1、 ENGINEERING MATERIAL SPECIFICATION Material Name Specification Number Date Action Revisions 2003 04 25 Revised Para 3.0 inserted; Para 3.8, 3.9, 3.10, 3.11, 3.12, 4 deleted 1993 08 13 NB00I10043054277 Released J.M. Showalter Printed copies are uncontrolled Page 1 of 7 Copyright 2003, Ford Global Te
2、chnologies, Inc. CABLE, LOW TENSION, VINYL INSULATED ( 85 C), BARE ESB-M1L56-A2 CABLE, LOW TENSION, VINYL INSULATED ( 85 C), TINNED ESB-M1L57-A2 1. SCOPE The materials defined by these specifications are stranded vinyl covered low tension cables. The vinyl covering shall be 85 C classification. 2. A
3、PPLICATION These specifications were released originally for material used for automotive electrical harnesses. 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-M9
4、9P1111-A). 3.1 WIRE SIZE Shall be specified on the engineering drawing and/or release according to the SAE wire size numbers appearing in Table I. Example: # 16 gage ESB-M1L56-A2 3.2 COLOR The color of the vinyl cover shall be specified on the engineering drawing and/or release by a numerical suffix
5、 following the letter suffix of the materials desired. The numerical color coding suffixes shall correspond to the following: 0 Black 5 - Green 1 - Brown 6 - Blue 2 - Red 7 - Violet 3 - Orange 8 - Gray 4 - Yellow 9 - White or natural Example: #16 gage ESB-M1L56-A2 shall designate a stranded 16 gage,
6、 brown vinyl covered, soft or annealed bare copper conductor, corresponding to the requirements of this specification. ENGINEERING MATERIAL SPECIFICATION ESB-M1L56-A2 ESB-M1L57-A2 Page 2 of 7 Copyright 2003, Ford Global Technologies, Inc. The first color coding numerical suffix shall be the base or
7、body color of the finished cable and the second number shall designate the tracer or other auxiliary marking. 3.3 CABLE QUALITY Shall meet all of the requirements listed herein and must be equal to the original approved purchase sample. ESB-M1L56-A2 similar to M-1L17-A ESB-M1L57-A2 similar to M-1L17
8、B 3.4 WIRE QUALITY The strands of the conductors prior to stranding shall consist of the following grades of wire: ESB-M1L56-A2: ESF-M2L1-A, soft or annealed bare copper wire ESB-M1L57-A2: ESF-M2L3-A, soft or annealed tinned copper wire 3.5 CABLE CONSTRUCTION See Tables I & II The cross sectional a
9、rea of stranded conductors shall not be less that 98% of the values specified in Table I. 3.6 INSULATION QUALITY The insulating material shall be a good grade vinyl chloride copolymer which will pass the following test requirements: The material shall adhere closely to, but strip readily from the co
10、nductors, leaving them reasonably clean and in suitable condition for soldering. Insulation thickness shall be in accordance with Table II for various wire sizes and shall be determined by measuring the diameter over the insulation, then removing the insulation and measuring the diameter of the cond
11、uctor. Half of the difference of the two measurements shall be considered as the wall thickness. 3.6.2 Mechanical Properties A test specimen of the thermoplastic insulation prepared as in the SAE J200 section on sampling shall be used. The dumbbell cut sample shall have marks placed upon it 50 mm ap
12、art. The sample shall then be stretched at the rate of 305 mm/minute. The tensile strength shall be calculated upon the original cross section of the test specimen before stretching. Testing shall be conducted at 23 +/- 2 C. Care should be exercised in cutting samples to obtain uniform cross section
13、 The properties shall be as follows: Tensile Strength, min 15.9 Mpa Elongation, min 125% ENGINEERING MATERIAL SPECIFICATION ESB-M1L56-A2 ESB-M1L57-A2 Page 3 of 7 Copyright 2003, Ford Global Technologies, Inc. 3.6.2 High Temperature Resistance Remove 25 mm of insulation from each end of a 610 mm sam
14、ple of the finished cable. The sample shall be suspended around a cylindrical mandrel having a diameter specified in Table III. Each end of the conductor shall have suspended from it, the weight shown in Table III. This condition shall be maintained for 120 h in a mechanical convection oven maintain
15、ed at a temperature of 120 +/- 2 C. When cool, the weight shall be removed from the specimen and it shall be taken off the mandrel, bent in the reverse direction around a mandrel of the diameter specified for the bend test in Table III at a rate not to exceed one complete turn/minute and then be sub
16、jected to the dielectric test, para 3.6.3. 3.6.3 Dielectric Test A specimen of the cable 610 mm long shall be formed into a loop. Remove 25 mm of insulation from each end of the wire and twist the ends together. The loop thus formed shall be immersed in water containing 5% salt by weight at 23 +/- 2
17、 C, so that not more than 152 mm of each end of the specimen protrudes above the solution. After being immersed for 5 h and while still immersed, the specimen shall withstand the application of 1000 volts (rms) at 60 Hz between the conductor and the water for 1 minute without rupture of the insulati
18、on. 3.6.4 Oil Absorption Test A specimen 610 mm long shall be immersed to within 38 mm from the ends in a mixture of equal parts of M14J167 hydrocarbon thinner and ESE-M2C36 heavy duty lubricating oil at a temperature of 48 - 50 C for a period of 20 h. The sample shall then be removed from the solut
19、ion, examined for deterioration of the insulation compound and gaged for swelling. The outside diameter of the insulation of the cable shall not increase more than 15%. The sample shall then be bent around a mandrel (Table III) and checked for cracking. After the bend test, the cable shall be subjec
20、ted to the dielectric test, para 3.6.3. 3.6.5 Cold Bend Test A straight specimen shall be reduced to a temperature of - 40 C at a rate not to exceed 50 C /minute. After maintaining this temperature for 3 h and while still at this low temperature, the cable shall be wrapped around the mandrel specifi
21、ed in Table III for 180 at the uniform rate of one turn in 10 s. The insulation shall be removed for a distance of 25 mm from each end of the specimen and the specimen subjected to the dielectric test, para 3.6.3. 3.6.6 Flame Test A 610 mm specimen shall be suspended in a vertical position within a
22、partial enclosure which allows a flow of sufficient air for complete combustion but is free from drafts. The tip of a 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 of the flame the specimen shall not continue to burn
23、for more than 30s. ENGINEERING MATERIAL SPECIFICATION ESB-M1L56-A2 ESB-M1L57-A2 Page 4 of 7 Copyright 2003, Ford Global Technologies, Inc. 3.6.7 Abrasion Resistance As per Table IV (SAE J 1128) 3.6.8 Non Staining The insulation shall not stain trim materials which it may contact in assembly. There s
24、hall be no evidence of stain on the face side of trim material when tested as follows: Test Method: Place a 150 mm length of insulated wire in intimate contact with the back of the trim material with which it may come in contact and expose for 7 days in a fluorescent sunlamp cabinet per FLTM BV 107-
25、02. 3.7 FOGGING , INTERIOR GLASS SURFACE, (SAE J1756, 3 h at 100 C heating, 21 C cooling plate, post test conditioning 1 h and 16 h) Fog Number, min 60 Formation of clear film, droplets or crystals is cause for rejection. Note: Anti-fogging is required for all wiring passing through the body shell l
26、uggage or passenger compartments. Wiring used exclusively in the engine compartment is excluded. ENGINEERING MATERIAL SPECIFICATION ESB-M1L56-A2 ESB-M1L57-A2 Page 5 of 7 Copyright 2003, Ford Global Technologies, Inc. TABLE I CABLE CONSTRUCTION SAE Wire Sizes No. of Wires Nominal Strand Size Approx.
27、Dia of Stranded Conductor Area of Conductor Awg mm mm mm222 7 30 0.254 0.76 0.355 20 7 28 0.320 1.02 0.554 18 16 30 0.254 1.27 0.795 18 10 28 0.320 1.27 0.804 16 19 29 0.287 1.52 1.186 16 16 28 0.320 1.52 1.186 14 41 30 0.254 1.91 1.914 14 26 28 0.320 1.91 1.914 14 19 27 0.361 1.91 1.914 12 65 30 0.
28、254 2.29 3.013 12 41 28 0.320 2.29 3.013 12 19 25 0.455 2.29 3.013 10 65 28 0.320 2.92 4.785 10 49 27 0.361 2.92 4.785 10 19 23 0.574 2.92 4.785 8 103 28 0.320 4.06 7.654 8 49 25 0.455 4.06 7.654 8 19 21 0.724 4.06 7.654 6 172 28 0.320 5.33 12.340 6 133 27 0.361 5.33 12.340 6 37 21 0.724 5.33 12.340
29、 4 133 25 0.455 6.99 19.472 4 61 22 0.643 6.99 19.472 4 49 21 0724 6.99 19.472 ENGINEERING MATERIAL SPECIFICATION ESB-M1L56-A2 ESB-M1L57-A2 Page 6 of 7 Copyright 2003, Ford Global Technologies, Inc. TABLE II INSULATION SAE Wire Sizes Nominal Insulation Wall Thickness Maximum Diameter of Finished Cab
30、le mm mm 22 0.58 2.10 20 0.58 2.41 18 0.58 2.54 16 0.58 2.92 14 0.58 3.18 12 0.66 3.81 10 0.79 4.70 8 0.94 6.22 6 1.09 7.75 4 1.12 9.53 TABLE III MANDREL SIZES Gage Size High Temperature Test Bend and cold Resistance Test Suspension Weight for High Temperature Test mm mm kg 22 114 76 0.45 20 114 76
31、0.45 18 114 76 0.45 16 165 76 0.454 14 165 152 0.45 12 165 152 0.45 10 254 152 1.36 8 254 152 1.36 6 254 254 2.72 4 254 254 2.72 ENGINEERING MATERIAL SPECIFICATION ESB-M1L56-A2 ESB-M1L57-A2 Page 7 of 7 Copyright 2003, Ford Global Technologies, Inc. TABLE IV ABRASION RESISTANCE DATA Gage Size Minimum Resistance Length of tape Weight Support Bracket Weight mm kg 22 457 A 0.45 20 457 A 0.45 18 533 A 0.45 16 559 A 0.45 14 305 B 1.36 12 406 B 1.36 10 508 B 1.36 8 635 B 1.36 6 635 C 1.93 4 762 C 1.93
