1、 ENGINEERING MATERIAL SPECIFICATION Material Name Specification Number Date Action Revisions 2003 04 25 Revised Para 3.0 inserted; Para 3.5 & 4 deleted 1981 10 07 CAL1-RD588050-7 Metricated and Retyped, Released by BEPE 1964 06 11 Release AS2-465 Printed copies are uncontrolled Page 1 of 4 Copyright
2、 2003, Ford Global Technologies, Inc. CABLE, LOW TENSION - VINYL INSULATED - STRANDED, FLEXIBLE ESA-M1L77-A 1. SCOPE The material defined by this specification is a stranded vinyl covered low tension flexible cable. The vinyl covering shall have a maximum service temperature of 85 C. 2. APPLICATION
3、This specification was released originally for material used for automotive electrical wiring. 3. REQUIREMENTS 3.0 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers and part producers must conform to the Companys Standard Requirements For Production Materials (WSS-M99P1111-A). 3.1 CO
4、LOR The color of the vinyl cover shall be specified on the engineering drawing and/or release by a numerical suffix following the letter suffix of the material desired. The numerical color coding suffixes shall correspond to the following: 0 - Black 5 - Green 1 - Brown 6 - Blue 2 - Red 7 - Violet 3
5、- Orange 8 - Gray 4 - Yellow 9 - White or natural The first color coding numerical suffix shall be the base or body color of the finished cable and the second number shall designate the tracer or other auxiliary marking. 3.2 CABLE CONSTRUCTION See Table I 3.3 WIRE QUALITY The strands of the conducto
6、rs prior to stranding shall consist of ESF-M2L1-A, soft or annealed bare copper wire. ENGINEERING MATERIAL SPECIFICATION ESA-M1L77-A Page 2 of 4 Copyright 2003, Ford Global Technologies, Inc. 3.4 INSULATION QUALITY Shall be a good grade vinyl chloride copolymer which will pass the following test req
7、uirements: The material shall adhere closely to, but strip readily from the conductors, leaving them reasonably clean and in suitable condition for soldering. 3.4.1 Mechanical Properties (ASTM D 412 - Die “A“ 12 in (305 mm)/min speed) Standard laboratory test slabs shall be prepared by compression m
8、olding the thermoplastic material of the same composition and grade as used for the wire insulation. Tensile Strength, min 1900 psi (13.1 MPa) Elongation, min 125% 3.4.2 Dielectric Test A specimen of the cable 24 in (610 mm) long shall be formed into a loop. One in (25 mm) of the insulation shall be
9、 removed from each end of the wire and the ends twisted together. The loop thus formed shall be immersed in water containing 5% salt by weight at 23 +/- 2 C, so that not more than 6 in (152 mm) of each end of the specimen protrudes above the solution. After being immersed for 5 h and while still imm
10、ersed, the specimen shall withstand the application of 1000 V (rms) at 60 Hz frequency between the conductor and the water for 1 min without rupture of the insulation. 3.4.3 High Temperature Resistance One in (25 mm) of the insulation shall be removed from each end of a 24 in (610 mm) sample of the
11、finished cable. The sample shall be suspended around a cylindrical mandrel having a diameter of 6.5 in (165 mm). Each end of the conductor shall have suspended from it a weight of 1 lb (0.45 kg). This condition shall be maintained for 120 h at 120 - 122 C in a circulating air oven. When cool, the we
12、ight shall be removed from the specimen and it shall be taken off the mandrel, bent in the reverse direction around a mandrel of 6 in (152 mm) diameter at a rate not to exceed one complete turn/min and then be subjected to the dielectric test, para 3.4.2. 3.4.4 Oil Resistance A specimen 24 in (610 m
13、m) long shall be immersed to within 1.5 in (38 mm) from the ends in a mixture of equal parts of kerosene and engine lubricating oil at a temperature of 50 +/- 2 C for a period of 20 h. The sample shall then be removed from the solution, examined for deterioration of the insulating compound, and gage
14、d for swelling. ENGINEERING MATERIAL SPECIFICATION ESA-M1L77-A Page 3 of 4 Copyright 2003, Ford Global Technologies, Inc. The outside diameter of the cable insulation shall not increase more than 15%. The sample shall then be bent around a mandrel 6 in (152 mm) in diameter and checked for cracking.
15、After the bend test the cable shall pass the dielectric test, para 3.4.2. 3.4.5 Cold Resistance A straight specimen shall be reduced to a temperature of -40 C at a rate not to exceed 5 C/min. After maintaining this temperature for 3 h and while still at this low temperature, the cable shall be wrapp
16、ed around a mandrel 6 in (152 mm) in diameter for 180 at the uniform rate of one turn in 10 s. The insulation shall be removed for a distance of 1.0 in (25 mm) from each end of the specimen and the specimen subjected to the dielectric test, para 3.4.2. 3.4.6 Flame Test A 24 in (610 mm) specimen shal
17、l be suspended in a vertical position within a partial enclosure which allows a flow of sufficient air for complete combustion but is free from drafts. The tip of a 2 in (50 mm) gas flame with an inner cone one-third its height shall then be applied to the end of the specimen for 15 s. After removal
18、 of the flame the specimen shall not continue to burn for more than 30 s. 3.4.7 Abrasion Resistance As per Table II (SAE J 1128) 3.4.8 Thickness A short length of insulation shall be stripped from the cable, and a thin cross section sliced from it. Measure the wall thickness. Wall Thickness, min 0.0
19、140 in (0.356 mm) Wall Thickness, max 0.0280 in (0.711 mm) ENGINEERING MATERIAL SPECIFICATION ESA-M1L77-A Page 4 of 4 Copyright 2003, Ford Global Technologies, Inc. TABLE I CABLE CONSTRUCTION SAE Wire Size No.of Wires Nominal Strand Size Minimum Dia. of Strand Area of Conductor Maximum Dia. of Finis
20、hed Cable Awg in mm cir mil mm2in mm 20 41 36 0.0049 0.124 980 0.497 0.080 2.03 18 65 36 0.0049 0.124 1560 0.790 0.090 2.29 16 65 34 0.0062 0.157 2420 1.226 0.105 2.67 14 65 32 0.0077 0.196 3850 1.951 0.125 3.18 TABLE II ABRASION RESISTANCE DATA Gage Size Minimum Resistance Length of Tape Weight Support Bracket Weight in mm lb kg 20 12 305 A 1 0.45 18 12 305 A 1 0.45 16 12 305 A 1 0.45 14 6 152 B 3 1.36
