1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions 2003 08 13 Revised Para 3.0 inserted; Para 3.1, 3.2, 3.3, 3.21, 4 deleted 1994 01 06 NC00E10244447020 Revised Table I Resistance L. Mastrofrancesco 1991 12 09 NC00E101404840001 Released L. Mastrofrancesco Printed copies are uncontrolled Copyri
2、ght 2003, Ford Global Technologies, Inc. Page 1 of 5 CABLE, LOW TENSION, CROSSLINKED ETFE INSULATED, WSA-M1L130-A TINNED SINGLE AND MULTIPLE CONDUCTOR 1. SCOPE The materials defined by this specification are either stranded insulated low tension wire, or twisted combinations of low tension wires. Th
3、e combined wires (referred to as “ cables: in this specification) may or may not have an overall jacket. The wire insulation system shall be suitable for continuous operation between temperatures of -65 to 150 C, but capable with intermittent temperatures as high as 300 C without damage. 2. APPLICAT
4、ION The products described by this specification are intended for use in automotive electrical systems and harnesses, especially in areas where mechanical toughness, temperature, fluids, and flex life areas are of concern. 3. REQUIREMENTS 3.0 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material s
5、uppliers and part producers must conform to the Companys Standard Requirements For Production Materials (WSS-M99P1111-A). 3.4 CONDUCTOR 3.4.1 Conductor Material (ASTM B 33, prior to bunching) 3.4.2 Conductor Elongation (ASTM B 33, values per Table 1, prior to insulating) 3.4.3 Conductor Diameter (AS
6、TM D 3032, Section 15 optical method, values per Table 1) 3.4.4 The conductor area may be determined by measuring individual strand diameters and calculating the sum of the individual strand areas. 3.4.5 Conductor Resistance (Table 1) ENGINEERING MATERIAL SPECIFICATIONWSA-M1L130-APrinted copies are
7、uncontrolled Copyright 2003, Ford Global Technologies, Inc. Page 2 of 5 3.5 FINISHED WIRE (Prior to twisting or combining with other wires) 3.5.1 The insulating material shall be a radiation cross-linked ethylene-tetrafluoroethylene (ETFE) extrusion. The surface shall be smooth and even without crac
8、ks, knots, blisters or other faults. 3.5.2 Dimensions (ASTM D 3032, Section 15 and 16) 3.5.3 The color of the finished wires are per the Munsell Color Coding system and shall conform to Table IV. The following method shall be used to evaluate the color of the cables. Comparison must be made by a per
9、son with normal or corrected vision, under cool white fluorescent lighting. The surface being inspected and the tolerance set must be in the same plane. Cable samples must be placed flat, overlapping the color standard. Color tolerance Reference Sets are available from SAE, 400 Commonwealth Drive, W
10、arrendale, PA 15096. 3.6 MULTICONDUCTOR CABLE (Finished Multiconductor) 3.6.1 When the grouped cables require an overall jacket, the jacket material shall be a radiationcrosslinked continuous extrusion of modified polyvinyledene fluoride (PVDF). The jacket surface shall be smooth and without cracks,
11、 knots, blisters or other faults. The grouped cables may be specified as twisted or not twisted in Table III. 3.6.2 Dimensions (ASTM D 3032, Sec. 15 and 16, per Table III) 3.6.3 Tensile and Elongation (ASTM D 3032, Sec. 17 using 25 mm jaw separation and bench marks, and a jaw separation speed of 50
12、mm/minute) 3.6.3.1 Tensile Strength, min 27.6 MPa 3.6.3.2 Elongation, min 200% 3.7 FAULT TESTING OF THE COMPLETE DELIVERY (in process testing) 3.7.1 When pulling the grounded dry cable through the test electrodes connected to the test voltage, there must be no punctures. The test electrodes may cons
13、ist of a coil, a metal tube, metal ball chains or any other type of suitable electrode. 3.7.2 Test Voltage 1.5 kVeff The power supply shall be a transformer delivering a sinusoidal voltage. The electrode length and the frequency of the AC voltage shall be chosen, considering the speed of the cable r
14、unning through the field of the electrode, so that each point of the cable shall be loaded by at least nine voltage cycles. If in place of a sinusoidal voltage unidirectional pulses are applied, there must be 18 pulses on each point of the cable. ENGINEERING MATERIAL SPECIFICATIONWSA-M1L130-APrinted
15、 copies are uncontrolled Copyright 2003, Ford Global Technologies, Inc. Page 3 of 5 3.8 CABLE JACKET HEAT SHOCK (For Multiconductor cables with outer jacket only) A 600 mm specimen of finished cable shall be hung over a horizontal polytetrafluoroethylene coated mandrel and each end loaded with weigh
16、ts as specified in Table 3. The specimen, so prepared, shall be conditioned in an air circulating oven for 1 hour at 225 C. The oven shall be shut off and the specimen allowed to return to 23 +/- C in the oven. When cool, the specimen shall be freed of tension and rewound around the mandrel in its c
17、entral portion for two close turns. No visible cracks are permitted. 3.9 INSULATION RESISTIVITY (ASTM D 3032, Section 6) 3.9.1 Volume Resistivity, min 1.5 x 10.2 ohm/m 3.10 CABLE JACKET COLD BEND (For Multiconductor cables with outer jacket only) Using the mandrel and weight from Table 3, a 1.5 m sp
18、ecimen shall have one end attached to a horizontal mandrel in a cold chamber with the weight on the outer end. After conditioning for 4 hours at -65 C, the specimen shall be wound for its entire length, on the mandrel, while at the low temperature. The mandrel with the wound specimen shall be remove
19、d from the chamber and visually inspected. No visible cracks are permitted. 3.11 RETENTION OF CORE (FLTM BB 101-18) 3.11.1 Specimen Length 150 +/- 5 mm 3.12 HEAT AGING A 600 mm specimen of wire shall be hung over a horizontal polytetrafluoroethylene coated mandrel and each end loaded with weights as
20、 specified in Table 2. The specimen, so prepared, shall be conditioned in an air circulating oven for 168 hours at 200 +/- 3 C. The oven shall be shut off and the specimen allowed to return to 23 +/- 2 C in the oven. When cool, the specimen shall be freed of tension and immersed in saline solution t
21、o within 150 mm of its ends for 15 minutes. After this time, 2500 Vac, 60 Hz, shall be applied between the specimen conductor and the saline solution for a period of 5 minutes. There shall be no dielectric breakdown. 3.13 INSULATION COMPRESSION TEST AT HIGH TEMPERATURE (FLTM BB 101-14) 3.13.1 Specim
22、en Length 100 mm 3.13.2 Test Temperature 80 C 3.14 HEAT SHRINKAGE (FLTM BB 101-15) 3.14.1 Specimen Length 200 mm 3.14.2 Insulation Shrinkage, max 4% ENGINEERING MATERIAL SPECIFICATIONWSA-M1L130-APrinted copies are uncontrolled Copyright 2003, Ford Global Technologies, Inc. Page 4 of 5 3.15 RESISTANC
23、E TO FLAME PROPAGATION (FLTM BB 101-16, Method A except 30 degree wire angle) 3.15.1 Specimen Length 0.5 mm 3.15.2 Burn Rate, max 100 mm/minute 3.15.3 Extinguishing Time 30 s 3.16 OIL RESISTANCE (FLTM BB 101-19, Method A) 3.16.1 Specimen Length 1.2 mm 3.16.2 Insulation Thickness Change, max 5% 3.16.
24、3 Mandrel Diameter 3.2 mm 3.17 FUEL RESISTANCE (FLTM BB 101-19, Method B except immerse for 168 hours) 3.17.1 Specimen Length 1.2 mm 3.17.2 Insulation Thickness Change, max 5% 3.17.3 Mandrel Diameter 12.7 mm 3.18 AUTOMATIC TRANSMISSION FLUID RESISTANCE (FLTM BB 101-19, Method A except use Dexron ATF
25、) 3.18.1 Specimen Length 1.2 mm 3.18.2 Insulation Thickness Change, max 5% 3.18.3 Mandrel Diameter 3.2 mm 3.19 ABRASION RESISTANCE (FLTM BO 101-20) 3.19.1 Specimen Length 750 mm 3.20 FOGGING, INTERIOR GLASS SURFACE (FLTM BO 116-03) Fog Number, min 60 The formation of droplets or coalescence into a c
26、lear film is cause for rejection. ENGINEERING MATERIAL SPECIFICATIONWSA-M1L130-APrinted copies are uncontrolled Copyright 2003, Ford Global Technologies, Inc. Page 5 of 5 TABLE I - CONDUCTOR Size Construction Elongation(*) Conductor Diameter Resistance AWG (# x AWG) min % min (mm) max (mm) max at 20
27、 C Ohms/1000 ft 22 154 x 44 5 0.737 0.838 18.8 (*) Elongation is prior to insulation on bunched conductor but not on individual strands. TABLE II, INDIVIDUAL CABLE Size Wall Thickness Diameter Crosslink Proof Test AWG min (mm) min (mm) max (mm) Mandrel Weight 22 0.127 0.991 1.194 12.7 mm 0.375 # TAB
28、LE III, MULTICONDUCTOR CABLE Size No. Jacket Wall Diameter Heat Shock Cold Bend Conductors Min (mm) Max (mm) Max (mm) Mandrel Weight Mandrel Weight 22 2 0.152 0.203 2.845 76.2 0.375 76.2 3.0 TABLE IV, COLOR CHART Color Low Concentrate High Concentrate Black N2.25 - Blue 4.6PB 3.8/10.2 5.6PB 2.75/9.4 Brown 5YR 6.23/4.0 5YR 5.3/4.6 Gray N6.3/(10GY, 0.2) N5.1/(10GY, 0.2) Green 0.5G 6.25/6.3 0.5G 5.1/7.5 Orange 8.75R 6.0/11.5 8.75R 5.5/13.5 Red 2.5R 4.1/11.2 4.4R 3.4/10.4 Violet 4.4P 3.9/6.7 3.4P 2.8/6.7 White - 5Y 9/1 Yellow 8.4Y 8.5/8.3 8Y 8.5/11.2
