Engineering Specification

PART NAME PART NUMBER

FORD GLOBAL WIRE SPECIFICATION ES-AU5T-1A348-AA
LET A A A A A A A A A A A A A A A A A A A
FR 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
LET A A A A A A A A A A
FR 20 21 22 23 24 25 26 27 28 29
LET FR REVISIONS DR CK REFERENCE
10-24-07 A ALL Released ES-AU5T-1A348-AA RP MW WSK-1A348-A2,A3,A4
10-24-07 Notice # AELE-E-11789584-040 RP MW PREPARED/APPROVED BY
Rakesh Patel
CHECKED BY DETAILED BY
Mike Wrobel
CONCURRENCE/APPROVAL
SIGNATURES
Design Engineering Supervisor
Mike Wrobel
Design Engineering Management
George Kawwas
Manufacturing Engrg.

Quality Control

Purchasing

Supplier Quality Assistance

FRAME 1 OF 29 REV A
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May 1988 3947a1e (Previous editions may NOT be used)
Engineering Specification
Ford Global Wire specification

FRAME 2 OF 29 REV. LET. A PART NO. ES-AU5T-1A348-AA

TABLE OF CONTENT

ENGINEERING SPECIFICATION
1 SCOPE 3
2 APPLICATION 3
3 REQUIREMENTS 3
3.1 QUALITY SYSTEM REQUIREMENTS 3
3.2 INFRARED SPECTROPHOTOMETRY AND/OR THERMAL ANALYSIS 3
3.3 TESTING, CONDITIONING AND TEST CONDITIONS 3
3.3.1 OVEN 3
3.4 CABLE TEMPERATURE CLASS 4
3.5 CABLE OUTSIDE DIAMETER 4
3.6 CONDUCTOR 4
3.7 CONDUCTOR DIAMETER 4
3.8 INSULATION COLOUR 4
3.9 INSULATION THICKNESS 4
3.10 ELECTRICAL CHARACTERISTICS 5
3.10.1 CONDUCTOR RESISTANCE 5
3.10.2 WITHSTAND VOLTAGE, 30 MINUTES 5
3.10.3 1 MINUTE WITHSTAND VOLTAGE 6
3.10.4 INSULATION FAULTS 6
3.10.5 INSULATION VOLUME RESISTIVITY 7
3.11 MECHANICAL CHARACTERISTICS 7
3.11.1 PRESSURE TEST AT HIGH TEMPERATURES 7
3.11.2 LOW TEMPERATURE WINDING 8
3.11.3 LOW TEMPERATURE IMPACT 9
3.11.4 ABRASION RESISTANCE 10
3.11.5 SHORT TERM HEAT AGING 12
3.11.6 LONG TERM HEAT AGING (For Initial Qualification Only) 13
3.11.7 THERMAL OVERLOAD 13
3.11.8 SHRINKAGE BY HEAT 14
3.11.9 LOSS OF MASS (For Initial Qualification Only) 14
3.11.10 FLEXIBILITY TESTS 14
3.11.11 NOTCHING RESISTANCE 15
3.11.12 RESISTANCE TO FLAME PROPAGATION 16
3.11.13 COLUMN STRENGTH 17
3.11.14 HOT WATER TEST (For Initial Qualification Only) 18
3.12 RESISTANCE TO CHEMICLALS (initial qualification only) 19
3.13 ENVIRONMENTAL CYCLING 20
3.14 RESISTANCE TO OZONE 21
4 SUPPLIER'S RESPONSIBILITY 22
5 TABLES 23
5.1 Table 1 - CONDUCTOR STRANDING AND DIMENSIONS 23
5.2 Table 2 – WIRE DIMENSIONS 24
5.3 Table 3 - CONDUCTOR RESISTANCE ( / km, max) 25
5.4 Table 4.1 - SCRAPE ABRASION 25
Table 4.2 - SANDPAPER ABRASION 26
5.5 Table 5 - MANDREL DIAMETERS 26
5.6 Table 6 - FLUID COMPATIBILITY 27
5.7 Table 7 - FLEXIBILITY TEST: WIRES ≤3.0 mm². 27
5.8 Table 8 - IMPACT 27
5.9 Table 9 - INSULATION COLORS 28
6 Draft Code 28
APPENDIX A WIRE SIZE COMPARISON CHART 29

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Engineering Specification
Ford Global Wire specification

FRAME 3 OF 29 REV. LET. A PART NO. ES-AU5T-1A348-AA

1 SCOPE
The products defined by these specifications are low tension stranded and insulated cables.

PRIMARY LOW TENSION CABLE 85°C

PRIMARY LOW TENSION CABLE 100°C
PRIMARY LOW TENSION CABLE 125°C
PRIMARY LOW TENSION CABLE 150°C

The specification has been agreed by the following FORD Business Units:

Ford NA
Ford of Europe
Jaguar
Volvo Cars
Land Rover

2 APPLICATION
These cable specifications were originally released for use at 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, ISO-9000. Material
specification requirements are to be used for initial qualification of 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 process/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.

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 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 TESTING, CONDITIONING AND TEST CONDITIONS

Initial qualification tests shall be performed by a certified, independent test laboratory unless otherwise agreed
with the appropriate Ford business unit.

All test values indicated herein are based 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.

3.3.1 OVEN
An oven with air exchange, either natural or by pressure should be used. The air shall enter the oven in such a
way that it flows over the surface of the test pieces and leaves near the top of the oven. The oven shall have
not less than 8 and not more than 20 complete air changes per hour at the specified ageing temperature. If the
insulating material on the tested wire includes a volatile softener with influence on flexibility and performance in
low temperature winding test after ageing, the air should be changed a minimum of thirty five (35) times per
hour.

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3.4 CABLE TEMPERATURE CLASS

Depending upon the service conditions, the cables shall be made to belong to one of the following four classes
of temperature:
o
Class 1 -40 to + 85 C
Class 2 -40 to + 100 oC
o
Class 3 -40 to + 125 C
o
Class 4 -40 to + 150 C

3.5 CABLE OUTSIDE DIAMETER

No single value shall be outside the acceptable range of diameter as specified in Table 2.

Test Sample: The test sample length shall be approximately 4m.

Procedure: Determine the outside cable diameter by taking four sets of measurements rotated at 90° at least
1m apart. Record the overall diameter at each point. The accuracy of the measuring instrument shall be +/-
0.01 mm. The measuring device shall not deform the test sample when taking measurements.

3.6 CONDUCTOR
Conductors shall consist of soft annealed copper, soft annealed compressed/compacted copper, hard un-
annealed copper, tinned copper. The specifications for the conductors are to be in line with ASTM B1, ASTM
B3 and ASTM B33. Elongation and lay length requirements shall be per ASTM B174.

Minimum conductor strand count and diameter shall comply with Table 1. Strand count according to Structure A
– C shall be agreed on with the appropriate Ford business unit before commencement of testing. The finished
cable shall meet the resistance requirements of Table 3.

3.7 CONDUCTOR DIAMETER

No single value of strand and conductor diameter shall be outside the acceptable range of diameter as
specified in Table 1 and Table 2.

Test Sample: The test sample length shall be approximately 4m.

Procedure: Determine the conductor diameter by stripping the insulation at the point of measurement and
taking four sets of measurements rotated at 90°, at least 1m apart. Record the conductor diameter at each
point. The accuracy of the measuring instrument shall be +/- 0.01 mm. The measuring device shall not deform
the test sample when taking measurements.

3.8 INSULATION COLOUR

The colour of the insulation shall be specified on engineering drawings. The insulation colour tolerances are
specified in Table 9.

Where striping is specified, either one or two stripes may be used. The individual stripe 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.

3.9 INSULATION THICKNESS

Test samples
Prepare three test samples from a cable 3 meters in length; the samples are to be taken at intervals of 1 meter.
Strip the insulation from the cable and cut 3 X thin cross sections of insulation at the distances specified above.
Care must be taken to ensure that deformation of the sample does not occur during the preparation process. If
cable marking causes indentation of the insulation, take the first sample through this indentation.

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Apparatus
The accuracy of the measuring instrument shall be +/- 0.01 mm; the device shall not cause deformation.

Procedure
Place the test sample under the measuring equipment, with the plane of the cut perpendicular to the optical
axis. Determine the minimum insulation thickness of each sample.

Requirement:
No single value shall be less than the appropriate insulation thickness specified in table 2.

3.10 ELECTRICAL CHARACTERISTICS

3.10.1 CONDUCTOR RESISTANCE
Procedure:
Prepare a test sample of 1m length plus the length necessary for connections. Other lengths may be used
providing that the resistance reading is adjusted using the equation below. The ends of the test sample may be
soldered.

Apparatus
Use a resistance measuring device with an accuracy of +/- 0.5% of the measured value and a thermometer
with an accuracy of +/- 0.5°C.

Rt
R20 =
L[1 + 0,00393(t − 20 )]

Where:
o
R20 is the corrected conductor resistance at the reference temp of 20 C, expressed in m /m.
Rt is the conductor resistance in m , measured at the conductor temperature t.
L is the unsoldered conductor in length, expressed in m,
t is the conductor temperature at the time of measuring, expressed in °C

Note:
The value of 0,00393 is the temperature coefficient for copper with 100% conductivity at temperatures near
20°C. For coated wires or alloys, the correction factor shall be established by agreement between the supplier
and customer.

Requirement:
Resistance values should meet those specified in Table 3.

3.10.2 WITHSTAND VOLTAGE, 30 MINUTES

Test Sample:

Prepare a test sample to a minimum length of 350 mm, strip 25 mm of insulation from each end and twist them
together to form a loop.

Apparatus:

Partially fill a non-conductive vessel with salt water [3% by weight of NaCl in water] with the ends of the test
sample emerging above the bath as shown in Figure 1. Use a 50 or 60 Hz voltage source.

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Immerse the test sample as shown in Figure 1 for 4 h in the bath and then apply a test voltage of 1kV (rms) for
30 min between conductor and the bath. Then increase the voltage at a rate of 500 V/s until the following value
is reached:

3 kV (rms) for cables < 0.5 mm²

5 kV (rms) for cables => 0.5 mm²

Requirement:
Breakdown shall not occur.

3.10.3 1 MINUTE WITHSTAND VOLTAGE

This test is only to be performed when specifically requested.

Test Sample:
Prepare a test sample to a minimum length of 350 mm, strip 25 mm of insulation from each end, and twist them
together to form a loop.

Apparatus:
Partially fill a non-conductive vessel with salt water [3% by weight of NaCl in water] with the ends of the test
sample emerging above the bath as shown in Figure 1. Use a 50 or 60 Hz voltage source. Immerse the test
sample as shown in Figure 1 for 10min in the bath and then apply a test voltage of 1kV (rms) for 1 min

Requirement:
Breakdown shall not occur.

3.10.4 INSULATION FAULTS

This test is to be carried out under production conditions. Subject all cables to the following:

Apparatus:
Use a sinusoidal voltage source at the value shown in the table below. The test electrode may consist of metal
ball chains, metal brushes, or any other type of suitable electrodes. Choose the electrode length and frequency
considering the speed of the cable running through the field of the electrode so that each point of the cable is
loaded by at least nine voltage cycles.

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Voltage Rating kV (rms)

Conductor
size mm2 60 V Cables
< 0.5 3
= > 0.5 5

Requirement:
No breakdown shall occur when the earthed cable is drawn through the test electrode.

3.10.5 INSULATION VOLUME RESISTIVITY

Prepare a test sample of 5 m length and remove 25 mm of insulation from each end.

Apparatus
Partially fill a non-conductive vessel with tap water at a temperature of (70 +/- 2) ºC. Use a resistance
measuring device with a DC voltage of 500 V. Voltages between 100 V and 500 V are allowed; however, if a
dispute arises, the referee apparatus shall be a resistance measuring device with a DC voltage of 500 V.

Procedure: Immerse the test sample for 2 h with each end emerging from the bath by 250 mm. Apply the DC
voltage between the conductor and the bath. Measure the insulation resistance 1 min after application of the
voltage. Calculate the 'Insulation volume resistivity' using the following formula:

L× R
ρ 0 = 2,725 ×
D
lg
d
Where:
0 is the insulation volume resistivity, expressed in mm;
L is the immersed length of the test sample in mm;
R is the measured insulation resistance in ;
D is the outside cable diameter in mm according to Table 1;
d is the conductor diameter in mm according to Table 2;
lg is logarithm to the base 10.

Requirement:
The insulation volume resistivity shall not be less than 109 mm.

3.11 MECHANICAL CHARACTERISTICS

3.11.1 PRESSURE TEST AT HIGH TEMPERATURES

Prepare 3 test samples, each of 600mm in length.

Apparatus
Perform this test with the test apparatus shown in Figure 2.

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Ensure that the apparatus is free from vibrations. Apply the force F by the blade to the test sample as given by
the formula:
F=0,8 i(2×D−i)

Where:
F is the total vertical force exerted on the test sample in N;
0,8 is a coefficient which carries the dimension in (N/mm);
D is the appropriate "Outside cable diameter maximum" in mm according to Table 2;
i is the appropriate nominal value of the "Insulation thickness" in mm according to Table 2.

The calculated force may be rounded off at the lower digit, but not beyond 3%.

Procedure:
Place the test samples as shown in Figure 2. Attach the test samples to the support so as not to bend under the
pressure of the blade. The load and the blade of the apparatus shall be perpendicular to the test sample axis.
Place the test samples under load, not preheated, for 4 h in an oven at the maximum rated cable class
temperature. Then cool the test samples within 10 s by immersion in cold water. After immersion, subject the
test samples where the pressure was applied to the '1 min withstand voltage' test as specified in 3.10.3

Requirement:
Breakdown shall not occur during the withstand voltage test.

3.11.2 LOW TEMPERATURE WINDING

This test is to be carried out on all cable sizes up to and including 10mm2, using the masses and mandrels
listed in Table 5.

Test Samples:
Prepare two test samples of 600 mm and remove 25 mm of insulation from each end.

Apparatus
A freezing chamber at(-40 +/- 2)°C. Either a rotatable or a stationary mandrel may be used.

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Rotatable mandrel – When a rotatable mandrel is used, it shall conform to Figure 3 and the test samples shall
be fixed on the mandrel as shown in the fig. The free ends are loaded with the mass. Position the mandrel with
the test samples hanging vertically The masses and mandrels are specified in Table 5.

Stationary mandrel – When a stationary mandrel is used, no mass is used. The test samples shall be wrapped
around the mandrel by hand.

Procedure:
The test samples and mandrel shall be conditioned for a minimum of 4 h in the freezing chamber. Wind at least
the 'minimum number of turns' specified in Table 5 around the mandrel within the freezing chamber at 'winding
speed' as specified in Table 5. Take care to ensure that there is continuous contact between the test samples
and the mandrel.

After the cold winding, allow the test sample to return to room temperature and conduct a visual examination of
the insulation. If no exposed conductor is visible, perform the '1 min withstand voltage' test as specified in
3.10.3.

Figure 3- Apparatus for winding

Requirement:
After winding, no conductor shall be visible. During the 'withstand voltage' test, breakdown shall not occur.

3.11.3 LOW TEMPERATURE IMPACT

This test is to be conducted on all wire sizes.

Prepare three test samples, each of 1.2 m length and remove 25 mm of insulation from each end. Perform the
'impact test' using the apparatus shown in Figure 4, positioned on a sponge rubber pad of 40mm thickness.

The mass of the hammer is specified in Table 8. Set the freezing chamber temperature to (-15 +/- 2)°C.

Procedure:
Perform the 'impact test' in the middle of the test samples. Place the apparatus, positioned on the sponge
rubber pad, together with the test samples in the freezing chamber for at least 16 h. If the apparatus is pre-
cooled, a freezing time of 4h is sufficient, providing that the test samples have reached the specified
temperature. At the end of this period, place the test sample parallel to the steel base. The hammer is then

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allowed to fall from a height of 100 mm. After the impact, allow the test samples to return to room temperature,
and make a visual examination of the insulation.

If no exposed conductor is visible, perform the '1 min withstand voltage' test as specified in 3.10.3.

Requirement:
After impact, no conductor shall be visible. During the '1 min withstand voltage' test, breakdown shall not occur.

Figure 4 – Apparatus for impact

3.11.4 ABRASION RESISTANCE

Usage of test
This test is only applicable to cables with a conductor size 6 mm2, for which either 3.11.4.1 (Scrape abrasion)
or 3.11.4.2 (Sandpaper abrasion) shall be used. The customer and supplier shall define which test shall be
2
used. No abrasion test is required for conductor sizes > 6 mm .

3.11.4.1 SCRAPE ABRASION

Prepare a test sample of 1 m length and remove 25 mm of insulation from each end.

Apparatus
Use a Scrape Abrasion apparatus as detailed in figure 5a.

It consists of a device designed to abrade the surface of the insulation in both directions along the longitudinal
axis of the test sample and a counter for recording the numbers of cycles to failure. It shall be controlled so that
when the needle abrades through the insulation and makes contact with the conductor, the machine will stop
operating.

The characteristics of a suitable apparatus shall be as follows:

Diameter of needle: 0.45mm +/- 0.01mm

Type of needle: Spring wire (polished) material according to ISO 8458-2;
Frequency: (55 +/- 5) cycles/min (one cycle = one reciprocating movement);

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Displacement of the needle: (20 +/- 1) mm;

Length of abrasion: (15.5 +/- 1) mm;
Type of movement: Design details shall not influence the test result;
Mass (position, value, design details): The vertical force on the test sample constant under dynamic conditions;
Test sample mounting force: The test sample shall not move during test. If fixing is necessary, the
tension applied on the conductor shall not exceed 100 N/mm²;
Stability of equipment: The apparatus shall be so stable that the results shall not be affected;

Procedure:
Apply a total vertical force of (7 +/- 0,05) N to the test sample. Determine the number of cycles by taking four
measurements at a temperature of (23 +/- 1)°C. After each reading, move the test sample 100 mm and rotate it
clockwise 90°. Change the needle after each reading.

Needle diameter d:
0.45 ± 0.01 mm

Figure 5a – Apparatus for Scrape Abrasion

Requirement:
The scrape abrasion resistance shall meet the minimum abrasion requirements in Table 4.1.

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3.11.4.2 SANDPAPER ABRASION

Prepare a test sample of 1 m length and remove 25 mm of insulation from each end.

Apparatus

Measure the "Resistance to sandpaper abrasion" using 150 J garnet sandpaper tape with 5 - 10 mm
conductive strips perpendicular to the edge of the sandpaper spaced a maximum of every 75 mm. Mount a
suitable bracket to the pivoting arm (see Figure 5b) to maintain the test sample position over an unused portion
of the sandpaper abrasion tape. Exert a force of (0,63 ± 0,05) N on the test sample by the combination of the
bracket, support rod, and pivoting arm. The total vertical force exerted on the test sample shall be the
combination of the force exerted by the bracket, pivoting arm, support rod and additional mass. The additional
mass shall be according to Table 4.2.

Procedure

Mount the test sample taut, without stretching, in a horizontal position using an area of the sandpaper abrasion
tape not previously used. Place the additional mass and bracket on top of the test sample. Draw the sandpaper
abrasion tape under the test sample at a rate of (1500 ± 75) mm/min and record the length of sandpaper
abrasion tape necessary to expose the conductor. Move the test sample 50 mm and rotate the test sample
clockwise 90°. Repeat the procedure for a total of four readings. The mean of the readings shall determine the
resistance to sandpaper abrasion.

Key
1 Support rod
2 Additional mass
3 Pivoting arm
4 Test sample
5 Bracket
6 Tape supporting pin, diameter = 6,9 mm
7 150 J, garnet sandpaper abrasion tape

Figure 5b — Apparatus for sandpaper abrasion test

Requirement

The resistance to sandpaper abrasion shall meet or exceed the minimum length of sandpaper requirements
according to Table 4.2.

3.11.5 SHORT TERM HEAT AGING

This test is to be carried out on 3 sample colours, Red, White and Blue. The samples are to be prepared from
wire manufactured under production conditions.

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Test samples:
Prepare two test samples of each colour, each of a minimum length of 350 mm and remove 25 mm of insulation
from each end.

Apparatus
Perform the short-term aging test using an oven at the upper limit temperature specified in Para 3.4 + 25°C;
and winding test in a freezing chamber at (-25 +/- 2)°C. The masses and mandrels are specified in Table 5.

Procedure:
The air contained in the oven shall be completely changed a minimum of eight (8) times and a maximum of
twenty (20) times per hour at the specified temperature. If the insulating material on the tested wire includes a
volatile softener with influence on flexibility and performance in low temperature winding test after ageing, the
air should be changed a minimum of thirty five (35) times per hour.

Place the test samples for 240 h in an oven. Fix the test samples by the conductor to avoid any contact
between the insulation and the supports. The test samples shall be separated by at least 20 mm from each
other and from the inner surface of the oven. Cable insulations made of different materials shall not be tested at
the same time. After aging, withdraw the test samples from the oven and maintain them at (23 +/- 5)°C for at
least 16 h. After conditioning at room temperature, perform the 'winding test' (see clause 3.11.2) using the
freezing chamber and the mandrels described in table 5. After winding, allow the test samples to return to room
temperature, and make a visual examination of the insulation.

If no exposed conductor is visible, perform the '1 min withstand voltage' test as specified in 3.10.3

Requirement:
After winding, no conductor shall be visible. Colour must be identifiable after the test. During the 'withstand
voltage' test, breakdown shall not occur.

3.11.6 LONG TERM HEAT AGING (For Initial Qualification Only)

This test is to be carried out on 3 sample colours, Red, White and Blue. The samples are to be prepared from
wire manufactured under production conditions.

Test samples

Prepare two test samples of each colour, each of a minimum length of 350 mm, and remove 25 mm of
insulation from each end.

Perform the long-term aging test using an oven at the upper limit temperature specified in Para 3.4. The
masses and mandrels are specified in Table 5.

Procedure:
Follow the same procedure as 3.11.5 with the following two exceptions.

Use an ageing time of 3000 h

Perform the 'winding test' at room temperature

Apply the 1 minute withstand voltage test as specified in 3.10.3

Requirement:
After winding, no conductor shall be visible. Colour must be identifiable after the test. During the 'withstand
voltage' test, breakdown shall not occur.

3.11.7 THERMAL OVERLOAD

This test is to be carried out on 3 sample colours. Red, White and Blue. The samples are to be prepared from
wire manufactured under production conditions.

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Prepare two test samples of each colour, each of 350 mm minimum length, and remove 25 mm of insulation
from each end.

Apparatus
Perform the thermal overload test using an oven at the upper limit temperature specified in Para 3.4 + 50°C.
The masses and mandrels are specified in Table 5.

Procedure:
Follow the same procedure as 3.11.5 with the following two exceptions

Use an aging time of 6 h

Perform the 'winding test' at room temperature

If no exposed conductor is visible, perform the '1 min withstand voltage' test as specified in 3.10.3

Requirement:
After winding, no conductor shall be visible. Colour must be identifiable after the test. During the 'withstand
voltage' test, breakdown shall not occur.

3.11.8 SHRINKAGE BY HEAT

Test samples:
Prepare three test samples, each of 100 mm length.

Apparatus
Perform the test using an oven at (150 +/- 3)°C.
Procedure:
Measure the exact length of the insulation of the test samples at room temperature (23 +/- 5)°C prior to the test.
Put the test samples in the oven, in a horizontal position, so that air may circulate freely from all sides for 15
min. After cooling to (23 +/- 5)°C, measure the length of the insulation again.

Requirement:
The maximum shrinkage shall not exceed 2 mm from either end.

3.11.9 LOSS OF MASS (For Initial Qualification Only)

In accordance with SAE J1756.

3.11.10 FLEXIBILITY TESTS

This is to be conducted on wires 3.0 mm² in a test equipment according to Figure 6a and 6b.

Procedure:
A force of 2N (F2) will be applied to the wire. The wire will be pulled through the apparatus at a speed of 50
mm/min. Once the tensile force (F1) is stable it will be measured over a wire length of 125mm.

To determine the resistance of the equipment the force (F3) can be measured by pulling an aramid roving
through the apparatus at 50 mm/min.

The force required to pull the wire through the equipment can be calculated as follows: F = F1 - F2 - F3

Requirement:
For Temp class (Para 3.4) 2, 3 and 4 wires, the force (F) should meet the requirements of Table 7.

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2
Figure 6a Apparatus for flexibility test (Wire size 3 mm )

2
Figure 6b – Apparatus for flexibility test (Wire size 3 mm )

3.11.11 NOTCHING RESISTANCE

This test is to be performed after Resistance to Chemical test.

Procedure:
The test set-up (see Figure 7) comprises a tensile testing machine, a notching tool (blade), a power circuit with
a small voltage and a load-sensing device (plotter or other display unit).

The notching tool must use a 0.45mm round spring wire in accordance with ISO 8458-2.

All sample sizes taken from the table under "Requirements" shall be secured in the tensile testing machine in
accordance with Figure 7.

The steel wire shall be pushed through the insulation at a constant speed of max. 10 mm/min, until an electrical
contact between the steel wire and the conductor shuts off the machine. The axes of the specimen and the
blade are at right angles to each other here.

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The force recorded at the time of contact is noted. After each reading the specimen is move along by 25 mm
more and rotated a total of 4 times by 90° through its longitudinal axis. The average value of the 4
measurements is the notching force

Figure 7 – Apparatus for Notching

Requirement:
The initial (un-aged) notching force must meet the requirements of the following table.

Nominal cable mm² 0.22 0.35 0.5 0.75 1.0 1.5 2.0 2.5 4.0 6.0
section
Notching force (min.) N 20 30 40 50 50 60 60 70 100 120

3.11.12 RESISTANCE TO FLAME PROPAGATION

2
Prepare three test sample of wire size 0.5 mm with at least 600 mm of insulation.

Apparatus:
Determine the 'resistance to flame propagation' using a Bunsen burner fed with appropriate gas (Figure 8),
having a combustion tube of 9 mm internal diameter, and a flame height of 100 mm. The length of the inner
blue cone of the flame shall be 50 mm.

Procedure:
Suspend the test sample in a draught free chamber and expose the test sample to the tip of the inner cone of
the flame, a shown in Figure 8. The upper end of the cable shall point from the closest wall of the chamber.
The sample shall be subject to a stress, e.g. by means of a weight over a pulley, in order to keep it strait at all
times. The angle of the cable shall be 450 + 10 relative to the vertical line. Apply the flame (500 + 5) mm from
the upper end of the insulation. Finish the exposure to the test flame when the conductor becomes visible, or
after 15 s for cables with conductor sizes < 2,5 mm² and 30 s for cables with conductor sizes > 2,5 mm².
Remove the flame sideways from the cable after exposure.

Requirement:

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Any combustion flame of insulating material shall extinguish within 30 s from the end of ignition and a minimum
of 50 mm of insulation at the top of the test sample shall remain unburned. All the three samples must pass the
test.

Figure 8 – Apparatus for Resistance to flame propagation

3.11.13 COLUMN STRENGTH

Procedure: Test shall be conducted by the use of a tensile test machine and the test fixture described in Figure
9.

Figure 9 – Test fixture for Column Strength Test

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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 is not required for smaller sizes.

Prepare twenty-five (25) test samples of 40 mm +/- 0.5 mm long. Do not bend the wire prior to testing. Insert
the test wire in the appropriate cavities of the test fixture. The hole diameter shall not exceed the maximum
cable diameter for a specific wire size by more than +/- 0.03 mm. Ensure 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 compressed. This force shall be higher than the
values specified in the requirements below.

Requirements: Wire Size Min Force

0.35 mm2 15 N
0.5 mm2 15 N

3.11.14 HOT WATER TEST (For Initial Qualification Only)

Resistance to hot water is required on cables with all conductor sizes shall meet the requirements; however,
compliance may be demonstrated by testing examples of large and small conductor sizes only. Testing of
cables with conductor sizes of 0.35 mm² and 2.5 mm² is preferred.

For heavy duty cables, testing of cables with conductor sizes of 0.35 mm2 and 2.5 mm2 is acceptable if the
insulating material used is the same as the heavy duty cable.

Test samples:
Prepare two test samples, each of (2.5 +/- 0.1) m length and remove 25 mm of insulation from each end.

Apparatus:
The apparatus consists of a non-conductive vessel containing an unused salt water bath with 10 g/l of NaCl in
water at 85°C for each test, a 48 V DC power source, a mandrel 5 times the outside diameter of the test
sample, and a resistance measuring device.

Figure 10 – Apparatus for Resistance to Hot water

Procedure:

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Closely wind at least three complete turns of a test sample on the mandrel and secure the wraps as shown in
Figure 10. Immerse the test sample in the bath with both ends projecting 250 mm above the bath. To avoid
interactions between materials, do not test samples with different insulating materials in the same bath.
Connect one end of the test sample and the positive electrode of the power source.

After 7 days, disconnect the power supply and measure the 'insulation volume resistivity'. Use the procedure in
3.10.5 with the following changes: Measure the 'insulation volume resistivity' in the saltwater bath at 85°C. This
completes one cycle.

Repeat this procedure for a total of 5 cycles, i.e. 35 days. After conditioning, remove the test sample from the
bath, allow it to cool to room temperature, and a visual examination of the insulation. Ignore any damage
caused by the ties, which secure the coils.

If no exposed conductor is visible, perform the '1 min withstand voltage' test.

Repeat the entire test procedure using the second test sample but
with the polarity of the 48 VDC power supply reversed.

Requirement:
The 'insulation volume resistivity' shall not be less than 109 mm. A visual examination of the insulation shall
show no cracks. During the 'withstand voltage' test, breakdown shall not occur.

3.12 Resistance to chemicals

General
When any resistance to chemicals test is specified, compliance for a cable family may be demonstrated by
testing large and small sizes only.

The expressions "chemicals" and "fluids" may be used synonymous in the clause 3.12.

Purpose

This test is intended to verify resistance of the insulation to chemical loads in automotive environments where
exposure is limited.

Test setup

The test shall consist of one or several exposures to chemicals with intermediate exposure to heat ageing
conditions. Two different test media groups in accordance with Table 6 shall be tested, Media Group 1 with a
heat ageing period of 1000 hours at the actual cable class temperature, Media Group 2 with a heat ageing
period of 240 hours at the actual cable class temperature, see details under Test Performance.

Test samples

Prepare individual test samples, each 600 mm long with 25 mm of insulation removed from each end, bended
around a mandrel specified in Table 5 to an U-shape. The stripped ends should be formed as hooks, allowing
the test objects to be hung on to the grids in the oven. The number of test objects to be prepared for each
chemical according to Table 6.

Apparatus

Use an oven at the respective maximum temperature class rating according to Para 3.4. The oven shall be
equipped with grids, making it possible to hang the test objects on them. A collecting tray shall be placed in the
bottom of the oven to gather spill of chemicals.

Test Performance

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For each fluid to be tested: Immerse 2/3 of the test objects 10 s in the fluid, then remove from the fluid and
allow to drain off for 3 minutes before storage in the oven. Care should be taken that the stripped ends are not
exposed to the fluid. Test objects from one and the same type of tested cable, but exposed to the different test
fluids, can be stored in the same oven. Test objects from different types of cables are not allowed to be stored
in the same oven.

For Media Group 1 objects, the immersing in the respective fluid shall be repeated at 240, 480 and 720 h of the
1000h test in the following way: Initially immerse 8 objects for each fluid and store in the oven. At 240 h take
out two objects and pass them on to final test according to below, the remaining 6 objects should be re-
immersed and stored in the oven for another 240 h exposure. At 480 h take out another two objects for final
test, and re-immerse the remaining 4 objects. At 720 h, again take out two objects for final testing and re-
immerse the remaining 2 objects for storing up to 1000 h.

Media Group 2 objects should only be immersed once, before the exposure in the actual cable class
temperature.

After fulfilled exposure, remove the test samples from the oven and maintain them at RT (23 ± 5 oC) for 30 min.
Thereafter, perform the "Winding test" at room temperature. Make sure that the winding test is performed in the
middle of the test objects. After winding, make a visual examination of the insulation. If no exposed conductor is
visible, perform the "1 minute Withstand voltage" test.

Requirements

Insulation shall not exhibit cracks after mandrel wrap test.

No dielectric failure shall occur during withstand voltage test. The notching resistance force values of all heat
aged samples must be at least 20% of those values recorded against the comparable virgin samples.

3.13 ENVIRONMENTAL CYCLING

Prepare two samples of approximately 600 mm length and remove 25 mm of insulation from each end. For
wires <3mm² use 0.75mm². For wires 3 mm2 and <10 mm2, use 4mm². For wires >10 mm2, use 25mm2.

Apparatus
Perform the test in a temperature chamber, which is capable of cycling between (-40 +/- 2)°C and the maximum
wire temperature.
The chamber shall also be capable of controlling the relative humidity between (5 +/- 5)% and (90 +/- 5)%. See
Table 5 for mandrel sizes.

Procedure: Wind at least the 'minimum number of turns' specified in Table 5 around the mandrel and secure the
ends. Condition the test samples according to the temperature and relative humidity shown in Figure 11. The
cycle begins and ends with the chamber at (-40 +/- 2) °C and (5 +/- 5) % relative humidity. This will constitute
one cycle.

Repeat the cycle for a total of 40 cycles. While still on the mandrel, remove the test sample from the chamber,
allow them to warm at room temperature for approximately 30 min, and unwind it from the mandrel. Make a
visual examination of the insulation, Ignore any damage caused by the clamps, which secure the ends.

Apply the 1 minute withstand voltage test as specified in 3.10.3

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Figure 11 – Procedure for Environmental Cycling

Requirement:
After unwinding, no conductor shall be visible. Colour must be identifiable after the test. During the 'withstand
voltage' test, breakdown shall not occur.

3.14 RESISTANCE TO OZONE

Resistance to ozone is specified on cables with all conductor sizes shall meet the requirements however
compliance may be demonstrated by testing examples of large and small conductor areas. Testing 0,75 mm²
and 16 mm² is preferred. Test conditions for cables with other conductor sizes have been included for
reference purposes.

Prepare three test samples, each of 300 mm length.

Apparatus
Use an ozone chamber in accordance with IEC 811-2-1 with an
-6
atmosphere containing a mass fraction of (1 +/- 0,05) x 10 of ozone at (65 +/- 3)°C.

Attention is drawn to the highly toxic nature of ozone. Efforts should be made to minimize the exposure of
workers at all times. See Table 5 for 'mandrel diameter'.

Aluminum mandrels are preferred since other materials may affect the ozone concentration.

Procedure: Wind at least the 'minimum number of turns' specified in Table 5 and secure the ends. Condition the
test samples for 192 hours in the ozone chamber. While still on the mandrel, remove the test samples from the
ozone chamber; allow them to cool to room temperature, and make a visual examination of the insulation.
Ignore any damage caused by the clamps, which secure the ends.

Requirement:
The visual examination of the insulation shall show no cracks.

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4 SUPPLIER'S RESPONSIBILITY
All materials supplied to this specification must be equivalent in all characteristics to the material upon which
approval was originally granted.

Prior to making any change in the properties, composition, construction, colour, processing or labeling of the
material originally approved under this specification, whether or not such changes affect the material's ability to
meet the specification requirements. The Supplier shall notify Purchasing, Toxicology and the affected
Materials Engineering activity of the proposed changes and obtain the written approval of the Materials
Engineering activity. Test data, test samples and a new code Identification, are to be submitted with the
request.

Substance restrictions imposed by law, regulations or Ford, apply to the materials addressed by this document.
The regulations are defined in Engineering Materials Specification WSS-M99P9999-A1 latest issue (NB: This
document is normally updated annually). Suppliers must review this specification periodically to ensure product
is validated to the latest version.

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5 TABLES
5.1 Table 1 - CONDUCTOR STRANDING AND DIMENSIONS

Structure A Structure B Structure C

(symmetrical) (asymmetrical) (asymmetrical)

Min. No Min. No Min. No

ISO of Strand of Strand of Strand
Conductor strands diameter strands diameter strands diameter
size, mm2 Max. Max. Max.
mm mm mm
0,13 7 0,16 NA NA NA NA
0,22 7 0,21 NA NA NA NA
0,35 7 0,27 12 0,21 19 0,16
0.5 7 0,30 NA NA NA NA
0,5 19 0,19 16 0,21 26 0,16
0,75 19 0,24 24 0,21 38 0,16
1 19 0,27 32 0,21 54 0,16
1,25 19 0,30 NA NA NA NA
1,5 19 0,33 30 0,26 76 0,16
2 19 0,38 28 0,31 105 0,16
2,5 37 0,28 50 0,26 140 0,16
3 37 0,34 44 0,31 160 0,16
4 37 0,38 56 0,31 224 0,16
5 37 0,43 70 0,31 250 0,16
6 37 0,45 84 0,31 320 0,16
8 50 0,46 98 0,33 240 0,21
10 63 0,46 80 0,41 320 0,21
12 154 0,33 96 0,41 380 0,21
16 105 0,46 126 0,41 512 0,21
20 247 0,33 152 0,41 610 0,21
25 154 0,46 196 0,41 790 0,21
30 361 0,33 224 0,41 900 0,21
35 551 0,3 276 0,41 1070 0,21
40 494 0,33 308 0,41 1200 0,21
50 798 0,3 396 0,41 1600 0,21
60 741 0,33 296 0,51 1200 0,26
70 1140 0,3 360 0,51 1427 0,26
95 836 0,4 475 0,51 1936 0,26
120 1064 0,4 608 0,51 2450 0,26

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5.2 Table 2 – WIRE DIMENSIONS

Standard Wall Thin Wall Ultra Thin Wall

ISO Conductor Nominal Minimum Minimum Maximum Nominal Minimum Minimum Maximum Nominal Minimum Minimum Maximum
cond max OD mm mm Cable OD Cable OD mm mm Cable OD Cable OD mm mm Cable OD Cable OD
size mm mm mm mm mm mm mm
mm²
0.13 0.55 - - - - 0.25 0.20 1.05 0.20 0.16 0.85 0.95
0.22 0.70 - - - - 0.25 0.20 1.10 1.20 0.20 0.16 0.95 1.05
0.35 0.90 - - - - 0.25 0.20 1.20 1.40 0.20 0.16 1.10 1.20

0.50 1.10 - - - - 0.28 0.22 1.40 1.70 0.20 0.16 1.30 1.40
0.75 1.30 - - - - 0.30 0.24 1.70 1.90 0.20 0.16 1.45 1.60
1.0 1.50 - - - - 0.30 0.24 1.90 2.10 0.20 0.16 1.65 1.75

1.5 1.80 - - - - 0.30 0.24 2.20 2.40 0.20 0.16 1.95 2.10
2.0 2.00 - - - - 0.35 0.28 2.50 2.80 0.25 0.20 2.25 2.40
2.5 2.20 - - - - 0.35 0.28 2.70 3.00 0.25 0.20 2.55 2.70

3.0 2.40 - - - - 0.40 0.32 3.10 3.40 - - - -

4.0 2.80 - - - - 0.40 0.32 3.40 3.80 - - - -
5.0 3.10 - - - - 0.40 0.32 3.90 4.20 - - - -

6.0 3.40 - - - - 0.40 0.32 4.00 4.30 - - - -

10.0 4.50 1.00 0.80 5.90 6.50 0.60 0.48 5.50 6.00 - - - -
16.0 6.30 1.00 0.80 7.30 8.30 0.65 0.52 6.90 7.90 - - - -

25.0 7.80 1.30 1.04 8.40 10.40 0.65 0.52 8.20 9.40 - - - -
35.0 9.00 1.30 1.04 9.60 11.60 - - - - - - - -
50.0 10.50 1.50 1.20 11.50 13.50 - - - - - - - -

70.0 12.50 1.50 1.20 13.50 15.50 - - - - - - - -

95.0 14.50 1.60 1.28 16.00 18.00 - - - - - - - -
120.0 16.50 1.60 1.28 17.70 19.70 - - - - - - - -

Other conductor sizes may be used providing they meet the electrical and dimensional requirements and are agreed with the Engineering Department of the relevant Ford Business Unit

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5.3 Table 3 - CONDUCTOR RESISTANCE (m / m, max)

ISO conductor size Plain Copper Tinned Copper

mm²
0.13 136 140
0.22 84.4 86,5
0.35 54.4 55,5
0.5 37.1 38,2
0.75 24.7 25,4
1 18.5 19,1
1.5 12.7 13,0
2.0 9.42 9,69
2.5 7.60 7,82
3 6.15 6,36
4 4.71 4,85
5 3.94 4,02
6 3.14 3,23
10 1.82 1,85
16 1.16 1,18
25 0.743 0,757
35 0.527 0,538
50 0.368 0,375
70 0.259 0,264
95 0.196 0,2
120 0.153 0,156

5.4 ABRASION RESISTANCE

5.4.1 Table 4.1 - SCRAPE ABRASION RESISTANCE

ISO Wire Size Number Of Applied

(mm2) Double Strokes Vertical Loads (N)

0.13 75 7
0.22 150 7
0.35 200 7
0.5 300 7
0.75 350 7
1 500 7
1.5 - 6 1500 7

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5.4.2 Table 4.2 - SANDPAPER ABRASION RESISTANCE

ISO Thin wall Ultra-thin wall
conductor
size Additional Minimum Additional Minimum
mass length of mass length of
sandpaper sandpaper
2
mm kg mm kg mm

0,13 200 150

0,22 0,1 225 0,05 175
0,35 250 200
0,5 300 175
0,75 350 200
1 0,2 400 0,1 225
1,5 450 250
2 500 275
2,5 250 0,2 125
3 300
4 0,5 350
-- --
5 430
6 500
NOTE: The total vertical force exerted on the test sample shall be the combination of
the force exerted by the bracket, pivoting arm, support rod and additional mass.

5.5 Table 5 - MANDREL DIAMETERS

Mandrel Diameter (mm)

Cross- sectional Winding test Resistance Long Environm Mass Winding Min
area, at Low to Ozone Term ental Speed Number
mm2 Temp., Short Heat Cycling of Turns
Term Heat Ageing Kg s-1
Ageing, &
Chemical
resistance

< 0.75 6 6 2 2 0.5 1 3

> 0.75 < 1.5 10 10 3 3 2.5 1 3
> 1.5 < 2.5 15 15 4 4 5 1 3
> 2.5 < 6 20 20 5 5 5 1 3
> 6 < 10 40 40 8 8 8 0.5 0.5
> 10 < 25 50 50 10 10 10 0.5 0.5
> 25 < 50 75 75 15 15 20 0.5 0.5
> 50 < 95 100 100 20 20 30 0.2 0.5
>95 < 120 125 125 30 30 30 0.2 0.5

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5.6 Table 6 - FLUID COMPATIBILITY

Media
Specification Objects Storage time in
Group Fluid
(pcs) oven at class temp.
(h)
Engine Coolant 50% ethylene glycol + 50% 8
distilled water
1 Engine Oil ISO 1817, Oil No 2 8 240 h + 240 h + 240 h
Salt Water (road) 5% NaCl , 95 % Water (mass 8 + 280 h
%)
Windscreen Washer 50% Iso-propanol, 50% water 8
Fluid
Gasoline ISO 1817, liquid C 2
Diesel 90% ISO 1817, Oil No 3 + 10 % 2
p-xylene
2 Ethanol 85% Ethanol + 15% ISO 1817 2
liquid C 240 h
Power Steering Fluid ISO 1817, Oil No 3 2
Auto. Transmission Fluid Dexron III 2
Brake Fluid SAE RM-66-05 2
Battery Acid 25% H2SO4 and 75% H2O, 2
density 1.28
NOTE: Solutions are determined as % by volume if not otherwise specified.

5.7 Table 7 - FLEXIBILITY TEST: WIRES ≤3.0 mm².

Max. Force (N) for temperature class:

Cross- sectional A2 A3 A4
2
area's (mm )
0.35 1 1.7 1.7
0.5 1.5 2.3 2.3
0.75 2.2 3.6 3.6
1.0 3.5 5.0 5.0
1.5 5.5 9 9
2.5 10 17 17
3.0 10 22 22

5.8 Table 8 - IMPACT

ISO conductor Mass of the hammer (g)

Size
Thick Thin Ultra thin
a wall wall wall cable
mm² cable cable
a =< 0,5 - N/A N/A
0,5 < a =< 2,5 100 100 N/A
2,5 < a =< 4 100 100 -
4 < a =< 10 200 200 -
10 < a =< 25 300 300 -
25 < a =< 50 300 - -
50 < a =< 120 400 - -

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5.9 Table 9 – INSULATION COLOURS

Color Munsell Color Coding DIN 40772 or IEC

304
Light Dark RAL

Black N2.25 Not Applicable 9005

Blue 4.6PB 3.8/10.2 5.6PB 2.75/9.4 5017
Brown 7.5YR 4/5 7.5YR 3/6 8003
Gray N6.3/(10GY,0.2) N5.2/(10GY,0.2) 7000
Green 0.5G 6.25/6.3 0.5G 5.1/7.5 6018
Orange 8.75R 6.0/11.5 8.75R 5.5/13.5 2003
Red 2.5R 4.2/11.2 4.4R 3.4/10.4 3000
Violet 4.4P 3.9/6.7 3.4P 2.8/6.7 4005
White Not Applicable 5Y 9/1 1013
Yellow 8.4Y 8.5/8.3 8Y 8.5/11.2 1021

6 DRAFT CODE:

For the purposes of identification on Engineering Drawings, wire shall be identified to this
specification in the following manner:

Example wire code: 1TAD

2. Wall Thickness (Table 2) 4. Conductor Type/Other

1TA D
1. Temperature Class (Para 3.4) 3. Strand Configuration (Table 1)

1. Temperature Class:
0
1 85 C
2 1000C
0
3 125 C
0
4 150 C

2. Wall Thickness (Table 2):

S Standard Wall
T Thin Wall
U Ultra Thin Wall
X Un-insulated (bare wire)

3. Strand Configuration (Table 1):

A Symmetrical
B Asymmetrical
C Flexible - Asymmetrical

4. Conductor type/ Other

D Bare Copper Conductor

E Tinned Copper Conductor
F Bare Copper Conductor, Flexible wire (Flexibility Test requirement)

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Appendix A

WIRE SIZE COMPARISON CHART (FOR INFORMATION ONLY)

SAE Cross-Sectional mm² Cross-Sectional

(AWG) Area, Min. (mm²) (European) Area (mm²)

24 ga. 0.205 0.22 0.202 - 0.214

22 ga. 0.345 0.35 0.329 - 0.350

20 ga. 0.543 0.5 0.469 - 0.490

18 ga. 0.779 0.75 0.692 - 0.737

16 ga. 1.184 1.0 0.925 - 0.982

14 ga. 1.875 1.5 1.345 - 1.436

12 ga. 2.956 2.5 2.250 - 2.390

10 ga. 4.734 4.0 3.640 - 3.870

08 ga. 7.504 6.0 5.520 - 5.870

06 ga. 12.433 10.0 9.400 - 10.000

04 ga. 18.93 16.0 14.740 - 15.6800

02 ga. 31.643 32.0 -

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