1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions 2010 12 08 Revised Inserted Minimum Diameter of Finished Cable to Table II M. Gramlich, NA 2003 04 28 Revised Para 3.0 inserted; Para 3.6, 3.7, 3.8, 3.9, 3.10, 4 deleted 1973 12 14 AC4-39 Released (Was XF-M1LX13) Printed copies are uncontroll
2、ed Copyright 2010, Ford Global Technologies, Inc. Page 1 of 5 CABLE, BATTERY, CROSS LINKED POLYETHYLENE JACKET ESF-M1L92-A CABLE, BATTERY, CROSS LINKED POLYETHYLENE JACKET ESF-M1L92-A2 1. SCOPE The materials defined by this specification are stranded, flame retardant cross-linked polyethylene covere
3、d low tension cables, which shall have a maximum continuous service temperature of 125 C. 2. APPLICATION This specification was released originally for material used for higher temperature battery cables. 3. REQUIREMENTS Shall conform to SAE J1127 except as follows: 3.0 STANDARD REQUIREMENTS FOR PRO
4、DUCTION MATERIALS Material suppliers and part producers must conform to the Companys Standard Requirements For Production Materials (WSS-M99P1111-A). 3.1 WIRE SIZE The wire size shall be specified on engineering drawings and/or releases according to the SAE wire size numbers appearing in Table I. Ex
5、ample: #4 gage ESF-M1L92-A 3.2 CABLE QUALITY The materials shall meet all of the requirements listed herein and shall be equal to the original approved sample. 3.3 WIRE QUALITY The strands of the conductors prior to stranding shall consist of ESF-M2L1-A, soft or annealed bare copper wire. 3.4 CABLE
6、CONSTRUCTION See Tables I and II ENGINEERING MATERIAL SPECIFICATION ESF-M1L92-A/A2 Printed copies are uncontrolled Copyright 2010, Ford Global Technologies, Inc. Page 2 of 5 3.5 INSULATION QUALITY Shall be a good grade of flame retardant cross-linked polyethylene which will pass the following test r
7、equirements: Shall adhere closely to, but strip readily from, the conductors leaving them reasonably clean and in suitable condition for soldering. Insulation thickness shall be in accordance with Table II for the various wire sizes and shall be determined by measuring the diameter over the insulati
8、on, then removing the insulation and measuring the diameter of the conductor. Half of the difference of the two measurements shall be considered as the average wall thickness. For any cross section of a test specimen, the minimum wall thickness shall not be less than 50% of the maximum wall thicknes
9、s. 3.5.1 Mechanical Properties A test specimen of the flame retardant cross-linked polyethylene insulation prepared as in the SAE J200 section on sampling, shall be used. The dumbbell cut sample shall have marks placed upon it 60 mm apart. The sample shall then be stretched at the rate of 300 mm/min
10、ute. 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. The physical properties shall be as follows: Tensile Strength,
11、min 10.4 MPa Elongation, min 200% 3.5.2 High Temperature Resistance One test specimen 25 mm long of the insulation shall be removed from each end of a 610 mm sample of the finished cable. The sample shall be suspended around a cylindrical mandrel having a diameter specified in Table III. Each end of
12、 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 maintained at a temperature of 177 +/- 3 C. When cool, the weight shall be removed from the specimen and it shall be taken off the mandrel, bent in
13、 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 subjected to the dielectric test, para 3.5.3. 3.5.3 Dielectric Test A specimen of the cable 610 mm long shall be formed into a loop. One test
14、specimen 25 mm long of the insulation shall be 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 152 mm each end of the specimen protrudes above the solution. After being
15、 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 insulation. ENGINEERING MATERIAL SPECIFICATION ESF-M1L92-A/A2 Printed copies are uncontrolled Copyright 2010,
16、Ford Global Technologies, Inc. Page 3 of 5 3.5.4 Oil Absorption Test A specimen 610 mm long shall be immersed to within 38 mm from the ends of a mixture of equal parts of mineral spirits hydrocarbon thinner and SAE 20W20 heavy duty lubricating oil at a temperature of 48 - 50 C for a period of 20 h.
17、The sample shall then be removed from the solution, 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;
18、 after the bend test, the cable shall be subjected to the dielectric test, para 3.5.3. 3.5.5 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 sh
19、all be wrapped around the mandrel specified 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 3.5.3. 3.5.6 Flame Test A bunsen burner having a 13
20、mm inlet, a nominal bore of 19 mm, a length of approximately 100 mm, equipped with a wingtop flame spreader having a 1.5 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 flow of s
21、ufficient 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 then be applied to the center of the suspended cable. The time of application of the flame shall be 15 s*. After removal of the bunsen burner flame, the specimen
22、shall not continue to burn for more than 30 s. *For SAE wire sizes 10 through 20, and 30 s for SAE wire size 8 and larger. 3.5.7 Abrasion Resistance As per Table IV (SAE J 1128) 3.5.8 Electrical Overload Test A test specimen 1524 mm long shall be subjected to an overload current sufficient to raise
23、the temperature of the conductor to 205 +/- 2 C as determined by a thermocouple implanted in the wire for a period of 30 minutes in a draft free enclosure. After the overload test, cut 457 mm from each end of the specimen and discard. The remaining 610 mm specimen (which was at the center of the ori
24、ginal 1524 mm specimen) shall then be subjected to the dielectric test, para 3.5.3. 3.5.9 Ozone Resistance: (ESF-M1L92-A2 Only) 300 mm (12 inch) sample of finished cable shall be wound a minimum of 180 around the mandrel specified in Table III at a uniform rate of one turn in 10 seconds and secured.
25、 The assembly shall then be conditioned for 192 hours at 65 +/- 3 C in an atmosphere containing 100 +/- 5 pphm of ozone. A visual inspection shall reveal no cracks or splits. ENGINEERING MATERIAL SPECIFICATION ESF-M1L92-A/A2 Printed copies are uncontrolled Copyright 2010, Ford Global Technologies, I
26、nc. Page 4 of 5 3.5.10 Acid Resistance Test: (ESF-M1L92-A2 Only) A sample of cable approximately 18 inches long shall be formed in a loop. The cable loop shall be placed in a sealed container approximately half full of sulfuric acid (S.G.: 1.3 +/- 0.05). The ends of cable may protrude through the to
27、p of the container to prevent acid attack of copper at the sample ends. The container shall be placed in an oven at a temperature of 100 C. After 21 days, the container shall be removed from the oven and allowed to stay at room temperature for an additional seven days. The sample shall then be remov
28、ed from the acid, carefully dried and the cable diameter measured. Change of diameter: Max: +/- 15% ENGINEERING MATERIAL SPECIFICATION ESF-M1L92-A/A2 Printed copies are uncontrolled Copyright 2010, Ford Global Technologies, Inc. Page 5 of 5 TABLE I - CABLE CONSTRUCTION SAE No. Wire of Area of Resist
29、ivity Size Wire AWG Conductor at 20 C, max Construction cir mil mm2 ohms/ft ohms/m 8 103 28 15105 7.654 0.000652 0.00214 Bunched 6 48 23 23379 11.846 0.000430 0.00141 Bunched 4 133 25 40796 20.671 0.000266 0.00087 7 x 19 or Bunched 2 203 25 62269 31.550 0.000168 0.00045 7 x 29 or Bunched 2 (optional
30、) 259 26 62259 31.550 0.000168 0.00045 7 x 37 or Bunched TABLE II - INSULATION SAE Nominal Insulation Minimum Diameter Maximum Diameter Wire Size Wall Thickness of Finished Cable of Finished Cable in mm in mm in mm 8 0.043 1.09 0.230 5.842 0.245 6.25 6 0.046 1.17 0.266 6.756 0.296 7.52 4 0.046 1.17
31、0.325 8.255 0.360 9.14 2 0.046 1.17 0.412 10.465 0.430 10.92 TABLE III - MANDREL SIZES Gage High Temperature Bend and Cold Suspension Weight for Size Test Resistance Test High Temperature Test in mm in mm lb kg 8 10 254 6 152 6 2.72 6 10 254 6 152 6 2.72 4 10 254 6 152 6 2.72 2 - - 10 254 - - TABLE IV - ABRASION RESISTANCE DATA Gage Minimum Resistance Weight Support Size Length of Tape Bracket Weight In mm lb kg 8 39 990 B 3 1.36 6 39 990 B 4.25 1.93 4 39 990 B 4.25 1.93 2 No abrasion reqt (SAE J1127) - - -
