1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions 2003 0812 Revised Para 3.0 inserted; Para 3.1, 3.2, 3.6, 4 deleted 1995 03 31 Activated J.M. Showalter Printed copies are uncontrolled Copyright 2003, Ford Global Technologies, Inc. Page 1 of 6 CABLE, PRIMARY LOW TENSION, 85 C, VINYL WSB-M1L13
2、4-A1 INSULATED-THIN WALL 1. SCOPE The material defined by this specification is a low tension stranded cable, vinyl insulated with a non-coated conductor. The cable is similar to SAE J1128 (General Purpose-Thermoplastic Insulated) but with a reduced insulation wall thickness and an 85 C classificati
3、on. 2. APPLICATION This specification was released originally for material used in automotive electrical harnesses. Note: The assemblers of electrical wire harnesses shall use the bulk wire suppliers as shown in the Ford Motor Company Materials Approved Source List. 3. REQUIREMENTS 3.0 STANDARD REQU
4、IREMENTS FOR PRODUCTION MATERIALS Material suppliers and part producers must conform to the Companys Standard Requirements For Production Materials (WSS-M99P1111-A). 3.3 CONDUCTOR (ASTM B 1/ASTM B 174) 3.3.1 The individual strands of the conductor shall be soft or annealed copper (Hard copper wire m
5、ay be used for wire sizes smaller than SAE wire size 0.5 mm2(No. 20). Annealed copper strand elongation shall conform to ASTM B 174. Hard copper strand elongations shall conform to ASTM B 1. Strand dimensions shall be controlled to yield the cross-sectional area listed for the conductor of the finis
6、hed cable per Table 1. Conductor area shall be determined by measuring individual strand diameters and calculating the sum of the individual strand areas. As an alternate method, conductor area may also be determined in accordance with ASTM B 263. 3.3.2 The strands shall be bunched per ASTM B 174. T
7、he maximum lay length shall be as specified in ASTM B 174, Table 3. Conductor strand count shall comply with Table 1 of this specification. Missing strands are not allowed. 3.3.3 Conductor resistance shall be measured by stripping 30 mm of insulation from each end of a 1050 mm cable (use of a longer
8、 specimen is optional). Solder (optional) 25 mm along each end of the specimen. Condition the specimen for a minimum of 4 hours at 23 C +/- 5 C. Measure the unsoldered length, the ambient temperature, and the resistance of the specimen. Calculate the resistance per meter. Calculate the resistance at
9、 20 C using the temperature correction method outlined in ASTM B 193. The maximum resistance values shall conform to those shown in Table 1. ENGINEERING MATERIAL SPECIFICATIONWSB-M1L134-A1Printed copies are uncontrolled Copyright 2003, Ford Global Technologies, Inc. Page 2 of 6 3.4 INSULATION (SAE J
10、1128) 3.4.1 The color of the vinyl insulation shall be specified on the engineering drawing of the component utilizing this material. Base and stripe color codes shall correspond to SAE J1128. Where striping is specified, the stripe shall be a minimum of 0.3 mm wide, but not more than 15% of the cir
11、cumference of the wire. The stripe shall be of the same material as the vinyl insulation. If the insulation is dyed or painted, all the cable quality tests in section 3.5 except 3.5.1, 3.5.2, 3.5.6 and 3.5.10 must be performed on the finished product. The insulation and the color may show no evidenc
12、e of peeling or cracking and must conform to the color tolerances specified. 3.4.2 The insulating material shall be a polyvinyl chloride (PVC) material, homogeneous in character, and similar to SAE J1128, Type GPT. The material shall adhere closely to, but strip readily from the conductors, leaving
13、them free of insulation and in suitable condition for applying terminals. 3.4.3 Insulation thickness shall comply with the requirements of Table 2. Measure the minimum wall thickness of a 2000 mm specimen with an optical measurement device accurate to +/- 0.01 mm (other devices may be used but the r
14、eferee method will be the optical device). Move the sample approximately 400 mm and repeat the procedure for a total of five readings. The minimum insulation thickness shall comply with the values listed in Table 2. 3.5 CABLE QUALITY (TESTS) (SAE J1128) The Physical Properties, Dielectric, and Cold
15、Bend Tests shall all be conducted in accordance with SAE J1128. Note: The following paragraphs shall be tested in accordance with SAE J1128, but with exceptions to the requirements as indicated. 3.5.1 Cable Diameter Measure the outside diameter of a 2000 mm specimen with an optical measurement devic
16、e accurate to +/- 0.01 mm (other devices may be used but the referee method will be the optical device) by taking a minimum of 2 readings approximately 90 degrees apart. Move the sample approximately 400 mm and repeat the procedure for a total of five cross-sections. The mean of all the readings wil
17、l determine the outside diameter of the cable. The outside diameter will conform to the values listed in Table 2. 3.5.2 Pinch Test (SAE J1128) Values as specified in Table 3 of this document. ENGINEERING MATERIAL SPECIFICATIONWSB-M1L134-A1Printed copies are uncontrolled Copyright 2003, Ford Global T
18、echnologies, Inc. Page 3 of 6 3.5.3 Flame Test A 600 mm. specimen shall be suspended at 45 degrees to the horizontal within a partial enclosure which allows a flow of air sufficient for complete combustion but is free from drafts. The tip of a 100 mm long flame from a 9-10 mm combustion tube shall t
19、hen be applied to the center of the cable at approximately 45 degrees to the horizontal and perpendicular to axis of the wire for 15 seconds; however, the exposure time shall not be greater than the time at which the conductor becomes visible. After removal of the flame, the specimen shall not conti
20、nue to burn for more than 30 seconds. 3.5.4 Heat Shrinkage (FLTM BB 101-15) Use a 200 mm sample for the test. The maximum insulation shrinkage shall not exceed 4%. 3.5.5 Ozone Resistance (for initial qualification only) (SAE J1128) There shall be no splits or cracks. See Table 6 for mandrel sizes an
21、d weights. 3.5.6 Abrasion Resistance (for initial qualification only) (SAE J1128-sandpaper tape) Conduct the test using the bracket sizes and weights specified in Table 3 of this document. Abrasion resistance requirements are specified in Table 4. 3.5.7 Long Term Aging (for initial qualification onl
22、y) Strip 25 mm of insulation from each end of a 600 mm specimen. Condition the specimen for 3000 hours in a circulating air oven at a temperature of 85 C +/- 2 C. Remove the specimen from the oven and allow it to remain at 23 C +/- 5 C for a minimum of 4 hours. After this time perform one of the fol
23、lowing tests: 1) Rotatable mandrel-fix one end of the specimen to the mandrel and attach a weight to the free end of the specimen. Wind at least 1/2 turn, but no more than 3 turns, around the mandrel at a uniform rate of 1 turn in 10 seconds. See Table 4 for weights and mandrel sizes. 2) Stationary
24、mandrel-Wind at least 1/2 turn, but no more than 3 turns, around the mandrel. Subject the specimen to the Dielectric test. There shall be no dielectric breakdown of the insulation. ENGINEERING MATERIAL SPECIFICATIONWSB-M1L134-A1Printed copies are uncontrolled Copyright 2003, Ford Global Technologies
25、, Inc. Page 4 of 6 3.5.8 Fluid Compatibility Remove 25 mm of insulation from each end of a 1000 mm specimen of cable and twist the two ends together. Measure the outside diameter as described in 3.5.1. Immerse one specimen in each of the fluids described in Table 5 for 20 hours. A maximum of 50 mm o
26、f each end of the specimen may protrude above the fluid. Withdraw the specimen and remove any excess fluid. Allow the specimen to remain at 23 C +/- 5 C for approximately four hours. After the elapsed time, measure the outside diameter of the specimen and compute the percent diameter change. Perform
27、 one of the following tests on the specimen: 1) Rotatable mandrel-fix one end of the specimen to the mandrel and attach a weight to the free end of the specimen. Wind at least 1/2 turn, but no more than 3 turns, around the mandrel at a uniform rate of 1 turn in 10 seconds. See Table 4 for weights an
28、d mandrel sizes. 2) Stationary mandrel-wind at least 1/2 turn, but no more than 3 turns, around the mandrel. Subject the specimen to the Dielectric test. There shall be no dielectric breakdown of the insulation. 3.5.9 Fogging (for initial qualification only) (FLTM BO 116-03) Fog number minimum 60 Th
29、e formation of droplets of coalescence into a clear film is cause for rejection. Note: Anti-fogging is required for all wiring passing through the body shell luggage or passenger compartments. Wiring used exclusively in the engine compartment is excluded. 3.5.10 Insulation Fault Test (UL Test Method
30、 1581, Section 900) All finished cable will be subjected to a spark tester with a 2 kV AC test voltage. All spark outs must be removed from the complete delivery. ENGINEERING MATERIAL SPECIFICATIONWSB-M1L134-A1Printed copies are uncontrolled Copyright 2003, Ford Global Technologies, Inc. Page 5 of 6
31、 Table 1 SAE Wire Size Minimum Number of Strands Conductor dia. Nom. Size mm Conductor Area mm2 Minimum Maximum Max Resistance 20 C (mohms/m) 22 7 0.76 0.34 0.36 54.4 20 7 0.97 0.54 0.58 37.1 18 19 1.17 0.78 0.83 24.7 16 19 1.45 1.18 1.27 18.5 14 19 1.80 1.88 2.01 12.7 Note: Conductor areas are base
32、d on SAE J1128 minimums where applicable, with a 7% tolerance. Table 2 SAE Wire Size Minimum Insulation Thickness mm Nominal Insulation Thickness Mm Finished Cable Diameter mm maximum minimum nominal 22 0.20 0.25 1.35 1.19 1.27 20 0.20 0.25 1.55 1.40 1.47 18 0.20 0.25 1.75 1.60 1.68 16 0.20 0.25 2.0
33、3 1.88 1.96 14 0.24 0.30 2.49 2.34 2.41 Table 3 SAE Wire Size No. Bracket Size Weight (with Bracket) Kg Min. Pinch Resistance Kg Minimum Abrasion Resistance mm 22 A 0.23 1.2 250 20 A 0.23 1.5 300 18 A 0.23 1.5 350 16 A 0.23 2.0 400 14 B 0.23 2.0 450 ENGINEERING MATERIAL SPECIFICATIONWSB-M1L134-A1Pri
34、nted copies are uncontrolled Copyright 2003, Ford Global Technologies, Inc. Page 6 of 6 Table 4 Mandrel Diameter (mm) Weight SAE Wire Size A B Kg 22 25 6 0.5 20 75 6 0.5 18 75 6 0.5 16 75 6 0.5 14 150 6 0.5 Legend: A = Physical properties, Long Term Aging, Cold Winding, and Fluid Compatibility. B =
35、Resistance to ozone. Table 5 Test Fluid Test Maximum Outer Temperature Diameter Change Name Referee Fluid (C +/- 3 C) (%) Engine Oil ASTM D 471 IRM 902 50 15 Gasoline ASTM D 471 Ref, Fuel C 25 15 Methanol ASTM D 471 Ref, Fuel K 25 15 Power Steering ASTM D 471 IRM 903 50 30 Auto. Trans. Citgo #33-123
36、 50 25 Engine Coolant ASTM D 471 Service Fluid 104 50 15 Battery Acid H2SO4, Specific Gravity = 1.260 +/- 0.005 25 5 Windshield Washer 40% Methanol + 59.5% Water Solution + 0.5% Surfactant and Blue Dye 25 15 Note: 1) The fluid compatibility tests are designed to simulate normal automotive exposure. For severe exposure, other tests may be necessary. 2) This wire cannot be used where it may come in contact with brake fluid.
