1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions 2003 08 18 Revised Para 3.0 inserted; Para 3.1, 3.20, 3.21, 3.22, 4 deleted 1997 06 05 Revised Rev. Title, 3.8-11,Table 2c , Del.3.5;Upd. P.Selucky 1990 06 11 EE00I10063626003 Released MD/PL-10 U. /Schwarz Printed copies are uncontrolled Copyr
2、ight 2003, Ford Global Technologies, Inc. Page 1 of 9 CABLE, LOW TENSION, VINYL INSULATED, 105 C, WSK-M1L124-A THIN WALL, BARE CABLE, LOW TENSION, VINYL INSULATED, 90 C, WSK-M1L124-B STANDARD WALL, BARE CABLE, LOW TENSION, VINYL INSULATED, 105 C, WSK-M1L125-A THIN WALL, TINNED 1. SCOPE The materials
3、 defined by these specifications are low tension stranded cables, vinyl-insulated conductors. The cables are similar to ISO 6722 with a standard and thin wall insulation thickness. 2. APPLICATION These specifications were released originally for materials used in automotive electrical harnesses. Not
4、e: The assemblers of electrical wire harnesses shall use the bulk wire suppliers as shown in the Ford Motor Company Approved Source List. 3. REQUIREMENTS 3.0 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers and part producers must conform to the Companys Standard Requirements For Pr
5、oduction Materials (WSS-M99P1111-A). 3.2 CABLE 3.2.1 Specimen Length 1.2 m 3.2.2 The maximum outside diameter shall be determined by taking measurements at three points along the conductor length separated by at least 100 mm and recording the greatest overall diameter at each point. No single value
6、shall exceed the maximum overall diameter as specified in Tables 2a, 2b, and 2c. 3.3 CONDUCTOR 3.3.1 The conductor of all cable classes shall consist of bunched or stranded soft annealed copper wires. 3.3.2 Specimen Length 1.2 m 3.3.3 Three sections 10 mm long and separated by at least 400 mm shall
7、be cut from the specimen. Carefully remove the conductor without deformation of the insulation. ENGINEERING MATERIAL SPECIFICATIONWSK-M1L124-AWSK-M1L124-BWSK-M1L125-APrinted copies are uncontrolled Copyright 2003, Ford Global Technologies, Inc. Page 2 of 9 3.3.4 The conductor diameter shall be deter
8、mined by measuring the inside diameter of the insulation taken at three points separated by at least 300 mm and recording the maximum inside diameter at each point. The measurements shall be made with an optical device accurate to at least 0.01 mm. No value shall exceed the maximum diameter of the c
9、onductor specified in Tables 2a, 2b, and 2c. 3.3.5 The conductor area may be determined by measuring individual strand diameters and calculating the sums of the individual strand areas. As an alternate method, conductor area may also be determined in accordance with FLTM BB 105-01 or by measuring th
10、e resistance in accordance with Tables 1 and 2c. 3.3.6 The strands shall be bunched and the maximum lay length shall be a maximum of 50 times the conductor diameter. Minimum number of wires shall comply with Tables 1 and 2c. Maximum variation between individual strand diameters must not exceed 10% p
11、er the following: Variation = max strand diameter - min strand diameter min strand diameter Missing strands are not allowed. 3.3.7 Elongation (ASTM B 3, prior to bunching) for d =/- 0.287 mm e 15% for d 0.287 mm e 20% where: d = individual strand diameter e = elongation of individual strand. 3.3.8 R
12、esistivity, max (ASTM B 193, at 20 C) Bare 1.7094 /cm Tinned 1.7593 /cm 3.4 INSULATION 3.4.1 The insulating material shall be polyvinyl chloride (PVC) material, homogeneous in character. The surface shall be smooth and even without cracks, knots, blisters, or other faults. ENGINEERING MATERIAL SPECI
13、FICATIONWSK-M1L124-AWSK-M1L124-BWSK-M1L125-APrinted copies are uncontrolled Copyright 2003, Ford Global Technologies, Inc. Page 3 of 9 3.4.2 The color of the cables are per the Munsell Color Coding System and shall conform to Table 3. The following method shall be used to evaluate the color of the c
14、ables. Comparison must be made by a person 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 availa
15、ble from SAE, 400 Commonwealth Drive, Warrendale, PA 15096. As an alternative, the color of the cables can be per the DIN 47002 or IEC 304 and shall conform to Table 4. 3.4.3 The minimum insulation thickness shall be determined by taking measurements at three points separated by at least 100 mm and
16、recording the minimum insulation thickness at each point. The thickness shall be measured with an optical device accurate to at least 0.01 mm. No single value shall be lower than the minimum insulation thickness specified in Tables 2a, 2b, and 2c. 3.5 FAULT TESTING OF THE COMPLETE DELIVERY (in proce
17、ss testing) 3.5.1 When pulling the grounded dry cable through the test electrodes connected to the test voltage, there must be no punctures. The test electrodes may consist of a coil, a metal tube, metal ball chains or any other type of suitable electrode. 3.5.2 Test Voltage For wires =/- 0.5 mm23 k
18、Veff For wires 0.5 mm25 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 cable running through the field of the electrode, so that each point of the cable shall be loaded
19、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. 3.6 DURATION TEST VOLTAGE AND BREAKDOWN VOLTAGE (FLTM BB 101-12, The cable must not be punctured.) 3.6.1 Specimen Length 1.2 m 3.7 INSULATION RE
20、SISTIVITY (FLTM BB 101-13) 3.7.1 Specimen Length 5 m 3.7.2 Volume Resistivity, min 2 megaohm/m 3.8 INSULATION COMPRESSION TEST AT HIGH TEMPERATURE (FLTM BB 101-14) 3.8.1 Specimen Length 100 mm ENGINEERING MATERIAL SPECIFICATIONWSK-M1L124-AWSK-M1L124-BWSK-M1L125-APrinted copies are uncontrolled Copyr
21、ight 2003, Ford Global Technologies, Inc. Page 4 of 9 3.8.2 Test Temperature Standard Wall 70 C Thin Wall 80 C 3.9 HEAT AGING TEST (ISO 188/ASTM D 573, 3000 h at 105 C) 3.9.1 Tensile Strength, min 11 MPa 3.9.2 Mandrel Wrap Test According to ISO 6722/1 3.10 HEAT AGING TEST (ISO 188/ASTM D 573, 48 h a
22、t 120 +/- 2 C) 3.10.1 Tensile Strength, min 11 MPa 3.10.2 Mandrel Wrap Test According to ISO 6722/1 3.11 HEAT SHRINKAGE (FLTM BB 101-15) 3.11.1 Specimen Length 200 MPa 3.11.2 Insulation Shrinkage, max 4% 3.12 RESISTANCE TO FLAME PROPAGATION (FLTM BB 101-16, Method A) 3.12.1 Specimen Length 0.5 m 3.1
23、2.2 Burn Rate, max 100 mm/minute 3.12.3 Extinguishing Time 30 s 3.13 FLEXIBILITY AT LOW TEMPERATURE 3.13.1 Wire Sizes Less Than 10 mm2(FLTM BB 101-17, Method A, at - 40 +/- 2 C) 3.13.1.1 Specimen Length 1.2 m 3.13.1.2 The insulation must not show puncture, crack or break. The conductor must not prot
24、rude from the insulation sheath and not be pushed out. 3.13.1.3 Perform Voltage Breakdown Test (perform per para 3.7) ENGINEERING MATERIAL SPECIFICATIONWSK-M1L124-AWSK-M1L124-BWSK-M1L125-APrinted copies are uncontrolled Copyright 2003, Ford Global Technologies, Inc. Page 5 of 9 3.13.2 Wire Size 10 m
25、m2and larger, (FLTM BB 101-17, Method B) 3.13.2.1 Specimen Length 1.2 m 3.13.2.2 The insulation must not show puncture, crack or break. The conductor must not protrude from the insulation sheath and not be pushed out. 3.13.2.3 Perform Voltage Breakdown Test (Perform per para 3.7) 3.14 RETENTION OF C
26、ORE (FLTM BB 101-18) 3.14.1 Specimen Length 150 +/- 5 mm Applicable to cables up to and including 6.0 mm23.15 OIL RESISTANCE (FLTM BB 101-19, Method A) 3.15.1 Specimen Length 1.2 m 3.15.2 Insulation Thickness Change, max +/- 4% 3.15.3 Perform Voltage Breakdown Test (Perform per para 3.7) 3.16 FUEL R
27、ESISTANCE (FLTM BB 101-19, Method B and C) 3.16.1 Specimen Length 1.2 m 3.16.2 Insulation Thickness Change, max +/- 8% 3.16.3 Perform Voltage Breakdown Test (perform per para 3.7) 3.17 ABRASION RESISTANCE (FLTM BB 101-20) 3.17.1 Specimen Length 750 mm 3.18 THERMAL STABILITY OF THE INSULATION 3.18.1
28、pH 5 - 3 Test Method: Section 50 mm length of insulation into very small pieces. Place them in a one end sealed glass tube (100 mm long, 5 mm diameter with a wall thickness of 0.5 - 0.75 mm). Fill to a height not exceeding 30 mm. Suspend a strip of dry pH indicating paper of a length of 15 mm, folde
29、d longitudinally, approximately 10 mm into the glass tube. Insert the glass tube 60 mm deep into a container which is heated to a temperature of 200 +/- 2 C. After 30 minutes observe the color of the indicating paper. ENGINEERING MATERIAL SPECIFICATIONWSK-M1L124-AWSK-M1L124-BWSK-M1L125-APrinted copi
30、es are uncontrolled Copyright 2003, Ford Global Technologies, Inc. Page 6 of 9 3.19 FOGGING (SAE J1756, 3 h at 100 C heating, 21 C cooling plate, post test conditioning 1 h and 16 h) Fog Number, min 60 IEC 540 Para 7: Loss of Mass, max 1 mg/cm2Formation of clear film, droplets or crystals is cause f
31、or 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. ENGINEERING MATERIAL SPECIFICATIONWSK-M1L124-AWSK-M1L124-BWSK-M1L125-APrinted copies are uncontrolled Copyright
32、 2003, Ford Global Technologies, Inc. Page 7 of 9 Table 1 CABLE CONSTRUCTION Wire Min Max Min Max Size Conductor Conductor Strand Resistance Area Area Count per Unit Lay Length Length (mm2) (mm2) (mm2) (milliohms/m) (mm) 0.22 0.202 0.214 7 79.7 84.8 25 0.35 0.329 0.350 7, 12 48.9 52.0 25 0.5 0.461 0
33、.490 19 34.9 37.1 45 0.75 0.692 0.737 19, 24 23.2 24.7 45 1.0 0.925 0.982 32, 37 17.4 18.5 45 1.5 1.345 1.436 30, 37 11.9 12.7 45 2.5 2.25 2.39 37, 50 7.14 7.60 60 4.0 3.64 3.87 /= 56 4.42 4.70 65 6.0 5.52 5.87 /= 84 2.91 3.10 85 10.0 9.40 10.00 /= 75 1.71 1.82 110 16.0 14.74 15.68 /= 120 1.09 1.16
34、135 Table 2a INSULATION CONSTRUCTION WSK-M1L124-B (Standard Wall) Wire Min Max Min Max Approximate Size Thickness of Diameter of Overall Overall Weight Per Insulation Conductor Diameter Diameter Unit Length (mm2) (mm) (mm) (mm) (mm) (kg/km) 0.5 0.44 1.1 2.0 2.3 9 0.75 0.44 1.3 2.2 2.5 12 1.0 0.44 1.
35、5 2.4 2.7 15 1.5 0.44 1.8 2.7 3.0 20 2.5 0.53 2.2 3.2 3.6 32 4.0 0.62 2.8 4.0 4.4 48 6.0 0.62 3.4 4.6 5.0 68 10.0 0.80 4.5 5.8 6.5 117 16.0 0.80 6.3 7.3 8.3 189 ENGINEERING MATERIAL SPECIFICATIONWSK-M1L124-AWSK-M1L124-BWSK-M1L125-APrinted copies are uncontrolled Copyright 2003, Ford Global Technolog
36、ies, Inc. Page 8 of 9 Table 2b INSULATION CONSTRUCTION WSK-M1L124-A (Thin Wall) Wire Min Max Min Max Approximate Size Thickness of Diameter of Overall Overall Weight per Insulation Conductor Diameter Diameter Unit Length (mm2) (mm) (mm) (mm) (mm) (kg/km) 0.22 0.20 0.7 1.1 1.2 3 0.35 0.20 0.9 1.2 1.4
37、 4.5 0.5 0.22 1.0 1.4 1.6 6 0.75 0.24 1.2 1.7 1.9 9 1.0 0.24 1.35 1.9 2.1 11 1.5 0.24 1.7 2.2 2.4 16 2.5 0.28 2.2 2.7 3.0 25 4.0 0.32 2.75 3.4 3.7 40 6.0 0.32 3.3 4.0 4.3 61 10.0 0.48 4.5 5.5 6.0 110 16.0 0.48 6.0 7.0 7.5 175 Table 2c CABLE & INSULATION CONSTRUCTION WSK-M1L125-A (Thin Wall - Tinned)
38、 Wire Min Max Strand Max Max Size Conductor Conductor Count Resistance Lay Length Area Area per Unit Length (mm2) (mm2) (mm2) (milliohms/m) (mm) 0.35 0.317 0.339 7 55.5 18 0.5 0.461 0.498 19 38.2 30 Wire Min Max Min Max Approximate Size Thickness of Diameter of Overall Overall Weight per Insulation
39、Conductor Diameter Diameter Unit Length (mm2) (mm) (mm) (mm) (mm) (kg/km) 0.35 0.18 0.8 1.20 1.30 4.5 0.5 0.22 1.0 1.40 1.60 6.0 Note: Length of Lay - 18 mm max ENGINEERING MATERIAL SPECIFICATIONWSK-M1L124-AWSK-M1L124-BWSK-M1L125-APrinted copies are uncontrolled Copyright 2003, Ford Global Technolog
40、ies, Inc. Page 9 of 9 Table 3 Munsell Color Coding System Color Low Concentrate High Concentrate Black N2.25 - Blue 4.6PB 3.8/10.2 5.6PB 2.75/9.4 Brown 5YR 6.25/4.0 5YR 5.5/4.6 Gray N6.3/(10GY,0.2) N5.2/(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 Table 4 DIN 47002 or IEC 304 Color RAL Color RAL Black 9005 Orange 2003 Blue 5015 Red 3000 Brown 8003 Violet 4005 Gray 7000 White 1013 Green 6018 Yellow 1021
