1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions 2006 11 17 Revised ESB-M1L85-C/D re-activated back to N-Status; Revised 2, Table 1b, Table III and Table IV R. Lord2006 09 07 Revised ESB-M1L85-C/D inactivated and removed; no replacement named R. Lord 1967 07 24 Released AW1 # 1058 Printed co
2、pies are uncontrolled Copyright 2006, Ford Global Technologies, LLC Page 1 of 7 CABLE-LOW TENSION, POLYETHYLENE ESB-M1L85-A INSULATED - BARE CABLE-LOW TENSION, POLYETHYLENE ESB-M1L85-B INSULATED (THIN WALL) - BARE CABLE-LOW TENSION, POLYETHYLENE NOT TO BE USED FOR NEW DESIGN ESB-M1L85-C INSULATED (E
3、XTRA THIN WALL) - BARE CABLE, STRANDED (FLEXIBLE), LOW TENSION, NOT TO BE USED FOR NEW DESIGN ESB-M1L85-D POLYETHYLENE INSULATED (THIN WALL) BARE CABLE-LOW TENSION, POLYETHYLENE ESB-M1L86-A INSULATED - TINNED 1. SCOPE The materials defined by these specifications are stranded flame retardant cross-l
4、inked polyethylene or ethylene copolymer-covered low tension cables. The covering shall have a maximum service temperature of 150 C. 2. APPLICATION These specifications were released originally for cables used for automotive electrical harnesses. The ESB-M1L85-D specification was released for the tr
5、uck rear axle brake sensor jumper. 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 WIRE SIZE Shall be specified on engineering drawings and/or re
6、leased according to the SAE wire size numbers appearing in Table Ia. Example #16 gage ESB-M1L85-A. 3.2 COLOR The color of the flame retardant cross-linked polyethylene color shall be specified on the engineering drawing per the ES-D1AB-1274-AA Circuit description and Color Specification. The color s
7、hades shall be within the limits specified below (Reference Numbers per Color Association of the U.S., Inc.). ENGINEERING MATERIAL SPECIFICATIONESB-M1L85-A/B/C/D ESB-M1L86-A Printed copies are uncontrolled Copyright 2006, Ford Global Technologies, LLC Page 2 of 7 Color Nominal Dark Light Black None
8、None None Brown 70107 70108 70106 Tan 70093 70094 70092 Red 70180 70082 70179 Orange 70072 70041 70071 Yellow 70205 70068 70067 Dark Green 70065 70066 70064 Light Green 70062 70063 70061 Dark Blue 70086 70087 70085 Light Blue 70143 70144 70142 Purple 70135 70164 70134 Gray 70152 70153 70185 White 70
9、003 70004 None Pink 70098 70099 70097 3.3 CABLE QUALITY The materials shall meet all of the requirements listed herein and shall be equal to the original approved sample. 3.4 WIRE QUALITY The strands of the conductors prior to stranding shall consist of the following: ESB-M1L85 ESF-M2L1, soft or ann
10、ealed copper round bare wire. ESB-M1L86 ESF-M2L3, soft or annealed copper round tinned wire. 3.5 CABLE CONSTRUCTION See Tables Ia after the bend test, the cable shall be subjected to the dielectric test, para 3.6.3. ENGINEERING MATERIAL SPECIFICATIONESB-M1L85-A/B/C/D ESB-M1L86-A Printed copies are u
11、ncontrolled Copyright 2006, Ford Global Technologies, LLC Page 4 of 7 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/min. After maintaining this temperature for 3 h and while still at this low temperature, the cable shall be wrapped a
12、round the mandrel specified in Table II 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 bunsen burner having a 13 mm inlet, nominal
13、 bore of 19 mm, a length of approximately 102 mm, above the primary inlets, equipped with a wing-top flame spreader having a 1.6 x 51 mm opening fitted to the top of the burner shall be used. A 610 mm sample shall be suspended taut in a horizontal position within a partial enclosure which allows a f
14、low of sufficient air for complete combustion but is free from drafts. The tip of a 51 mm gas flame with an inner cone one-third its height shall than be applied to the center of the suspended cable. The time of application of the flame shall be 15 s for SAE wire sizes 10 through 20, and 30 s for SA
15、E wire size 8. After removal of the bunsen burner flame, the specimen shall not continue to burn for more than 30 s. 3.6.7 Abrasion Resistance As per Table III (SAE J1128) 3.6.8 Electrical Overload Test In an ambient temperature of 24 +/- 3 C a 1524 mm sample cable suspended in air, or lying on a tr
16、ansite table top, shall be subjected to an overload current sufficient to raise the conductor temperature to 204 +/- 2 C and to hold it there for a period of 30 min (thermocouple to be inserted into sample conductor stranding 457 mm from one end). After the overload test, cut 457 mm from each end of
17、 the cable and discard. The remaining 610 mm portion (which was in the center of the original 1524 mm sample) shall then be subjected to dielectric Test, para 3.6.3). 3.6.9 Pinch Test 25 mm of the insulation shall be removed from one end of a 914 mm sample of finished cable. The specimen shall then
18、be placed taut without stretching, on a steel anvil and be subjected to the force of a weighted 3.2 mm diameter rod. Increasing weight shall be applied to the steel rod by means of flowing water or equivalent method at the rate of 1.36 kg/min with a lever advantage of 10. At the moment the insulatio
19、n is pinched through, the 3.2 mm diameter rod will contact the sample conductor, and the test shall stop. The weight of the water in the receptacle shall then be recorded in kilograms. After each reading, the specimen shall be moved forward 51 mm and rotated clockwise 90. Eight readings shall be obt
20、ained for each sample. Obtain an average by calculating the arithmetic mean of all those readings. This average shall define the pinch resistance of the wire under test and shall be no less than the minimum specified in Table IV. The pinch test apparatus shall be equivalent to that shown in Fig I. E
21、NGINEERING MATERIAL SPECIFICATIONESB-M1L85-A/B/C/D ESB-M1L86-A Printed copies are uncontrolled Copyright 2006, Ford Global Technologies, LLC Page 5 of 7 TABLE Ia CABLE CONSTRUCTION SAE Wire Size No of Wires Nominal strand size Approx. Dia. Of Stranded Conductor Area of conductor Awg mm mm m222 7 30
22、0.254 0.76 0.355 20 7 28 0.320 1.02 0.554 *19 105 40 0.079 1.14 0.469 7 36 0.102 - Steel *18 168 40 0.079 1.32 0.823 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 26 28 0.320 1.91 1.914 14 19 27 0.361 1.91 1.914 12 41 28 0.320 2.29 3.013 1
23、2 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 6 133 27 0.361 5.72 13.397 6 49 23 0.574 4.95 12.347 6 37 21 0.724 5.33 14.909 *The conductor shall consist of 7 rope lay
24、ed members; central core around which 6 members are rope layed. The central core member shall consist of 7 strands of #36 Birmingham Wire Gage steel wire plus 9 strands of #40 Awg bare copper wire. The 6 outer members shall each consist of 16 strands of #40 Awg bare copper wire. The cross linked pol
25、yethylene jacket will be extruded directly over the stranding. The cable is not a standard SAE wire size. ENGINEERING MATERIAL SPECIFICATIONESB-M1L85-A/B/C/D ESB-M1L86-A Printed copies are uncontrolled Copyright 2006, Ford Global Technologies, LLC Page 6 of 7 TABLE Ib CABLE CONSTRUCTION SAE Wire Siz
26、e Nominal Insulation Wall Thickness Maximum Diameter of Finished Cable Suffix A B - D C A B - D C mm mm mm mm mm mm 22 - - 0.33 - - 1.52 20 0.74 0.58 - 2.79 2.41 - 19 0.74 0.58 - 2.67 2.41 - 18 0.76 0.58 0.33 3.05 2.54 2.03 16 0.81 0.58 - 3.43 2.92 - 14 0.89 0.58 - 3.94 3.18 - 12 0.94 0.66 - 4.57 3.
27、81 - 10 1.04 0.79 - 5.33 4.70 - 8 1.09 0.94 - 7.75 6.22 - 6 1.40 1.09 - 8.51 7.80 - TABLE II MANDREL SIZES Gage Size High Temperature Test Bend and cold Resistance Test Suspension Weight for High Temperature Test mm mm kg 22 114 25 0.45 20 114 25 0.45 19 114 25 0.45 18 114 25 0.45 16 165 25 0.45 14
28、165 76 0.45 12 165 76 1.36 10 254 76 1.36 8 254 152 1.36 6 254 152 2.72 TABLE III ABRASION RESISTANCE DATA Gauge Size Minimum Resistance Length of Tape Weight Support Bracket Weight Suffix A B - D C A B - D C A B - D C mm mm mm kilograms kilograms kilograms 22 - - 305 - - A - - 0.23 20 457 305 - A A
29、 - 0.45 0.45 - 19 533 406 - A A - 0.45 0.45 - 18 533 406 305 A A A 0.45 0.45 0.23 16 559 457 - A A - 0.45 0.45 - 14 305 457 - B A - 1.36 0.45 - 12 406 406 - B B - 1.36 1.36 - 10 508 457 - B B - 1.36 1.36 - 8 635 559 - B B - 1.36 1.36 - 6 635 635 - C C - 1.93 1.93 - ENGINEERING MATERIAL SPECIFICATION
30、ESB-M1L85-A/B/C/D ESB-M1L86-A Printed copies are uncontrolled Copyright 2006, Ford Global Technologies, LLC Page 7 of 7 TABLE IV PINCH TEST (TYPE SXL CABLE) Minimum Pinch Resistance SAE Wire Size Suffix A Suffix B -D Suffix C kilograms kilograms kilograms 22 - - 2.3 20 5.0 3.6 - *19 5.0 3.6 - 18 7.3 5.4 2.3 16 8.2 6.4 - 14 9.1 7.3 - 12 11.3 8.2 - 10 13.6 9.1 - 8 15.9 10.0 - 6 18.1 13.6 - *Not standard SAE wire size. FIGURE 1 ASSEMBLY SKETCH OF PINCH APPARATUS
