1、 ENGINEERING MATERIAL SPECIFICATION Material Name Specification Number Date Action Changes/Revisions 2014 06 11 N Status No replacement named L. Sinclair, NA 1999 11 18 Revised Added A7 Comp. Revision R. J. Patel 1997 03 12 Activated R. J. Patel Page 1 of 15 CABLE, PRIMARY LOW TENSION, THIN WALL, 85
2、C WSS-M22P7-A1 CABLE, PRIMARY LOW TENSION, THIN WALL, 100C WSS-M22P7-A2 CABLE, PRIMARY LOW TENSION, THIN WALL, 125C WSS-M22P7-A3 CABLE, PRIMARY LOW TENSION, THIN WALL, 150C WSS-M22P7-A4 CABLE, PRIMARY LOW TENSION, THIN WALL, NI PLATED, 175C WSS-M22P7-A5 CABLE, PRIMARY LOW TENSION, THIN WALL, NI PLAT
3、ED, 200C WSS-M22P7-A6 CABLE, PRIMARY LOW TENSION, THIN WALL, NI PLATED, 225C WSS-M22P7-A7 CABLE, PRIMARY LOW TENSION, THIN WALL, NI PLATED, 250C WSS-M22P7-A8 NOT TO BE USED FOR NEW DESIGN 1. SCOPE The products defined by these specifications are low tension stranded and insulated cables. The cables
4、are similar to that described in ISO 6722. This specification includes different temperature ratings and different conductor types i.e. plain copper, tinned copper, nickel plated copper, copper clad steel and copper alloy. 2. APPLICATION These cable specifications were originally released for use at
5、 a nominal system voltage of 60 V rms or less in automotive electrical harnesses. 3. REQUIREMENTS 3.1 QUALITY SYSTEM REQUIREMENTS Material suppliers and part producers must conform to Quality System Requirements, QS-9000. Material specification requirements are to be used for initial qualification o
6、f materials. A Control Plan for ongoing production verification is required. This plan must be reviewed and approved by the relevant Ford Materials activity and/or Ford Supplier Technical Assistance (STA) prior to production parts submission. Appropriate statistical tools must be used to analyze pro
7、cess/product data and assure consistent processing of the materials. Part producers using this material in their products, must use Ford approved materials and must conform to a process control plan which has been approved by STA and/or the relevant Materials Activity. ENGINEERING MATERIAL SPECIFICA
8、TION WSS-M22P7-A1/A8 Page 2 of 15 3.2 INFRARED SPECTROPHOTOMETRY AND/OR THERMAL ANALYSIS Ford Motor Company, at its option, may conduct infrared and/or thermal analysis of material/parts supplied to this specification. The IR spectra and thermograms established for initial approval shall constitute
9、the reference standard and shall be kept on file at the designated material laboratory. All samples shall produce IR spectra and thermograms that correspond to the reference standard when tested under the same conditions. 3.3 CONDITIONING AND TEST CONDITIONS All test values indicated herein are base
10、d on material conditioned in a controlled atmosphere of 23 +/- 2 C and 50 +/- 5 % relative humidity for not less than 24 h prior to testing and tested under the same conditions unless otherwise specified. 3.4 CABLE TEMPERATURE CLASS Depending upon the service conditions, the cables shall be made to
11、belong to one of the following eight classes of temperature: Class A1 - 40 to + 85C Class A2 - 40 to + 100C Class A3 - 40 to + 125C Class A4 - 40 to + 150C Class A5 - 40 to + 175C Class A6 - 40 to + 200C CLASS A7 - 40 to + 225C CLASS A8 - 40 to + 250C 3.5 CABLE OUTSIDE DIAMETER (ISO 6722) No single
12、value shall be outside the acceptable range of diameter as specified in Table 2. 3.6 CONDUCTOR (ASTM B 1, ASTM B 3, ASTM B 174, ASTM E 8, ISO 6722) 3.6.1 The individual strands of the conductor shall be soft or annealed copper per ASTM B 3 or tin-plated per ASTM B 33. Conductors of 0.35 mm2 size and
13、 smaller may use hard copper strands per ASTM B 1 or copper alloy strands. Annealed copper strand elongation (after bunching) and lay length shall conform to ASTM B 174. For high temperature applications, nickel plated copper shall be used. Minimum conductor strand count shall comply with Table 1 of
14、 this specification. Missing strands are not allowed. ENGINEERING MATERIAL SPECIFICATION WSS-M22P7-A1/A8 Page 3 of 15 3.6.2 The conductor diameter and electrical resistance shall be determined in accordance with ISO 6722. The Conductor Breaking Load Test shall be conducted in accordance with ASTM E
15、8. The values are specified in Table 1. 3.7 INSULATION (ISO 6722) 3.7.1 The color of the insulation shall be specified on engineering drawing. Base, stripe, and band marking color codes shall correspond to Table 4. Where striping is specified, either one or two stripes may be used. The individual st
16、ripe shall be a minimum of 7% wide, but not more than 15% of the circumference of the wire. The stripe shall be of the same class of material as the insulation. Where band marking is specified (for sizes 0.13 and 0.22 mm2), the band mark shall be 3 mm +/- 1 mm wide with a 25 mm +/- 5 mm pitch. If th
17、e insulation is dyed or painted, the Durability of Cable Marking Test must be performed on the finished product. 3.7.2 The material shall adhere closely to, but strip readily from the conductors, leaving them free of insulation and in suitable condition for applying terminals. The insulation thickne
18、ss shall be determined in accordance with ISO 6722. The insulation thickness shall comply with the values listed in Table 2. 3.8 CABLE QUALITY (TESTS) Insulation Resistance, Withstand Voltage, Thermal Overload, Winding test at Low Temperature (mandrel sizes per Table 5), Pressure at High Temperature
19、, and Heat Shrinkage Tests shall all be conducted in accordance with ISO 6722. Ozone Resistance Test shall be conducted in accordance with SAE J1128. Note: The following tests, 3.8.1, 3.8.2, 3.8.3, 3.8.4, 3.8.5 and 3.8.6 shall be tested in accordance with ISO 6722, but with exceptions to the require
20、ments as indicated. 3.8.1 Test for Insulation Faults (In Process Testing) The test voltage shall be: 0.13 - 0.5mm 3 KV 0.5mm2 5 KV 3.8.2 Short Term Heat Aging (ISO 6722) During Withstand Voltage Test, the voltage shall be applied immediately after immersion for 1 minute. Mandrel sizes are specified
21、in Table 5. ENGINEERING MATERIAL SPECIFICATION WSS-M22P7-A1/A8 Page 4 of 15 3.8.3 Long Term Heat Aging (For Initial Qualification Only) (ISO 6722) During Withstand Voltage Test, the voltage shall be applied immediately after immersion for 1 minute. The test temperatures are specified in the para 3.4
22、. Mandrel sizes are specified in Table 5. 3.8.4 Resistance to Flame Propagation (ISO 6722) Any combustion flame of insulating material shall extinguish within 70 seconds. 3.8.5 Fluid Resistance (ISO 6722) The fluids and the requirements are specified in Table 6. 3.8.6 Abrasion Resistance For sizes 6
23、.0mm either clause 3.8.6.1 or 3.8.6.2 Shall be used to fulfill the requirement. For sizes larger than 6.0mm sandpaper abrasion shall be specified. 3.8.6.1 Sandpaper (SAE J1128) The sandpaper abrasion resistance shall meet the minimum abrasion requirements in Table 3. 3.8.6.2 Scrape (ISO 6722) The sc
24、rape abrasion resistance shall meet the minimum abrasion requirements in Table 3. 3.8.7 Loss Of Mass (For Initial Qualification Only) (IEC 540, para 7 (7d) at 100 +/- 2 C) This test is required for wire size of 0.75 mm. The maximum loss of mass shall be 1 mg/cm2. Note: Loss of mass is required for c
25、lass A & B wiring passing through the body shell luggage or passenger compartments. Wiring used exclusively in the engine compartment is excluded. ENGINEERING MATERIAL SPECIFICATION WSS-M22P7-A1/A8 Page 5 of 15 3.8.8 Durability of Cable Marking 3.8.8.1 Procedure Prepare three test samples of approxi
26、mately 600 mm. The apparatus shall consist of two pieces of felt without dressing, having a minimum wool content of 75 %, and with a packing density of 0.171 to 0.191 g/cm3 (approximate dimensions 50 x 50 x 3 mm) and a vessel containing ISO 1817, No. 1 Oil or ASTM D471, IRM 902 at 50 +/- 2 C. Immers
27、e the test sample in the oil for 20 h with the cable ends emerging approximately 50 mm above the surface of the liquid. Remove the test sample from the oil and allow it to drain at room temperature for approximately 30 minutes. Position the test sample between two pieces of felt and apply a pressure
28、 of 10 +/- 1 N while pulling the test sample from between the felt. Visually inspect the cable. Note: This test is required only for marked cables that are not extruded. 3.8.8.2 Requirements The insulation and the color shall show no evidence of peeling or cracking, and the markings shall remain leg
29、ible. 3.8.9 Hot Water Resistance (For Initial Qualification Only) 3.8.9.1 Procedure Closely wind three complete turns of the center section of cable on a mandrel 5 times the outside diameter of the test sample. Tie the remaining cable in a coil. Immerse the test sample in a bath with 3 g/l of NaCl i
30、n water at 85C with both ends projecting 250mm above the bath. Connect one end of the test sample and the positive electrode to a 48 V DC power source. After 7 days disconnect the 48 V supply, and measure the “insulation volume resistivity”, as describe in ISO 6722, in the salt water bath at 85C. Th
31、is completes one cycle. Repeat this procedure for a total of 5 cycles, 35 days. After conditioning, remove the test sample from the bath , allow it to cool to room temperature, and make a visual inspection of the insulation. Ignore any damage caused by the ties, which secure the coils. If no exposed
32、 conductor is visible, perform the “Withstand Voltage” test, however the following changes shall be made to the procedure. ENGINEERING MATERIAL SPECIFICATION WSS-M22P7-A1/A8 Page 6 of 15 . The test sample shall be immersed in the salt solution for a minimum of 10 min prior to the application of the
33、voltage. . The 1kV (rms) voltage shall be applied for 1 minute. . The voltage shall not be ramped up after the application of the 1 kV (rms) voltage. “Insulation Volume Resistivity Formula” po = 2.725 lxR log D d Where: (po) is the “Insulation Volume Resistivity” expressed in Ohm. millimeters. (l) i
34、s the immersed length of the test sample, expressed in millimeters. (R) is the measured insulation resistance, expressed in Ohms. (D) is the outside cable diameter, expressed in millimeters. (d) is the conductor diameter, expressed in millimeters. Upon completion of the test repeat the entire test p
35、rocedure with a new sample except the polarity of the 48 V supply shall be reversed. 3.8.9.2 Requirements The volume resistivity shall not be less than 109 ohm mm. A visual inspection of the insulation shall show no cracks. During the “Withstand voltage test”, breakdown shall not occur. 3.8.10 Colum
36、n Strength 3.8.10.1 Procedure Test shall be conducted by the use of a tensile test machine and the test fixture described in Figure 1. Note: This test is for the wire sizes 0.35 and 0.5 mm2. Smaller sizes are applicable only for terminals with insulation displacement. Therefore, column strength test
37、 is not required for smaller sizes. Do not bend the wire prior to testing. ENGINEERING MATERIAL SPECIFICATION WSS-M22P7-A1/A8 Page 7 of 15 Prepare twenty-five (25) test samples of 40 mm +/- 0.5 mm long. Insert the test wire in the appropriate cavities of the test fixture. The hole diameter shall not
38、 exceed the maximum cable diameter for a specific wire size by more than +/- 0.03 mm. Insure that the fixture and the wire are vertically aligned with each other. Apply a compressive force at the constant speed of 50 +/- 0.5 mm/minute and record the highest force attained as the wire is being compre
39、ssed. This force shall be higher than the values specified in the requirements. Figure 1 3.8.10.2 Requirements Wire Size Min Force 0.35 mm2 15 N 0.5 mm2 15 N ENGINEERING MATERIAL SPECIFICATION WSS-M22P7-A1/A8 Page 8 of 15 3.9. COMPATIBILITY TESTS (initial qualification only) 3.9.1 Convolute Compatib
40、ility (for A2 thru A8) 3.9.1.2 Procedure 1) Insert a wire bundle of size equal to 80.0% of the tubing I.D into approximately 380mm in length of appropriate production tubing. Age the test sample horizontally in an oven set at 25C above the respective wire temperature class rating for 240 hours. Next
41、, condition the test sample for at least 30 minutes at room temperature. Remove the wire bundle from the convolute and wrap the center of the bundle around a mandrel of diameter equal to four times the bundle OD at a uniform rate of one turn per 10 seconds. Next, perform the Withstand Voltage Test a
42、s specified in the ISO 6722 specification except the duration of soak time shall be 10 minutes and the 1 Kv voltage shall be applied for 1 minute. 2)Insert a wire bundle of size equal to 80.0% of the tubing I.D into approximately 380mm in length of appropriate production tubing. Age the test sample
43、horizontally in the test chamber at 85 C (+/- 5 C) and 90 (+/-5%) relative humidity for 5.5 hours then ramp the temperature up at a rate of 2 C/minute to the respective temperature for the wire as shown in section 3.4. for 2 hours. This will constitute one cycle. Repeat the cycle for a total of 40 c
44、ycles. Next, condition the specimen for at least 30 minutes at room temperature. Remove the bundle from the convolute and wrap the center of the bundle around a mandrel of diameter equal to four times the bundle OD at a uniform rate of one turn per 10 seconds. Next, perform the Withstand Voltage Tes
45、t as specified in the ISO 6722 specification except the duration of soak time shall be 10 minutes and the 1 Kv voltage shall be applied for 1 minute. Note: The test to be performed on all types of tubing (to be supplied by Harness Manufacturer). 3.9.1.2 Requirement (1 & 2) Insulation shall not exhib
46、it cracks after mandrel wrap test. No dielectric failure shall occur during withstand voltage test. ENGINEERING MATERIAL SPECIFICATION WSS-M22P7-A1/A8 Page 9 of 15 3.10 Tape Compatibility (for A2 thru A8) 3.10.1 Procedure 1) Assemble a 380mm in length wire bundle of approximately 12mm (for sizes 0.3
47、5 thru 4.0mm) or 25mm (for sizes 6.0 thru 16.0mm) in diameter and candy stripe wrap the bundle using appropriate tapes (include PVC tape) leaving approximately a 6mm opening between tape wraps. Age the test sample horizontally in an oven set at 25C above the respective wire temperature class rating
48、for 240 hours. Next, condition the test sample for at least 30 minutes at room temperature. Remove the bundle and wrap the center of the bundle around a mandrel of diameter equal to four times the bundle OD at a uniform rate of one turn per 10 seconds. Next, perform the Withstand Voltage Test as spe
49、cified in the ISO 6722 specification except the duration of soak time shall be 10 minutes and the 1 Kv voltage shall be applied for 1 minute. 2) Assemble a 380mm in length wire bundle of approximately 12mm (for sizes 0.35 thru 4.0mm) or 25mm (for sizes 6.0 thru 16.0mm) in diameter and candy stripe wrap the bundle leaving approximately a 6mm opening between tape wraps. Age the test sample horizontally in the test chamber at 85 C (+/- 5 C) and 90 (+/-5%) relative humidity for 5.5 hours then ramp the temperature up at a rate of 2 C/minute to the respective
