0.13 7 0.5 0.136 0.145 88.3(Alloy) - - 189 0.22 7 0.7 0.216 0.229 88.3(Alloy) - - 97 0.35 7 0.8 0.34 0.36 58.8 54.4 56.8 0.35* 7 0.8 0.34 0.36 88.3(Alloy) 65 0.5 7 1.0 0.54 0.58 88.3 37.1 38.6 - 0.75 19 1.2 0.78 0.83 137.3 24.7 25.7 - 1 19 1.4 1.18 1.27 - 18.5 19.3 - 1.5 19 17 1.88 2.01 - 12.7

43、 13.2 - Table 2 CABLE DIMENSIONS ISO Wire Size (mm2) Wall Thickness (mm) Cable Diameter (mm) Min Nominal Min Max ENGINEERING MATERIAL SPECIFICATION WSS-M22P6-A1/A2/A3/A4/A5/A6 WP 3948-b Page 8 of 9 0.13 0.12 0.15 0.7 0.85 0.22 0.12 0.15 0.85 0.95 0.35 0.12 0.15 1.0 1.1 0.5 0.12 0.15 1.1 1.25 0.75 0.

44、12 0.15 1.3 1.5 1 0.12 0.15 1.45 1.65 1.5 0.12 0.15 1.7 2.0 Table 3 ABRASION RESISTANCE ISO Wire Size (mm2) Bracket Size Mass (Without Bracket) (Kg) Min Abrasion Resistance (mm) 0.13 A 0.10 150 0.22 A 0.10 200 0.35 A 0.10 250 0.5 A 0.10 300 0.75 A 0.10 350 1 A 0.10 400 1.5 A 0.10 450 Table 4 COLOR C

45、ODING SYSTEM Color Munsell Color Coding Din 40772 or IEC 304 Light Dark Ral Black N2.25 Not Applicable 9005 Blue 4.6PB 3.8/10.2 5.6PB 2.75/9.4 5015 Brown 7.5YR 4/5 7.5YR 3/6 8003 Gray N6.3/ (10GY, 0.2) N5.2/(10GY,0.2) 7000 Green 0.5G 6.25/6.3 0.5G 5.1/7.5 6018 Orange 8.75R 6.0/11.5 8.75R 5.5/13.5 20

46、03 Red 2.5R 4.2/11.2 4.4R 3.4/10.4 3000 Violet 4.4P 3.9/6.7 3.4P 2.8/6.7 4005 White Not Applicable 5Y 9/1 1013 Yellow 8.5Y 8.5/8.3 8Y 8.5/11.2 1021 Table 5 MANDREL DIAMETERS Mandrel Diameter ENGINEERING MATERIAL SPECIFICATION WSS-M22P6-A1/A2/A3/A4/A5/A6 WP 3948-b Page 9 of 9 Cross-sectional area, s

47、mm2 Flexibility at Low Temp. & Short Term Heat Aging mm Long Term Heat Aging mm Fluid Resistance mm Mass Kg Winding Speed s-1 Min Number of Turns S2 0.75 6 2 25 0.5 1 3 0.75 s2 2.5 10 3 25 2.5 1 3 Table 6 FLUID COMPATABILITY Test Fluid Test Temperature (C +/- 3 C) Maximum Outer Diameter Change (%) N

48、ame Referee Fluid Engine Oil ASTM D 471, IRM 902 50 15 Gasoline ISO 1817, Liquid C 23 15 Methanol ASTM D 471, Ref. Fuel K 23 15 Diesel Fluid ASTM D 471, Ref. Fuel F 23 15 Power Steering ASTM D 471, IRM 903 50 30 Auto. Trans. Citgo #33123 50 25 Engine Coolant ASTM D 471, Service Fluid 104 50 15 Battery Acid H2SO4, Specific Gravity = 1.260 +/- 0.005 23 5 Note: The fluid compatibility tests are designed to simulate normal automotive exposure. For severe exposure, other tests may be necessary.