1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions 2003 08 13 Revised Para 3.0 inserted; Para 3.1, 3.5, 3.19, 4 deleted 1992 10 10 EE00E10176310000 Pages 1,3,4,8,9 Rev MD/FE-12 P. Rade 1990 10 23 EE00I0051754002 Released MD/PL-10 U. Schwarz Printed copies are uncontrolled Copyright 2003, Ford
2、Global Technologies, Inc. Page 1 of 7 CABLE, LOW TENSION, PTFE INSULATED, 260 C WSK-M1L127-A THIN WALL, NICKEL PLATED 1. SCOPE The material defined by this specification is a low tension stranded cable, polytetrafluoroethylene (PTFE) or perlfluoro alkoxyl alkane (PFA) insulated conductor. The cable
3、is similar to ISO 6722 with a thin wall insulation thickness. 2. APPLICATION This specification was released originally for materials 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 Approv
4、ed Source List. 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) 3.2 CABLE 3.2.1 Specimen Length 1.2 m 3.2.2 The maximum outside diameter shall be dete
5、rmined 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 shall exceed the maximum overall diameter as specified in Table 2. 3.3 CONDUCTOR 3.3.1 The conductor of all cable classes s
6、hall 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 be cut from the specimen. Carefully remove the conductor without deformation of the insulation. 3.3.4 The conductor diameter shall be det
7、ermined by measuring the inside diameter of the insulation taken at three points separated by at least 100 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
8、 conductor specified in Table 2. ENGINEERING MATERIAL SPECIFICATIONWSK-M1L127-APrinted copies are uncontrolled Copyright 2003, Ford Global Technologies, Inc. Page 2 of 7 3.3.5 The conductor area may be determined by measuring individual strand diameters and calculating the sums of the individual str
9、ands areas. As an alternate method, conductor area may also be determined in accordance with FLTM BB 105-01 or by measuring the resistance in accordance with table 1. 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 o
10、f wires shall comply with Tables 1 and 2. Maximum variation between individual strand diameters must not exceed 10% per the following: Variation = max strand dia-min strand dia min strand dia Missing strands are not allowed. 3.3.7 Elongation (ASTM B 3) for d 15% for d 0.287 mm e 20% where: d = indiv
11、idual strand diameter e = elongation of individual strand. 3.3.8 Resistivity, max 1.7544 /cm (ASTM B 193, at 20 C) 3.4 INSULATION 3.4.1 The insulating material shall be a polytetrafluoroethylene (PTFE) or perlfluoro alkoxyl alkane (PFA) material, homogeneous in character. The surface shall be smooth
12、 and even without cracks, knots, blisters, or other faults. 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 cables. Comparison must be made by a person with normal or corrected vision,
13、 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, Warrendale, PA 15096. As an alternati
14、ve, 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 recording the minimum insulation thickness at each point. The thickness sha
15、ll 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 Table 2. ENGINEERING MATERIAL SPECIFICATIONWSK-M1L127-APrinted copies are uncontrolled Copyright 2003, Ford Global Technologies, Inc. Page 3 of 7 3.6
16、FAULT TESTING OF THE COMPLETE DELIVERY (in process testing) 3.6.1 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 electr
17、ode. 3.6.2 Test Voltage for wires 0.5 mm25 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 sha
18、ll 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. 3.7 DURATION TEST VOLTAGE AND BREAKDOWN VOLTAGE (FLTM BB 101-12. The cable must not be punctured.) 3.7.1 Specimen Length 1.2 m 3.8
19、INSULATION RESISTIVITY (FLTM BB 101-13) 3.8.1 Specimen Length 5 m 3.8.2 Volume Resistivity, min 1 teraohm/m 3.9 INSULATION COMPRESSION TEST AT HIGH TEMPERATURE (FLTM BB 101-14, Method B) 3.9.1 Specimen Length 100 mm 3.9.2 Test Temperature, C 260 3.11 HEAT AGED (ISO 188/ASTM D 573, 3000 h at 260 C) 3
20、.11.1 Tensile Strength, min 11 MPa 3.11.2 Elongation, min 125% 3.12 HEAT SHRINKAGE (FLTM BB 101-15, Method B) 3.12.1 Specimen Length 200 mm 3.12.2 Insulation Shrinkage, max 4% ENGINEERING MATERIAL SPECIFICATIONWSK-M1L127-APrinted copies are uncontrolled Copyright 2003, Ford Global Technologies, Inc.
21、 Page 4 of 7 3.13 RESISTANCE TO FLAME PROPAGATION (FLTM BB 101-16, Method A) 3.13.1 Specimen Length 0.5 m 3.13.2 Burn rate, max 100 mm/minute 3.13.3 Extinguishing Time 30 s 3.14 FLEXIBILITY AT LOW TEMPERATURE 3.14.1 Wire Sizes less than 10 mm2(FLTM BB 101-17, Method A) 3.14.1.1 Specimen Length 1.2 m
22、 3.14.1.2 The insulation must not show puncture, crack or break. The conductor must not protrude from the insulation sheath and not be pushed out. 3.15 RETENTION OF CORE (FLTM BB 101-18) 3.15.1 Specimen Length 150 +/- 5 mm Applicable to cables up to and including 6.0 mm2. 3.16 OIL RESISTANCE (FLTM B
23、B 101-19, Method A) 3.16.1 Specimen Length 1.2 m 3.16.2 Insulation Thickness Change, max +/- 4% 3.16.3 Perform Voltage Breakdown Test (Perform per Para 3.7) 3.17 FUEL RESISTANCE (FLTM BB 101-19, Methods B and C) 3.17.1 Specimen Length 1.2 m 3.17.2 Insulation Thickness Change, max +/- 8% 3.17.3 Perfo
24、rm Voltage Breakdown Test (Perform per Para 3.7) 3.18 ABRASION RESISTANCE (FLTM BB 101-20) 3.18.1 Specimen Length 750 mm ENGINEERING MATERIAL SPECIFICATIONWSK-M1L127-APrinted copies are uncontrolled Copyright 2003, Ford Global Technologies, Inc. Page 5 of 7 3.19 FOGGING, INTERIOR GLASS SURFACE (FLTM
25、 BO 116-03 or IEC 540 Para 7, 7d at 100 +/- 2 C) FLTM BO 116-03: Fog Number, min 60 IEC 540 Para 7: Loss of Mass, max 1 mg/cm2Formation of excessive amount of clear film or droplets is cause for rejection. Note Anti-Fogging is required for all wiring passing through the body shell luggage or passeng
26、er compartments. Wiring used exclusively in the engine compartment is excluded. ENGINEERING MATERIAL SPECIFICATIONWSK-M1L127-APrinted copies are uncontrolled Copyright 2003, Ford Global Technologies, Inc. Page 6 of 7 TABLE 1 CABLE CONSTRUCTION Wire Size (mm2) Minimum Conductor Area (mm2) Maximum Con
27、ductor Area (mm2) Strand Count Min Max Resistance per Unit Length (milliohms/m) Lay Length (mm) 0.35 0.329 0.350 7, 12 51.2 54.5 25 0.5 0.461 0.490 19 35.9 38.2 45 0.75 0.692 0.737 19, 24 23.9 25.4 45 1.0 0.925 0.982 32, 37 18.0 19.1 45 1.5 1.345 1.436 30, 37 12.2 13.0 45 2.5 2.25 2.39 37, 50 7.33 7
28、.80 60 4.0 3.64 3.87 56 4.51 4.80 65 6.0 5.52 5.87 84 3.01 3.20 85 TABLE 2 INSULATION CONSTRUCTION Wire Size (mm2) Minimum Thickness of Insulation (mm) Maximum Diameter of Conductor (mm) Minimum Overall Diameter (mm) Maximum Overall Diameter (mm) Approximate Weight Per Unit Length (kg/km) 0.35 0.20
29、0.9 1.2 1.4 5 0.5 0.22 1.0 1.4 1.6 7 0.75 0.24 1.2 1.7 1.9 10 1.0 0.24 1.35 1.9 2.1 12 1.5 0.24 1.7 2.2 2.4 17 2.5 0.28 2.2 2.7 3.0 28 4.0 0.32 2.75 3.4 3.7 45 6.0 0.32 3.3 4.0 4.3 66 ENGINEERING MATERIAL SPECIFICATIONWSK-M1L127-APrinted copies are uncontrolled Copyright 2003, Ford Global Technologi
30、es, Inc. Page 7 of 7 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 Black 9005 Blue 5015 Brown 8003 Gray 7000 Green 6018 Orange 2003 Red 3000 Violet 4005 White 1013 Yellow 1021
