1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions 2003 08 18 Revised Para 3.0 inserted; Para 3.1, 3.2, 3.21, 4 deleted 1992 10 10 EE00E10176310000 Pages 1,.3, 9 & 10 Revised MD/FE-12 P. Rade 1992 07 10 EGE0E10221454000 Released MD/FE-12 P. Rade Printed copies are uncontrolled Copyright 2003,
2、Ford Global Technologies, Inc. Page 1 of 7 CABLE, LOW TENSION, PFA INSULATED, 260 C, THIN WSK-M1L127-A2 WALL, SHIELDED AND TWISTED, NICKEL PLATED, TWO CORE 1. SCOPE The material defined by this specification is a low tension stranded cable, perlfluoro alkoxyl alkane (PFA) insulated conductor. The ca
3、ble is similar to ISO 6722 with a thin wall insulation thickness. It is a spirally wound shielded and twisted wire with a 90% shield cover and a helix angle of 10%. 2. APPLICATION This specification was released originally for materials used in automotive electrical harnesses. Note: The assemblers o
4、f 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 Production Materials
5、(WSS-M99P1111-A). 3.3 CABLE 3.3.1 Specimen Length 1.2 m 3.3.2 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 shall exceed the ma
6、ximum overall diameter as specified in Table 2. 3.4 CONDUCTOR 3.4.1 The conductor of all cable classes shall consist of bunched or stranded soft annealed copper wire. 3.4.2 Specimen Length 1.2 m 3.4.3 Three sections 10 mm long and separated by at least 400 mm shall be cut from the specimen. Carefull
7、y remove the conductor without deformation of the insulation. 3.4.4 The conductor diameter shall be determined 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
8、 with an optical device accurate to at least 0.01 mm. No value shall exceed the maximum diameter of the conductor specified in Table 2. ENGINEERING MATERIAL SPECIFICATIONWSK-M1L127-A2Printed copies are uncontrolled Copyright 2003, Ford Global Technologies, Inc. Page 2 of 7 3.4.5 The conductor area m
9、ay 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 the resistance in accordance with table 1. 3.4.6 The strands shall be bun
10、ched 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 2. Maximum variation between individual strand diameters must not exceed 10 percent per the following: Variation = max strand dia - min strand dia _ min stran
11、d dia Missing strands are not allowed. 3.4.7 Elongation (ASTM B 3) for d 15% for d 0.287 mm e 20% where: d = individual strand diameter e = elongation of individual strand 3.4.8 Resistivity, max 1.7544 /cm (ASTM B 193, at 20 C) 3.5 INSULATION AND SHEATHING 3.5.1 The insulating material shall be a pe
12、rlfluoro alkoxyl alkane (PFA) material, homogeneous in character. The surface shall be smooth and even without cracks, knots, blisters, or other faults. 3.5.2 The color of the cables are per the Munsell Color Coding System and shall conform to Table 3. Comparison must be made by a person with normal
13、 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, Warrendale, PA 1
14、5096. As an alternative, the color of the cables can be per the DIN 47002 or IEC 304 and shall conform to Table 4. 3.5.3 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 poi
15、nt. 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 Table 2. ENGINEERING MATERIAL SPECIFICATIONWSK-M1L127-A2Printed copies are uncontrolled Copyright 2003, Ford Global Technologies,
16、 Inc. Page 3 of 7 3.6 CABLE CONSTRUCTION 1= CONDUCTOR NICKEL PLATED 2= INSULATION PFA 3= SHIELDING SPIRALLY WOUND SHIELD, NICKEL PLATED. 90% SHIELD COVER, HELIX ANGLE 10 DEGREE 4= SHEATHING PFA (BLACK) LAY LENGTH = 45 mm 3.7 FAULT TESTING OF THE COMPLETE DELIVERY (in process testing) 3.7.1 When pull
17、ing 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. 3.7.2 Test Voltage For wires 0.5 mm25 kVeff For conductor against shie
18、ld 1.5 kVeff for 1 minute 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 by a
19、t 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. 3.8 DURATION TEST VOLTAGE AND BREAKDOWN VOLTAGE (FLTM BB 101-12. The cable must not be punctured.) 3.8.1 Specimen Length 1.2 m ENGINEERING MATERIAL
20、SPECIFICATIONWSK-M1L127-A2Printed copies are uncontrolled Copyright 2003, Ford Global Technologies, Inc. Page 4 of 7 3.9 INSULATION RESISTIVITY (FLTM BB 101-13) 3.9.1 Specimen Length 5 m 3.9.2 Volume Resistivity, min 1 teraohm.m 3.10 INSULATION COMPRESSION TEST AT HIGH TEMPERATURE (FLTM BB 101-14, M
21、ethod B) 3.10.1 Specimen Length 100 mm 3.10.2 Test Temperature, C 260 3.11 HEAT AGED (ISO 188/ASTM D 573, 3000 h) Specimens are to be pieces of insulation removed from finished cable. 3.11.1 Test Temperature 260 C 3.11.2 Tensile Strength, min 11 MPa 3.11.3 Elongation, min 125% 3.12 HEAT AGED (ISO 18
22、8/ASTM D 573, 48 h) Specimens are to be pieces of insulation removed from finished cable. 3.12.1 Test Temperature 260 C 3.12.2 Tensile Strength, min 11 MPa 3.12.3 Elongation, min 125% 3.13 HEAT SHRINKAGE (FLTM BB 101-15) 3.13.1 Specimen Length 200 mm 3.13.2 Insulation Shrinkage, max 4% 3.14 RESISTAN
23、CE TO FLAME PROPAGATION (FLTM BB 101-16, Method A) 3.14.1 Specimen Length 0.5 m 3.14.2 Burn Rate, max 100 mm/minute 3.14.3 Extinguishing Time 30 s ENGINEERING MATERIAL SPECIFICATIONWSK-M1L127-A2Printed copies are uncontrolled Copyright 2003, Ford Global Technologies, Inc. Page 5 of 7 3.15 FLEXIBILIT
24、Y AT LOW TEMPERATURE 3.15.1 Wire Sizes Less Than 10 mm2(FLTM BB 101-17, Method A) 3.15.1.1 Specimen Length 1.2 m 3.15.1.2 The insulation must not show puncture, crack or break. The conductor must not protrude from the insulation sheath and not be pushed out. 3.15.1.3 Perform Voltage Breakdown Test (
25、Perform per para 3.7) 3.16 RETENTION OF CORE (FLTM BB 101-18) 3.16.1 Specimen Length 150 +/- 5 mm Applicable to cables up to and including 6.0 mm2. 3.17 OIL RESISTANCE (FLTM BB 101-19, Method A) 3.17.1 Specimen Length 1.2 m 3.17.2 Insulation Thickness Change, max +/- 4% 3.17.3 Perform Voltage Breakd
26、own Test (Perform per para 3.7) 3.18 FUEL RESISTANCE (FLTM BB 101-19, Method B and C) 3.18.1 Specimen Length 1.2 m 3.18.2 Insulation Thickness Change, max +/- 8% 3.18.3 Perform Voltage Breakdown Test (Perform per Para 3.7) 3.19 ABRASION RESISTANCE (FLTM BB 101-20) 3.19.1 Specimen Length 750 mm ENGIN
27、EERING MATERIAL SPECIFICATIONWSK-M1L127-A2Printed copies are uncontrolled Copyright 2003, Ford Global Technologies, Inc. Page 6 of 7 3.20 FOGGING, INTERIOR GLASS SURFACE (FLTM BO 116-03 or IEC 540 Para 7, 7 d at 100 +/- 2 C) FLTM BO 116-03: Fog Number, min 60 IEC 540 Para 7: Loss of Mass, max 1 mg/c
28、m2The formation 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 passenger compartments. Wiring used exclusively in the engine compartment is excluded. Table 1 CABLE CONSTRUCTION Wire Minimum
29、 Maximum Min Max Maximum Size Conductor Conductor Strand Resistance Lay Area Area Count per Unit Length Length (mm2) (mm2) (mm2) (milliohms/m) (mm) 0.75 0.692 0.737 19, 24 23.9 25.4 45 Table 2 INSULATION CONSTRUCTION Single Wire Wire Minimum Maximum Minimum Maximum Approximate Size Thickness Diamete
30、r Overall Overall Weight Per of Insul. of Cond. Diameter Diameter Unit Length (mm2) (mm) (mm) (mm) (mm) (kg/km) 0.75 0.24 1.2 1.7 1.9 10 Wire Bundle Wire Maximum Nominal Insulating Spirally Wound Size Cable Sleeve Wall Shield No. of Diameter Thickness Wires & Diameter Guide Value (mm2) (mm) (mm) (mm
31、) 0.75 5.4 + 0 - 0.4 0.6 42 x 0.20 ENGINEERING MATERIAL SPECIFICATIONWSK-M1L127-A2Printed copies are uncontrolled Copyright 2003, Ford Global Technologies, 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 Bro
32、wn 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
