1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions 2010 06 17 ESB-M1L85-A-INACTIVE ESB-M1L85-B N-STATUS No replacement named for either M. Gramlich, NA 2006 11 17 Revised ESB-M1L85-C/D re-activated back to N-Status; Revised 2, Table 1b, Table III and Table IV R. Lord 1967 07 24 Released AW1 #
2、1058 Printed copies are uncontrolled Copyright 2010, Ford Global Technologies, LLC Page 1 of 7 CABLE-LOW TENSION, POLYETHYLENE INACTIVE ESB-M1L85-A INSULATED - BARE CABLE-LOW TENSION, POLYETHYLENE NOT TO BE USED FOR NEW DESIGN ESB-M1L85-B INSULATED (THIN WALL) BARE CABLE-LOW TENSION, POLYETHYLENE NO
3、T TO BE USED FOR NEW DESIGN ESB-M1L85-C INSULATED (EXTRA 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
4、 specifications are stranded flame retardant cross-linked 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. T
5、he ESB-M1L85-D specification was released for the truck 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
6、Shall be specified on engineering drawings and/or released 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 Circ
7、uit description and Color Specification. The color shades 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 2010, Ford Global Technologies,
8、LLC Page 2 of 7 Color Nominal Dark Light Black None 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 Purp
9、le 70135 70164 70134 Gray 70152 70153 70185 White 70003 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 consi
10、st of the following: ESB-M1L85 ESF-M2L1, soft or annealed 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 SPECIFICATI
11、ONESB-M1L85-A/B/C/D ESB-M1L86-A Printed copies are uncontrolled Copyright 2010, 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 a
12、t this low temperature, the cable shall be wrapped around 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 Flam
13、e Test A bunsen burner having a 13 mm inlet, nominal 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
14、position within a partial enclosure which allows a flow 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
15、 s for SAE wire sizes 10 through 20, and 30 s for SAE 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 152
16、4 mm sample cable suspended in air, or lying on a transite 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).
17、After the overload test, cut 457 mm from each end of 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 m
18、m sample of finished cable. The specimen shall then 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
19、a lever advantage of 10. At the moment the insulation 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 a
20、nd rotated clockwise 90. Eight readings shall be obtained 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 app
21、aratus shall be equivalent to that shown in Fig I. ENGINEERING MATERIAL SPECIFICATIONESB-M1L85-A/B/C/D ESB-M1L86-A Printed copies are uncontrolled Copyright 2010, Ford Global Technologies, LLC Page 5 of 7 TABLE Ia CABLE CONSTRUCTION SAE Wire Size No of Wires Nominal strand size Approx. Dia. Of Stran
22、ded Conductor Area of conductor Awg mm mm m222 7 30 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 1
23、4 19 27 0.361 1.91 1.914 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 6 133 27 0.361 5.72 13.397 6 49 23 0.574 4.95 12.347 6 37 21 0.724 5.
24、33 14.909 *The conductor shall consist of 7 rope layed 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 stran
25、ds of #40 Awg bare copper wire. The cross linked polyethylene 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 2010, Ford Global Technologies, LLC
26、Page 6 of 7 TABLE Ib CABLE CONSTRUCTION SAE Wire Size 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
27、 - 14 0.89 0.58 - 3.94 3.18 - 12 0.94 0.66 - 4.57 3.81 - 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
28、45 19 114 25 0.45 18 114 25 0.45 16 165 25 0.45 14 165 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
29、kilograms 22 - - 305 - - A - - 0.23 20 457 305 - A A - 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 -
30、C C - 1.93 1.93 - ENGINEERING MATERIAL SPECIFICATIONESB-M1L85-A/B/C/D ESB-M1L86-A Printed copies are uncontrolled Copyright 2010, 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
