1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions 2004 02 18 Revised Revised Table 2 S. White 2003 06 24 Revised Para 3.0 inserted; Para 3.1, 3.2, 3.3, 3.7, 4 deleted 1999 06 16 Activated S. White Printed copies are uncontrolled Copyright 2004, Ford Global Technologies, LLC Page 1 of 5 CABLE,
2、 LOW TENSION, POLYETHYLENE INSULATED, WSS-M1L123-A4 THIN WALL THICKNESS, FLEX FUEL RESISTANT 1. SCOPE The material defined by this specification is a low tension stranded cable insulated with cross-linked polyethylene. The cable is similar to SAE J 1128, Type TXL. 2. APPLICATION This specification w
3、as originally released for automotive applications requiring the use of insulated low tension cable to be exposed to automotive flex fuels. 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. REQUIR
4、EMENTS 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). 3.4 CONDUCTOR 3.4.1 Unless otherwise specified, the individual strands of the conductor shall be soft or annea
5、led copper conforming to ASTM B 3, except strand dimensions. These dimensions shall be controlled to yield the cross-sectional area listed for the conductor of the finished cable per Table 1. Conductor area shall be determined by measuring individual strand diameters and calculating the sum of the i
6、ndividual strand areas. As an alternate method, conductor area may also be determined in accordance with ASTM B 263. For this procedure, let k=2 in accordance with ASTM B 174, para. 12.3. 3.4.2 The strands shall be bunched per ASTM B 174. The maximum lay length shall be as specified in ASTM B 174 Ta
7、ble 2, Column A. Conductor strand count shall comply with Table 1. Missing strands are not allowed. 3.5 INSULATION 3.5.1 The color of the insulation shall be specified on the engineering drawing of the component utilizing this material. Base and stripe colors shall correspond to SAE J 1128. Where st
8、riping is specified, one or two stripes may be used. The width of the stripe(s) shall be a minimum of 0.3 mm but not more than 15% of the circumference of the wire. If the insulation is dyed or painted, all cable quality tests in Section 3.6 must be performed on the finished product. The insulation
9、and the color may show no evidence of peeling or cracking and must conform to the color tolerances specified with the exception of quality tests 3.6.2 and 3.6.3. ENGINEERING MATERIAL SPECIFICATIONWSS-M1L123-A4Printed copies are uncontrolled Copyright 2004, Ford Global Technologies, LLC Page 2 of 5 3
10、.5.2 The insulating material shall be flame retardant, homogeneous, cross-linked polyethylene, similar to SAE J 1128, Type TXL. The material shall adhere closely to, but strip readily from the conductors, leaving them free of insulation and in suitable condition for applying terminals. 3.5.3 Insulat
11、ion Mechanical Properties These tests shall be conducted in accordance with SAE J 1128, for Type TXL, except that the insulation shall be conditioned for 24 +/- 2h at 60 +/- 2 C prior to taking original measurements and that the aging test temperature shall be 160 +/- 2 C. 3.5.4 Insulation thickness
12、 shall comply with the requirements of Table 2. Insulation thickness shall be measured with an optical device accurate to at least 0.01 mm or a pin micrometer with a diameter of 0.5 mm. The test method for determining minimum insulation thickness at any point shall be in accordance with ANSI/UL-1581
13、, Reference Standard for Electrical Wires, Cables and Flexible Cords, Paras 240 through 250.11. In case of dispute, the referee method shall be the optical device. 3.6 CABLE QUALITY TESTS The following tests: Dielectric Test, Cold Bend Test, Flame Test, Fluid Compatibility Test, Ozone Resistance, Pi
14、nch Test, Abrasion Resistance, Cross linking, and Strip Force shall be conducted per SAE J 1128 for type TXL cable. The tests listed below shall be conducted in addition to the tests listed above. 3.6.1 Cable Diameter Measure the outside diameter of a 2000 mm specimen with an optical measurement dev
15、ice 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 apart. Move the sample approximately 400 mm and repeat the procedure for a total of five cross-sections. The mean of all the readings will dete
16、rmine the outside diameter of the cable. The outside diameter will conform to the values listed in Table 2. 3.6.2 High Temperature Resistance 25 mm of insulation shall be removed from each end of a 600 mm sample of finished cable. The sample shall be suspended around a cylindrical mandrel having a d
17、iameter specified in Table 3. The weight specified for the Cold Bend Test above shall be suspended from each end of the conductor. This condition shall be maintained for 168 h in a mechanical convection oven at a temperature of 165 +/- 2 C. When cooled to room temperature, the specimen shall be remo
18、ved from the mandrel and wrapped in the reverse direction around a mandrel of diameter specified in the Cold Bend Test using the Cold Bend Test method (except reverse bend conducted at room temperature). No cracks or splits in the insulation are permitted. After the reverse mandrel wrap the specimen
19、 shall be subjected to the Dielectric Test. ENGINEERING MATERIAL SPECIFICATIONWSS-M1L123-A4Printed copies are uncontrolled Copyright 2004, Ford Global Technologies, LLC Page 3 of 5 3.6.3 Flex Fuel Compatibility Tests All samples tested shall comply with the Fluid Compatibility Test requirements in S
20、AE J1128, Type TXL, except: a. Immerse samples in test fuel for 168 h at 60 +/- 2 C. b. Fuel mixtures shall comply with FLTM AZ 105-02. c. Determine the cable outer diameter change, with respect to the original cable O.D., within 30 to 60 minutes after removal of sample from test fuels. d. Dry-out f
21、uel immersion tested samples by conditioning in a circulating air oven for 70 h at an air temperature of 60 +/- 2 C. e. Determine the cable outer diameter change with respect to the original cable O.D., perform the cable mandrel wrap and dielectric tests per the Fluid Compatability test method, and
22、perform the insulation Mechanical Properties tests all within 16 to 96 h after removal of the sample from an air circulating oven. f. The insulation Mechanical Properties tests shall comply with SAE J1128, Type TXL cable, except that the insulation shall not be aged for an additional 168 h in a circ
23、ulating air oven following fuel immersion and dry-out conditioning. The insulation tensile strength shall not be less than 80% of the original test value and the elongation shall not be less than 50% of the original test value. If insulation breaks or necks outside of extensometer gage grips then th
24、e individual test result shall be invalidated; additional insulation samples shall be run to meet minimum sample size. g. Compliance to the Flex Fuel Compatibility section shall be demonstrated by individual samples not just lot averages. h. The minimum sample size for demonstrating Flex Fuel Compat
25、ibility is 30 individual cable specimens per wire gage considered for qualification. The 30 cable specimens shall be divided between more than one cable lot with the preference being 3 cable lots with 10 cable samples per lot. A cable lot is defined as cable extruded from a distinct batch of insulat
26、ion resin (i.e. resin manufactured in a different batch or on a different manufacturing date for continuously produced resin). 3.6.3.1 Immersion in CE10 Fuel 3.6.3.1.1 Cable Outer Diameter Change after Fuel Immersion, max + 10% 3.6.3.1.2 Cable Outer Diameter Change after Fuel Immersion and Condition
27、ing in Circulating Air Oven, max - 6% 3.6.3.2 Immersion in CE85 Fuel 3.6.3.2.1 Cable Outer Diameter Change after Fuel Immersion, max + 10% ENGINEERING MATERIAL SPECIFICATIONWSS-M1L123-A4Printed copies are uncontrolled Copyright 2004, Ford Global Technologies, LLC Page 4 of 5 3.6.3.2.2 Cable Outer Di
28、ameter Change after Fuel Immersion and Conditioning in Circulating Air Oven, max - 6% 3.6.3.3 Immersion in CM15 Fuel 3.6.3.3.1 Cable Outer Diameter Change after Fuel Immersion, max + 10% 3.6.3.3.2 Cable Outer Diameter Change after Fuel Immersion and Conditioning in Circulating Air Oven, max - 6% 3.6
29、.3.4 Immersion in Auto-oxidized Fuel, PN 180 3.6.3.4.1 Cable Outer Diameter Change after Fuel Immersion, max + 10% 3.6.3.4.2 Cable Outer Diameter Change after Fuel Immersion and Conditioning in Circulating Air Oven, max - 6% TABLE 1 CONDUCTOR DIMENSIONS Conductor Area Wire Size SAE Conductor Strand
30、No. Stranding (a) Nom Size mm Minimum mm2Maximum mm2Nominal (a) Cond. Dia 22 7 0.254 0.3405 0.3643 0.762 20 7 0.320 0.5432 0.5812 0.965 18 19 0.234 0.7788 0.8333 1.170 18 16 0.254 0.7788 0.8333 1.170 16 19 0.287 1.184 1.267 1.450 14 19 0.361 1.876 2.007 1.800 12 19 0.455 2.956 3.163 2.290 10 19 0.57
31、4 4.734 5.066 2.870 (a) Neither the nominal strand diameter nor nominal conductor diameter are intended for specification purposes. However, the individual strands must not vary from nominal by more than plus or minus 10%. Conductor areas are based on SAE J1128 minimums where applicable, with a 7% t
32、olerance. ENGINEERING MATERIAL SPECIFICATIONWSS-M1L123-A4Printed copies are uncontrolled Copyright 2004, Ford Global Technologies, LLC Page 5 of 5 TABLE 2 INSULATION AND CABLE DIMENSIONS Finished Cable Wire Size Minimum Insulation Nominal Insulation Minimum Average Diameter SAE Thickness (single rea
33、dings) Thickness Insulation Thickness Minimum Maximum Nominal mm mm mm mm mm mm 22 0.305 0.406 0.365 1.50 1.65 1.57 20 0.305 0.406 0.365 1.70 1.85 1.78 18 0.305 0.406 0.365 1.91 2.06 1.98 16 0.305 0.406 0.365 2.18 2.34 2.26 14 0.305 0.406 0.365 2.54 2.69 2.62 12 0.381 0.457 0.411 3.10 3.30 3.20 10 0.432 0.533 0.480 3.84 4.04 3.94 TABLE 3 HIGH TEMPERATURE RESISTANCE MANDREL SIZES Wire Size SAE Mandrel Size SAE 22 115 20 115 18 115 16 165 14 165 12 165 10 255
