1、 ENGINEERING MATERIAL SPECIFICATION Material Name Specification Number Date Action Changes 2003 05 15 Revised Para 3.0 inserted; Para 3.10, 3.11, 4 deleted 1989 01 23 CHS2-RD253001 Revised 3.10 Added 3.11, 4.0 Updated 1981 12 11 PCR 881510-KPF Released K. Gillis, B. Towle Printed copies are uncontro
2、lled Page 1 of 5 Copyright 2003, Ford Global Technologies, Inc. BATTERY CABLE-FLEXIBLE EST-M1L118-A 1. SCOPE The material defined by this specification is a stranded, insulated, flexible, copper wire, electrical cable. 2. APPLICATION This specification was released originally for battery cables on h
3、eavy duty truck vehicles. 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 The wire size shall conform to the American Wire Gage as desc
4、ribed in ASTM B 258. The nominal solid diameter and corresponding nominal area are as noted in the following table. Size Diameter- mm Area - mm24/0 11.68 136.52 3/0 10.40 108.23 2/0 9.27 85.86 0 8.25 68.11 1 7.35 54.00 2 6.54 42.81 3 5.83 33.95 4 5.19 26.93 3.2 CABLE SIZE The finished cable diameter
5、 shall not exceed that noted in the table of physical and electrical requirements Table I. The cable insulation shall have a minimum wall thickness not less than 70% of the nominal wall thickness listed in Table I. ENGINEERING MATERIAL SPECIFICATION EST-M1L118-A Page 2 of 5 Copyright 2003, Ford Glob
6、al Technologies, Inc. 3.3 COLOR Black, unless otherwise specified on the engineering drawing. 3.4 MARKING The cable shall be marked for identification and coded with colored marking ink. The color used shall be that assigned to a specific cable size. The marking shall occur every 200 mm in 5.56 mm h
7、igh characters with no more than 125 mm between the finish of one marking and the start of another. The specific information to appear on each specific size of cable is listed below. Other sizes are to be determined. 4/0 gage green 3/0 gage yellow 2/0 gage blue 1/0 gage orange 3.5 INSULATION QUALITY
8、 The neoprene or synthetic rubber insulation shall meet all applicable requirements of SAE J1127 type SGR. 3.6 WIRE QUALITY The individual strands of the conductor shall consist of ESF-M2L1-A soft or annealed bare copper wire. 3.7 CABLE CONSTRUCTION The cable shall consist of a number of individual
9、strands that are bundled and layed in rope construction. The overall diameter of the bundles shall be served with a paper, polyester or polyester/aluminum tape to facilitate stripping and to prevent corrosion of the conductors. The serving shall be applied either spiraled or parallel lapped. The num
10、ber of bundles, minimum total strands, AWG size of the individual strand, and the total minimum area of all strands shall be as specified in the table of physical and electrical properties, Table I. 3.8 RESISTIVITY The finished cable shall have a maximum resistance as specified in Table I and measur
11、ed in accordance with ESF-M2L1-A. 3.9 PHYSICAL AND ELECTRICAL PROPERTIES Four samples of cable are required. One sample for each of the high temperature, low temperature, oil absorption, and acid resistance tests. All samples must pass the dielectric resistance test of para 3.9.5 at the completion o
12、f their respective tests. All samples are 610 mm in length with 25 mm of insulation stripped from both ends except for the acid resistance test sample which shall be 1830 mm in length. ENGINEERING MATERIAL SPECIFICATION EST-M1L118-A Page 3 of 5 Copyright 2003, Ford Global Technologies, Inc. 3.9.1 Hi
13、gh Temperature Resistance There shall be no fracture or splitting of the cable insulation visible on inspection. Test Method: Suspend the sample over a 254 mm diameter mandrel with a 4.54 kg weight at each end for 4/0, 3/0 and 2/0 gage cable, and a 2.72 kg weight at each end for 1/0, 1, 2, 3 and 4 g
14、age cable. Soak the sample at 120 +/- 2 C for 120 h in a circulating air oven. Cool to room temperature, remove the weight and bend the sample around the mandrel in a reverse direction at a rate not exceeding one turn per minute until a 180 bend is completed. 3.9.2 Low Temperature Resistance There s
15、hall be no fracture or splitting of the cable insulation visible on inspection. Test Method: Reduce the temperature of a straight sample to -34 C from room temperature at a rate not to exceed 50 C per minute. Soak the sample for 3 h. Then wrap the 4/0, 3/0 and 2/0 gage cable around a 457 mm diameter
16、 mandrel for 180 at a rate of 6 turns per minute. Wrap the 1/0, 1, 2, 3 and 4 gage cable around a 254 mm diameter mandrel for 180 at a rate of 6 turns per minute. 3.9.3 Oil Absorption Resistance The cable diameter shall not increase more than 15% after soaking. There shall be no fracture or splittin
17、g of the cable insulation visible after wrapping. Test Method: Immerse the sample to within 38 mm from the ends into a solution of 50% kerosene and 50% SAE 10W engine oil, and soak the sample for 20 h 50 +/- 3 C. Wrap the sample around a 254 mm diameter mandrel for 180 at a rate of 6 turns per minut
18、e. 3.9.4 Acid Resistance There shall be no deterioration of the cable insulation material or reaction to the conductors visible on inspection. Test Method: An insulated section of cable shall be immersed in an electrolyte solution of sulphuric acid with a specific gravity of 1.330 to 1.380 for a per
19、iod of 6 weeks. The uninsulated conductors at one end of the cable and out of the solution shall be connected to the positive post of a fully charged 12-volt battery. A conductor from the negative battery post will be immersed in the solution. ENGINEERING MATERIAL SPECIFICATION EST-M1L118-A Page 4 o
20、f 5 Copyright 2003, Ford Global Technologies, Inc. 3.9.5 Dielectric Resistance There shall be no rupture of the insulation visible on inspection. Test Method: Join the exposed ends of the sample and immerse the loop to within 152 mm of the ends in a 5 % salt bath (salt content by weight at 26.7 C).
21、Soak the sample for 5 h and then apply 1000V (rms) 60 Hz between the sample conductor and the salt bath for one minute. The power supply must be capable of delivering one amp into a short circuit, if rupture is evaluated visually, or a leakage of 10 milli-amps may be taken to indicate rupture. ENGIN
22、EERING MATERIAL SPECIFICATION EST-M1L118-A Page 5 of 5 Copyright 2003, Ford Global Technologies, Inc. Resistiv. Total Strand Total Awg Max. Nom. Wall At 20 C, Conductor Strand Strands, For Area Area, Size Dia. Thickness max. Bundles AWG min min min. mm mm micro ohms/m mm24/0 22.35 2.85 164 19 30 209
23、1 2112 104.88 4/0 22.35 2.85 164 19 30 2090 2112 104.88 3/0 21.26 2.85 207 19 30 1655 1672 83.03 3/0 21.26 2.29 207 19 30 1653 1672 83.03 2/0 18.42 2.85 263 19 30 1317 1330 66.05 2/0 18.42 2.08 263 19 30 1311 1330 66.05 0 15.24 1.04 331 19 24 256 259 51.97 0 15.24 1.04 331 7 30 1043 1046 51.95 1 14.
24、15 1.52 420 19 25 256 259 41.11 1 14.15 1.40 420 7 30 826 828 41.12 2 12.83 1.42 535 19 26 256 259 32.34 2 12.83 1.42 535 7 30 615 651 32.33 3 12.19 2.03 656 33 30 523 528 26.22 3 12.19 2.03 656 7 30 518 528 26.22 4 10.67 1.17 817 7 25 132 133 21.11 4 10.67 1.17 817 7 25 133 133 21.11 TABLE I The total minimum area must be met regardless of stranding.
