1、 ENGINEERING MATERIAL SPECIFICATION Material Name Specification Number Date Action Revisions 2003 04 25 Revised Para 3.0 inserted; Para 3.7 & 4 deleted 1985 03 20 CF40-RD888002-262 All Tables Added SAE Wire Size 22 1963 07 17 Released F6-1082 Printed copies are uncontrolled Page 1 of 7 Copyright 200
2、3, Ford Global Technologies, Inc. CABLE, LOW TENSION - VINYL ESF-M1L56-A INSULATED (85 C) - BARE CABLE, LOW TENSION - VINYL ESF-M1L57-A INSULATED (85 C) - TINNED 1. SCOPE The materials defined by these specifications are stranded vinyl covered low tension cables. The vinyl covering shall be 85 C cla
3、ssification. 2. APPLICATION These specifications were released originally for materials 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
4、 Materials (WSS-M99P1111-A). 3.1 WIRE SIZE Shall be specified on the engineering drawing and/or released according to the SAE wire size numbers appearing in Table 1. Example: #16 gage ESF-M1L56-A. 3.2 COLOR The color of the vinyl cover shall be specified on the engineering drawing and/or release by
5、a numerical suffix following the letter suffix of the materials 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 natural ENGINEERING MATERIAL SPECIFICATION ESF-M1L56-A
6、 ESF-M1L57-A Page 2 of 7 Copyright 2003, Ford Global Technologies, Inc. Example: #16 gage ESF-M1L56-A1 shall designate a stranded 16 gage, brown vinyl covered, soft or annealed bare copper conductor, corresponding to the requirements of this specification. The first color coding numerical suffix sha
7、ll be the base or body color of the finished cable and the second number shall designate the tracer or other auxiliary marking. 3.3 CABLE QUALITY Shall meet all of the requirements listed herein and must be equal to the original approved purchase sample. ESF-M1L56-A similar to M-1L17-A ESF-M1L57-A s
8、imilar to M-1L17-B 3.4 WIRE QUALITY The strands of the conductors prior to stranding shall consist of the following grades of wire: ESF-M1L56-A: ESF-M2L1-A, soft or annealed bare copper wire ESF-M1L57-A: ESF-M2L3-A, soft of annealed tinned copper wire 3.5 CABLE CONSTRUCTION See Tables I & II The cro
9、ss sectional area of stranded conductors shall not be less than 98% of the values specified in Table I. 3.6 INSULATION QUALITY The insulating material shall be a good grade vinyl chloride copolymer which will pass the following test requirements: The material shall adhere closely to, but strip readi
10、ly from the conductors, leaving them reasonably clean and in suitable condition for soldering. Insulation thickness shall be in accordance with Table II for the various wire and shall be determined by measuring the diameter over the insulation, then removing the insulation and measuring the diameter
11、 of the conductor. Half of the difference of the two measurements shall be considered as the wall thickness. ENGINEERING MATERIAL SPECIFICATION ESF-M1L56-A ESF-M1L57-A Page 3 of 7 Copyright 2003, Ford Global Technologies, Inc. 3.6.1 Mechanical Properties A test specimen of the thermoplastic insulati
12、on prepared as in the SAE J200 section on sampling shall be used. The dumbbell cut sample shall have marks placed upon it 50 mm apart. The sample shall then be stretched at the rate of 305 mm/min. The tensile strength shall be calculated upon the original cross section of the test specimen before st
13、retching. Testing shall be conducted at 23 +/- 2 C. Care should be exercised in cutting samples to obtain uniform cross section. The properties shall be as follows: Tensile Strength, min 15.9 MPa Elongation, min 125% 3.6.2 High Temperature Resistance Remove 25 mm of insulation from each end of a 610
14、 mm sample of the finished cable. The sample shall be suspended 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 m
15、aintained at a temperature of 120 - 122 C. When cool, the weight shall be removed from the specimen and it shall be taken off the mandrel, bent in 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/min and then be sub
16、jected to the dielectric test, para 3.6.3. 3.6.3 Dielectric Test A specimen of the cable 610 mm long shall be formed into a loop. Remove 25 mm of insulation from each end of the wire and twist the ends together. The loop thus formed shall be immersed in water containing 5% salt by weight at 23 +/- 2
17、 C, so that not more than 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 min without rupture of the insulation.
18、 3.6.4 Oil Absorption Test A specimen 610 mm long shall be immersed to within 38 mm from the ends in a mixture of equal parts of M14J167 hydrocarbon thinner and ESE-M2C36 heavy duty lubricating oil at a temperature of 48 - 50 C for a period of 20 h. The sample shall then be removed from the solution
19、, examined for deterioration of the insulation compound and gaged for swelling. The outside diameter of the insulation of the cable shall not increase more than 15%. The sample shall then be bent around a mandrel (Table III) and checked for cracking. After the bend test, the cable shall be subjected
20、 to the dielectric test, para 3.6.3. ENGINEERING MATERIAL SPECIFICATION ESF-M1L56-A ESF-M1L57-A Page 4 of 7 Copyright 2003, Ford Global Technologies, Inc. 3.6.5 Cold Bend Test A straight specimen shall be reduced to a temperature of -40 C at a rate not to exceed 50 C/min. After maintaining this temp
21、erature for 3 h and while still at this low 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 diele
22、ctric test, para 3.6.3. 3.6.6 Flame Test 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 ap
23、plied to the end of the specimen for 15 s. After removal of the flame the specimen shall not continue to burn for more than 30 s. 3.6.7 Abrasion Resistance As per Table IV (SAE J 1128) 3.6.8 Non Staining The insulation shall not stain trim materials which it may contact in assembly. There shall be n
24、o evidence of stain on the face side of trim material when tested as follows: Test Method: Place a 150 mm length of insulated wire in intimate contact with the back of the trim material with which it may come in contact and expose for 7 days in a fluorescent sunlamp cabinet per FLTM BV 107-02. ENGIN
25、EERING MATERIAL SPECIFICATION ESF-M1L56-A ESF-M1L57-A Page 5 of 7 Copyright 2003, Ford Global Technologies, Inc. TABLE I CABLE CONSTRUCTION SAE Wire Size No. of Wires Nominal Strand Size Approx. Dia. of Stranded Conductor Area of conductor Awg mm mm mm222 7 30 0.254 0.76 0.355 20 7 28 0.320 1.02 0.5
26、54 18 16 30 0.254 1.27 0.795 18 10 28 0.320 1.27 0.804 16 19 29 0.287 1.52 1.186 16 16 28 0.320 1.52 1.186 14 41 30 0.254 1.91 1.914 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 65 28 0.320 2.92 4.785 10 49 27 0.
27、361 2.92 4.785 10 19 23 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 6 133 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 SPE
28、CIFICATION ESF-M1L56-A ESF-M1L57-A Page 6 of 7 Copyright 2003, Ford Global Technologies, Inc. TABLE II INSULATION SAE Wire Size Nominal Insulation Wall Thickness Maximum Diameter of Finished Cable mm mm 22 0.58 2.10 20 0.58 2.41 18 0.58 2.54 16 0.58 2.92 14 0.58 3.18 12 0.66 3.81 10 0.79 4.70 8 0.94
29、 6.22 6 1.09 7.75 4 1.12 9.53 TABLE III MANDREL SIZES Gage Size High Temperature Test Bend and Cold Resistance Test Suspension Weight for High Temperature Test mm mm kg 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 0.45 10 254 152 1.36 8 254 152 1.36 6 254 25
30、4 2.72 4 254 254 2.72 ENGINEERING MATERIAL SPECIFICATION ESF-M1L56-A ESF-M1L57-A Page 7 of 7 Copyright 2003, Ford Global Technologies, Inc. TABLE IV ABRASION RESISTANCE DATA Gage Size Minimum Resistance Length of Tape Weight Support Bracket Weight mm kg 22 457 A 0.45 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 1.36 4 762 C 1.36
