1、 ENGINEERING MATERIAL SPECIFICATION Material Name Specification Number Date Action Revisions 2003 04 24 Revised Para 3.0 inserted; Para 3.9, 3.10, 3.11, 3.12, 3.13, 4 deleted 1991 01 31 DE00 E 00107002086 Revised 3.5 std para added J. Huebner 1963 08 16 CTS4-58846-1 Released Printed copies are uncon
2、trolled Page 1 of 3 Copyright 2003, Ford Global Technologies, Inc. COPPER WIRE, BATTERY CABLE - #1 GAGE ESF-M1L6-A 1. SCOPE The material defined by this specification is a #1 gage stranded, insulated battery cable. 2. APPLICATION This specification was released originally for material used as a batt
3、ery cable on heavy duty installations. 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 CABLE SIZE The finished cable diameter shall not exceed SA
4、E limits for type SGR cable. 3.2 INSULATION COLOR Black, unless otherwise specified on engineering drawing 3.3 CABLE QUALITY Shall meet all of the requirements listed herein and must be equal to the original approved sample. 3.4 WIRE QUALITY Shall consist of bare ESF-M2L1-A, soft or annealed round c
5、opper wire, prior to bunching or stranding. ENGINEERING MATERIAL SPECIFICATION ESF-M1L6-A Page 2 of 3 Copyright 2003, Ford Global Technologies, Inc. 3.5 CABLE CONSTRUCTION Shall consist of a minimum of 252 strands (nominal 259 strands) of #25 gage bare copper wire having a minimum area of 39.07 mm2.
6、 The strands are to be layed in rope construction and served with 0.08 mm minimum paper or polyester film tape with a 12 1/2 % minimum overlap, with no individual group containing more than 20 % of the total strands. 3.6 INSULATION QUALITY The finished cable shall be covered with a good grade of ela
7、stomer which meets SAE type SGR requirements. The insulation must have a 1.52 mm wall nominal thickness. 3.7 RESISTIVITY, FINISHED CABLE, max 443 microohms/m at 20 C 3.8 PHYSICAL AND ELECTRICAL PROPERTIES Three samples of cable are required. One for each of the high temperature, low temperature and
8、oil absorption tests. All samples are subjected to the dielectric breakdown test at the completion of their respective tests. These samples are 0.6 m in length with 25 mm of insulation stripped from both ends. 3.8.1 High Temperature Resistance No fracture or splitting of the insulation Test Method:
9、Suspend sample over a 254 mm mandrel with a 2.72 kg weight at each end. Soak at 121 +/- 2 C for 120 h in a circulating air oven. Cool to 23 +/- 2 C, remove the weight and bend the sample around the mandrel in a reverse direction at a rate not exceeding 1 turn per minute until a 180 bend is completed
10、. 3.8.2 Low Temperature Resistance No fracture or splitting of the insulation Test Method: Reduce temperature of a straight piece of sample to - 34 C at a rate not to exceed 68 C per minute. Hold for 3 h and then wrap around a 254 mm mandrel for 180 at a rate of 1 turn per 10 s. 3.8.3 Oil Absorption
11、 Resistance Cable dia shall not increase more than 15% nor shall the insulation fracture or split Test Method: Immerse sample to within 38 mm from the end into a solution of 50% kerosene and 50% SAE 10W engine oil for 20 h at 49 +/- 2 C. Wrap sample around a 254 mm mandrel for 180 . ENGINEERING MATE
12、RIAL SPECIFICATION ESF-M1L6-A Page 3 of 3 Copyright 2003, Ford Global Technologies, Inc. 3.8.4 Dielectric Resistance No rupture of the insulation Test Method: Join exposed ends of sample and immerse loop to within 150 mm of ends in a 5% salt bath (salt content by weight at 27 C). Soak 5 h and then apply 500 V (RMS) 60 cps (Hz) between sample conductor and salt bath for 1 minute.
