FORD ESB-M1L123-A-2012 CABLE LOW TENSION POLYETHYLENE INSULATED REDUCED WALL THICKNESS BARE TO BE USED WITH FORD WSS-M99P1111-A .pdf

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1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev 03 2012 05 30 Re-Activated Re-Activate A1 M. Gramlich, NA 2012 03 20 INACTIVATED ESB-M1L123-A inactivated M. Gramlich, NA 1988 06 09 CAS1-PF235551 Released R.D. Moore J.A. Ferrari Controlled document at www.MATS Copyright 2012, Ford Globa

2、l Technologies, Inc. Page 1 of 4 CABLE, LOW TENSION, POLYETHYLENE ESB-M1L123-A INSULATED, REDUCED WALL THICKNESS, BARE CABLE, LOW TENSION, POLYETHYLENE ESB-M1L123-A2 INSULATED, REDUCED WALL THICKNESS, TINNED 1. SCOPE The material defined by these specifications is a low tension stranded cable insula

3、ted with cross-linked polyethylene. The cable is similar to SAE J 1128 type SXL 2. APPLICATION These specifications were released for automotive applications requiring the use of cross-linked insulation. Note: The assemblers of electrical wire harnesses shall use the bulk wire suppliers as shown in

4、the Ford Motor Company Materials 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 (WSS-M99P1111-A). 3.2 CONDUCTOR 3.2.1 Unless otherwise specified

5、, the individual strands of the conductor shall be soft or annealed 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 measur

6、ing individual strand diameters and calculating the sum of the individual 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. When tinned conductor strands are specified, they

7、 shall withstand the continuity of coating tests specified in SAE J1128 (ESB-M1L123-A2 Only). 3.2.2 The strands shall be bunched per ASTM B 174. The maximum lay length shall be as specified in ASTM B 174 Table 2, Column A. Conductor strand count shall comply with Table 1. Missing strands are not all

8、owed. ENGINEERING MATERIAL SPECIFICATION ESB-M1L123-A ESB-M1L123-A2 Copyright 2012, Ford Global Technologies, Inc. Page 2 of 4 3.3 INSULATION 3.3.1 The color of the insulation shall be specified on the engineering drawing of the component utilizing this material. Base and strip colors shall correspo

9、nd to SAE J1128. Where striping 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 3.4 except 3.4.2, 3.4.3, and 3.4.4 mu

10、st be performed on the finished product. The insulation and the color may show no evidence of peeling or cracking and must conform to the color tolerances specified. 3.3.2 The insulating material shall be flame retardant, homogeneous, cross-linked polyethylene, similar to SAE J1128 type SXL. The mat

11、erial shall adhere closely to, but strip readily from the conductors, leaving them free of insulation and in suitable condition for applying terminals. Water soluble stripping agents shall not be used. 3.3.3 Insulation thickness shall comply with the requirements of Table 2. Insulation thickness sha

12、ll 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, Reference Standard for Electrical Wires, Cables, and Flexible Cords, P

13、aras 240 through 250.11. In case of dispute the referee method shall be the optical device. 3.4 CABLE QUALITY TESTS The following tests: Dielectric Test, Cold Bend Test, Flame Test, Oil Absorption Test, Overload Test, and Short Circuit Test correspond respectively to sections 4.3, 4.4, 4.5, 4.6, 4.7

14、, and 4.8 of SAE J1128 type SXL. For Cold Bend and Oil Absorption tests the requirements for 22 gage wire shall be the same as those for 20 gage wire. The test listed below shall be conducted in addition to the test listed above. 3.4.1 Insulation Physical Properties Test This test shall be conducted

15、 in accordance with Section 4.2 of SAE J1128 for type SXL except that the test temperature shall be 160 +/- 2 C. 3.4.2 Pinch Test This test shall be conducted in accordance with Section 4.9 of SAE J1128 except that the minimum values for pinch resistance shall comply with those listed in Table 3. 3.

16、4.3 High Temperature Resistance 25 mm of the insulation shall be removed from each end of a 600 mm sample of the finished cable. The sample shall be suspended around a cylindrical mandrel having a diameter specified in Table 4. The weight specified for the Cold Bend test above (SAE J1128, Section 4.

17、4, Table 5, Type SXL) 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 cool, the specimen shall be removed from the mandrel and wrapped in the reverse direction around a mandrel of th

18、e diameter specified for the Cold Bend Test in the manner prescribed for the Cold Bend Test. The specimen shall then be subjected to the Dielectric Test (SAE J1128, Section 4.3). ENGINEERING MATERIAL SPECIFICATION ESB-M1L123-A ESB-M1L123-A2 Copyright 2012, Ford Global Technologies, Inc. Page 3 of 4

19、TABLE 1 CONDUCTOR DIMENSIONS Wire Size SAE Conductor Stranding (a) Conductor Area (b) Nominal (a) Cond. Dia Strand No. Nom. Size mm Minimum mm2 Maximum mm2 mm 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 1.17 18 16 0.254 0.7788 0.8333 1.17 16 19 0.287 1.184

20、 1.267 1.45 14 19 0.361 1.876 2.007 1.80 12 19 0.455 2.956 3.163 2.29 10 19 0.574 4.734 5.066 2.87 (a) Neither the nominal strand diameter nor nominal conductor diameter are intended for checking purposes. However, the individual strands must not vary from nominal by more than plus or minus 10%. (b)

21、 Conductor areas are based on SAE J1128 minimums where applicable, with a 7% tolerance. TABLE 2 INSULATION DIMENSIONS Wire Size SAE Minimum Insulation Thickness Nominal Insulation Thickness Finished Cable Diameter mm (c) mm (d) Minimum Maximum Nominal mm mm mm 22 0.305 0.406 1.50 1.65 1.57 20 0.305

22、0.406 1.70 1.85 1.78 18 0.305 0.406 1.91 2.06 1.98 16 0.305 0.406 2.18 2.34 2.26 14 0.305 0.406 2.54 2.69 2.62 12 0.381 0.457 3.10 3.30 3.20 10 0.432 0.533 3.84 4.04 3.94 (c) Refer to para. 3.3.3. No one reading may be less than shown. (d) The average insulation thickness shall not be less than 90%

23、of nominal insulation thickness. ENGINEERING MATERIAL SPECIFICATION ESB-M1L123-A ESB-M1L123-A2 Copyright 2012, Ford Global Technologies, Inc. Page 4 of 4 TABLE 3 PINCH TEST Wire Size Min. Pinch Resistance SAE kg 22 2.0 20 2.7 18 4.0 16 4.0 14 4.0 12 4.5 10 5.0 TABLE 4 HIGH TEMPERATURE RESISTANCE MANDREL SIZES WIRE SIZE MANDREL SIZE SAE mm 22 115 20 115 18 115 16 165 14 165 12 165 10 255