1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions 2003 06 25 Revised Para 3.0 inserted; Para 3.7, 3.8, 3.9, 3.10, 3.11, 4 deleted 1990 07 11 DE00-E00107002060 Revised & Reactivated J. Huebner 1982 11 29 CF4M-RD887294-21 Released Printed copies are uncontrolled Copyright 2003, Ford Global Tech
2、nologies, Inc. Page 1 of 6 CABLE, LOW TENSION VINYL INSULATED (105 C) TINNED ESF-M1L119-A MULTIPLE CONDUCTOR 1. SCOPE The material defined by this specification is a stranded vinyl covered, multiple conductor, low tension cable. The vinyl covering shall be 105 C classification. 2. APPLICATION This s
3、pecification was released originally for material used for automotive electrical harnesses. 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). 3.1 WIRE
4、SIZE Shall be specified on the engineering drawing and/or release according to the SAE wire size numbers appearing in Table I. The number of conductors is also to be specified on the engineering drawing. Example: # 16 gage ESF-M1L119-A, 5 conductors. 3.2 COLOR The color of the vinyl cover shall be s
5、pecified on the engineering drawing and/or release by a numerical suffix following the letter suffix of the material desired. The numerical color coding suffixes shall correspond to the following: 0 - Black 5 - Green 1 - Brown 6 - Blue 2 - Red 7 - Violet 3 - Orange 8 - Gray 4 Yellow 9 - White or nat
6、ural Example: #16 gage ESF-M1L119-A1 shall designate a stranded 16 gage, brown vinyl covered, soft or annealed tinned copper conductor, corresponding to the requirements of this specification. The first color coding numerical suffix shall be the base or body color of the finished cable and the secon
7、d number shall designate the tracer or other auxiliary marking. ENGINEERING MATERIAL SPECIFICATIONESF-M1L119-APrinted copies are uncontrolled Copyright 2003, Ford Global Technologies, Inc. Page 2 of 6 3.3 CABLE QUALITY Shall meet all of the requirements listed herein and must be equal to the origina
8、l approved purchase sample. 3.4 WIRE QUALITY The strands of the conductors prior to stranding shall consist of ESF-M2L3-A, soft or annealed tinned copper wire. 3.5 CABLE CONSTRUCTION See Tables I and II The cross sectional area of stranded conductors shall not be less than 98% of the values specifie
9、d in Table I. 3.6 INSULATION QUALITY Shall be a good grade vinyl chloride copolymer which will pass the following test requirements: The material shall adhere closely to, but strip readily from the conductors, leaving them reasonably clean and in suitable condition for soldering. Insulation thicknes
10、s shall be in accordance with Table II for the various wire sizes and shall be determined by measuring the diameter over the insulation, then removing the insulation and measuring the diameter of the conductor. Half of the difference of the two measurements shall be considered as the wall thickness.
11、 3.6.1 Mechanical Properties Tear Strength, min 8.9 N Test Method: Split insulation between conductors. Pull at 500 +/- 25 mm/minute. 3.6.2 High Temperature Resistance A strip of the insulation 25 mm long shall be removed from each end of a 610 mm sample of the finished cable. The sample shall be su
12、spended around a cylindrical mandrel having a diameter specified in Table III. Each end of the conductor shall have suspended from it, the weight shown in Table III. This condition shall be maintained for 120 h in a mechanical convection oven maintained at a temperature of 135-137 C. When cool, the
13、weight shall be removed form the specimen and it shall be taken off the mandrel, bent in the reverse direction around a mandrel of the diameter specified for the bend test in Table III at a rate not to exceed one complete turn/minute and then be subjected to the dielectric test, para 3.6.3. 3.6.3 Di
14、electric Test A specimen of the cable 610 mm long shall be formed into a loop. A strip of the insulation 25 mm long shall be removed from each end of the wire and the ends twisted together. The loop thus formed shall be immersed in water containing 5% salt by weight at 23 +/- 2 C, so that no more th
15、an 152 mm of each end of the specimen protrudes above the solution. After being immersed for 5 h and while still immersed, the specimen shall withstand the application of 1000 volts (RMS) at 60 Hz between the conductor and the water for 1 minute without rupture of insulation. ENGINEERING MATERIAL SP
16、ECIFICATIONESF-M1L119-APrinted copies are uncontrolled Copyright 2003, Ford Global Technologies, Inc. Page 3 of 6 3.6.4 Cold Bend Test A straight specimen shall be reduced to a temperature -40 C at a rate not to exceed 50 C/minute. After maintaining this temperature for 3 h and while still at this l
17、ow temperature, the cable shall be wrapped around the mandrel specified in Table III for 180 at the uniform rate of one turn in 10 s. The insulation shall be removed for a distance of 25 mm from each end of the specimen and the specimen subjected to the dielectric test, para 3.6.3. 3.6.5 Flame Test
18、A 610 mm specimen shall be suspended in a vertical position within a partial enclosure which allows a flow of sufficient air for complete combustion but is free from drafts. The tip of a 50 mm gas flame with an inner cone one-third its height shall then be applied to the end of the specimen for 15 s
19、. After removal of the flame the specimen shall not continue to burn for more than 30 s. 3.6.6 Abrasion Resistance As per Table IV (SAE J 1128) ENGINEERING MATERIAL SPECIFICATIONESF-M1L119-APrinted copies are uncontrolled Copyright 2003, Ford Global Technologies, Inc. Page 4 of 6 TABLE I CABLE CONST
20、RUCTION SAE Wire Size No. of Wires Nominal Strand Size Approx. Dia. of Stranded Conductor Area of Conductor Awg mm mm mm227 1 27 0.361 0.361 0.103 24 19 36 0.127 0.635 0.242 24 7 32 0.203 0.610 0.228 22 7 30 0.254 0.787 0.355 22 19 34 0.160 0.813 0.382 20 7 28 0.320 1.02 0.554 18 16 30 0.254 1.27 0.
21、795 16 26 30 0.254 1.52 1.186 16 19 29 0.287 1.52 1.186 16 16 28 0.320 1.52 1.186 14 26 28 0.320 1.91 1.914 14 19 27 0.361 1.91 1.914 12 65 30 0.254 2.29 3.013 12 41 28 0.320 2.29 3.013 12 19 25 0.455 2.29 3.013 10 105 30 0.254 2.92 4.785 10 65 28 0.320 2.92 4.785 10 49 27 0.361 2.92 4.785 10 19 23
22、0.574 2.92 4.785 8 103 28 0.320 4.06 7.654 8 49 25 0.455 4.06 7.654 8 19 21 0.724 4.06 7.654 6 172 28 0.320 5.33 12.340 6 123 27 0.361 5.33 12.340 6 37 21 0.724 5.33 12.340 4 133 25 0.455 6.99 19.472 4 61 22 0.643 6.99 19.472 4 49 21 0.724 6.99 19.472 ENGINEERING MATERIAL SPECIFICATIONESF-M1L119-APr
23、inted copies are uncontrolled Copyright 2003, Ford Global Technologies, Inc. Page 5 of 6 TABLE II INSULATION SAE Wire Size Nominal Insulation Wall Thickness Maximum Diameter of Finished Cable mm mm 27 0.27 1.02 24 0.27 1.20 22 0.27 1.35 22 0.27 1.35 20 0.58 2.41 18 0.58 2.54 16 0.58 2.92 16* 0.79 3.
24、15 14 0.58 3.18 12 0.66 3.81 10 0.79 4.70 8 0.94 6.22 6 1.09 7.75 4 1.12 9.53 * Specified values for # 16 gage, 26 strand (30 Awg) wire only. TABLE III MANDREL SIZES Gage Size High Temperature Test Bend and Cold Resistance Test Suspension Weight for High Temperature Test mm mm kg 27 114 76 0.45 24 1
25、14 76 0.45 22 114 76 0.45 20 114 76 0.45 18 114 76 0.45 16 165 76 0.45 14 165 152 0.45 12 165 152 1.36 10 254 152 1.36 8 254 152 1.36 6 254 254 2.72 4 254 254 2.72 ENGINEERING MATERIAL SPECIFICATIONESF-M1L119-APrinted copies are uncontrolled Copyright 2003, Ford Global Technologies, Inc. Page 6 of 6 TABLE IV ABRASION RESISTANCE DATA Gage Size Minimum Resistance Length of Tape Weight Support Bracket Weight mm kg 27 Not Reqd 24 152 A 0.23 22 152 A 0.23 20 457 A 0.45 18 533 A 0.45 16 559 A 0.45 14 305 B 1.36 12 406 B 1.36 10 508 B 1.36 8 635 B 1.36 6 635 C 1.93 4 765 C 1.93
