SPECIFICATION: 62

THIS ISSUE: Issue 4

DATE: 30 September 2002
Wire and Harnessing Products REPLACES: Issue 3
501 Oakside Avenue, Redwood City, CA 94063-3800 PAGE: 1 of 10

CABLE, ELECTRIC, MODIFIED POLYESTER

INSULATED COPPER OR COPPER ALLOY

1. SCOPE

1.1 GENERAL

This specification covers finished cable, insulated with an extruded, flame retarded, modified
polyester material. The finished cable defined by this specification is intended for use in
surface vehicle low voltage circuits.

1.2 CLASSIFICATION

Products in accordance with this specification shall be the following type and as specified in
the applicable specification sheet.

Finished Cable: A single stranded wire, insulated as specified in the applicable

specification sheet.

1.2.1 Temperature Index

Products in accordance with this specification have a temperature index rating of at least 3000
hours at 150ºC (TI 3 kh/150ºC) when tested in accordance with ASTM D 3032.

2. APPLICABLE DOCUMENTS

The following documents form a part of this specification to the extent specified herein.
Unless otherwise indicated, the issue in effect on date of invitation for bids or request for
proposal shall apply.

2.1 AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI)

B46.1-1978 Surface Texture (Surface Roughness, Waviness, and Lay)

(Copies of ANSI publications may be obtained from Global Engineering Documents,

15 Inverness Way East, Englewood, CO 80112; or at www.global.ihs.com.)

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2.2 AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

B1 Standard Specification for Hard Drawn Copper Wire

B3 Specification for Soft or Annealed Copper Wire
B 33 Specification for Tinned Soft or Annealed Copper Wire for Electrical Purposes
B 193 Standard Test Method for Resistivity of Electrical Conductor Materials
B 471 Standard Test Method for Rubber Property - Effect of Liquids
B 624 Standard Specification for High-Strength, High-Conductivity Copper-Alloy Wire
for Electronic Application
B 975 Specification for Diesel Fuel Oils
D 3032 Standard Test Methods for Hookup Wire Insulation

(Copies of ASTM publications may be obtained from the American Society for Testing and
Materials, 1916 Race Street, Philadelphia, Pennsylvania 19103; or at www.astm.org.)

2.3 FEDERAL TEST METHOD STANDARDS

FED-STD-228 Cable and Wire, Insulated; Methods of Testing

(Copies of FED-STD-228 may be obtained from the Naval Publications and Forms Center,
5801 Tabor Avenue, Philadelphia, Pennsylvania 19120; or at www.global.ihs.com.)

2.4 INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)

ISO 6722/1 Road Vehicles - Unscreened low-tension cables - Part 1:

General requirements and test methods.

(Copies of ISO publications may be obtained from Global Engineering Documents, 2805
McGaw Avenue, Irvine, California 92714; or at www.iso.ch.)

2.5 SOCIETY OF AUTOMOTIVE ENGINEERS, INC. (SAE)

J1128 Low Tension Primary Cable

(Copies of SAE publications may be obtained from SAE, 400 Commonwealth Drive,
Warrendale, Pennsylvania 15096-0001; or at www.sae.org.)

2.6 RAYCHEM DOCUMENTS

Wire and Cable Division

Level 3 QC Procedures: QC/3/082

3. REQUIREMENTS

3.1 SPECIFICATION SHEETS

The requirements for the individual cables furnished under this specification shall be as
specified herein and in accordance with the applicable specification sheet. In the event of
conflict, the requirements of the specification sheet shall govern.

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SPECIFICATION 62, ISSUE 4 Page 3 of 10

3.2 MATERIALS

Materials not specifically designated herein shall be of the quality and form best suited for the
purpose intended. Unless otherwise specified, the materials shall meet the following
requirements:

3.2.1 Stranded Wire Materials

Stranded wire material shall be hard drawn copper in accordance with ASTM B 1, bare
annealed copper in accordance with ASTM B 3, tinned annealed copper in accordance with
ASTM B 33, high strength copper alloy in accordance with ASTM B 624, or as specified by
the applicable specification sheet.

3.2.2 Insulating Materials

The extruded insulation material shall be a proprietary modified polyester.

3.3 FINISHED CABLE

Finished cable shall conform to the requirements of Table I, to those of the applicable
specification sheet, and to the following, as applicable.

TABLE I. PROPERTIES OF FINISHED CABLE

Examination or Test Requirement Test Method Test Type
Abrasion Resistance Specification Sheet 4.4.1 Q
Cold Bend 3.3.1 4.4.2 Q
Color 3.3.2 and Table III SAE J1128 P
Concentricity Specification Sheet ASTM D 3032, Section 16 P
Conductor Resistance Specification Sheet QC/3/082 V
Dielectric Test 3.3.3 SAE J1128 Q
Dimensions Specification Sheet ASTM D 3032, Section 15 P
Flammability Specification Sheet SAE J1128 Q
Immersion (Fluid Resistance) 3.3.4 4.4.4 Q
Insulation-Continuity Proof Specification Sheet ASTM D 3032, Section 13, 100%
Testing Method A
Insulation Tensile Strength Specification Sheet 4.4.5.1 Q
and Ultimate Elongation 4.4.5.2 P
Materials and Construction 3.2 and Specification Sheet 4.4.3 P
Pinch Test Specification Sheet 4.4.6 Q
Shrinkage Specification Sheet 4.4.7 P
Strip Force Specification Sheet 4.4.8 Q
Temperature Index 1.2.1 ASTM D 3032, Section 14 Q
Thermal Stability Specification Sheet 4.4.9 Q
Weight Specification Sheet 4.4.10 P
Workmanship 3.3.5 4.4.3 P
P = In Process or Lot Test Q = Qualification Test
100% = 100% Finished Product Test V = Vendor Test

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3.3.1 Cold Bend

When tested in accordance with 4.4.2 herein, there shall be no cracking and no breakdown of
the finished cable insulation.

3.3.2 Color

Finished cable insulation color shall be in accordance with Table III and SAE J1128.
Insulation color shall be designated by the following codes:

TABLE III. FINISHED CABLE COLORS

Code Solid Color
0 Black
1 Brown
1L Tan
2 Red
2L Pink
3 Orange
4 Yellow
5L Light Green
5D Dark Green
6L Light Blue
6D Dark Blue
7 Purple
8 Gray
9 White

3.3.3 Dielectric Test

When finished cable is tested in accordance with the Dielectric Test of SAE J1128, there shall
be no dielectric breakdown.

3.3.4 Immersion (Fluid Resistance)

When tested in accordance with 4.4.4 herein, the finished cable sample shall meet the
requirements specified in Table II therein.

3.3.5 Workmanship

All details of workmanship shall be in accordance with high-grade wire and cable
manufacturing practice. The insulation shall be free of cracks, splits, irregularities, and
imbedded foreign material.

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SPECIFICATION 62, ISSUE 4 Page 5 of 10

4. QUALITY ASSURANCE PROVISIONS

4.1 RESPONSIBILITY FOR INSPECTION

The supplier is responsible for the performance of all inspection tests specified herein. The
supplier may utilize his own or any other inspection facility and services acceptable to the
buyer. Inspection records of the examinations and tests shall be kept complete and available to
the buyer as required.

4.2 QUALIFICATION INSPECTION

Qualification inspection shall consist of all tests in Table I. Requalification testing shall be
performed any time changes in materials or processes occur that are deemed to have the
potential for significantly altering the performance of the product.

4.2.1 Sampling for Qualification Inspection

Samples of cable for qualification shall be taken from production lots which have been
manufactured under the most current Quality Control Plan.

4.3 QUALITY CONFORMANCE INSPECTION

Quality conformance inspection consists of a matrix of tests and inspections that assure that
raw materials and manufacturing processes are consistent and result in products that conform
to specification requirements. The classification and frequency of testing shall be determined
in accordance with the requirements of the individual specifications to which the product is
supplied.

4.3.1 Inspection Definitions

a. Vendor Control (V) - Requirements for raw materials such as conductor and insulation
materials over which the vendor has control and responsibility.

b. Process Control (P) - Inspections performed on samples taken from the lots of cable.
Inspections may be performed on finished cable or after the process which establishes the
specified characteristic. The Quality Control Plan establishes the frequency of inspection
based on process control data.

c. One hundred percent (100%) - Test performed on the total length of each cable. Tests may
be performed on the finished product or "in process" as applicable.

d. Qualification (Q) - Test performed only at the time of initial qualification or

requalification.

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4.4 TEST METHODS

4.4.1 Abrasion Resistance

Abrasion resistance shall be quantified as the number of scrape cycles required for a blade to
abrade through the insulation of a finished cable and contact the stranded wire within. The
blade, polished to an 18 finish per ANSI B46.1-1978, shall be a 90-degree wedge of tungsten
carbide with its edge rounded to a radius of 0.0050 ± 0.0005 inch (.127 ± .0127 mm). The
cable sample shall be fully supported so as not to bow or otherwise deflect from the force of
the blade. Means shall be provided to apply an adjustable downward force through the blade
onto the cable. The cable shall be scraped longitudinally along its axis while in contact with
the blade, and an electrical detection circuit and counter mechanism shall be used to stop the
test and record the number of cycles when electrical contact has occurred. One such fixture is
shown in Figure 1. However, the methods and fixture described in ISO 6722/1 are also
satisfactory for use.

FIGURE 1. SCRAPE ABRASION TESTER

4.4.1.1 Abrasion Procedure

One inch (25 mm) of insulation shall be removed from a minimum 60-inch (152-cm) cable
sample and connected to the detection circuit. The cable shall be firmly clamped in the fixture,
and a force of 7.33 Newtons (1.649 lbf) shall be carefully applied to the surface of the
insulation through the blade. The fixture stroke length shall be 20 ± 1 mm (0.79 ± 0.04 inch)
and the frequency shall be 40 ± 1 cycles per minute (2 scrapes = 1 cycle). Eight tests shall be
performed, with the cable advanced in the fixture 6 inches (152 mm) and rotated 90 degrees.
The average number of cycles to electrical contact shall equal or exceed the minimum
requirement specified on the applicable specification sheet.

4.4.2 Cold Bend

Cold Bend shall be performed in accordance with the Cold Bend Test of SAE J1128 for Type
SXL, except the test temperature shall be -55ºC.

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4.4.3 Examination of Product

All samples shall be examined carefully to determine conformance to this specification and to
the applicable specification sheets with regard to requirements not covered by specific test
methods.

4.4.4 Immersion (Fluid Resistance)

One 12 inch (300 mm) finished cable sample shall be prepared for each fluid listed in Table II.
The sample shall be immersed to within 1-1/2 inch (40 mm) from the end of the insulation in
the fluids for the times and temperatures specified therein. Upon removal from the test fluids,
the sample shall be blotted with an absorbent tissue and changes in outer diameter of the cable
measured per ASTM D 3032.

Changes in diameter shall be defined as follows and shall not exceed the amount specified in
Table II below.

(D1 - D0)
% Change = 100 x
D0

Where: D1 = post-immersion outer diameter

D0 = pre-immersion outer diameter

TABLE II. FLUIDS TABLE

Max. Dia.
Temperature Time
Test Fluid Change
(ºC) (hours)
(%)
ASTM D 471, Oil #1 150 24 5
ASTM D 471, IRM 902 150 24 5
ASTM D 471, IRM 903 150 24 5
Gasoline, ASTM D 471, Fuel C 25 24 5
Diesel Fuel, ASTM D 975, Fuel 2D 70 24 5
Power Steering Fluid 50 24 5
Transmission Fluid, Dexron II 150 24 5
Brake Fluid, (DOT Type 3) 50 24 5
Methyl Alcohol 65* 24 5
Ethyl Alcohol 78* 24 10
*Reflux temperature at atmospheric pressure.

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4.4.5 Insulation Tensile Strength and Ultimate Elongation

4.4.5.1 Qualification

Testing of insulation tensile strength and ultimate elongation shall be performed in accordance
with ASTM D 3032, Section 17, with the following conditions and exceptions:

a. Crosshead speed (jaw separation rate) shall be 2 inches (50 mm) per minute.

b. Initial jaw separation shall be 1 inch (25 mm).

4.4.5.2 Process Control

Testing of ultimate elongation shall be performed in accordance with ASTM D 3032,

Section 17, with the following exceptions:

a. Crosshead speed (jaw separation rate) shall be 20 inches (500 mm) per minute.

b. Initial jaw separation shall be 1 inch (25 mm).

c. One specimen shall be tested.

4.4.6 Pinch Test

The pinch test shall be performed in accordance with the Pinch Test of SAE J1128. Test
apparatus which provides the same constant rate of force may be substituted. (Note: If the
apparatus used to perform the test applies the force directly to the sample instead of through a
lever arm, the values obtained are to be divided by 10 in order to normalize the values to the
data measured by the apparatus of SAE J1128.) The arithmetic average of four readings shall
define the pinch resistance of the cable under test. This value shall be at least the minimum
value specified on the applicable specification sheet.

4.4.7 Shrinkage

A 36 inch (900 mm) specimen of finished cable, while at normal room temperature
(23 ± 5ºC), shall be cut in half. The length the cut ends of the insulation creep back from the
stranded wire shall be measured and shall not exceed the value listed in the applicable
specification sheet.

4.4.8 Strip Force

Strip force testing shall be performed per ASTM D 3032, Section 27, with the following
conditions and exceptions:

a. The portion of undisturbed insulation (insulation slug) left on the test specimen shall be
2 inches (50.8 mm).

b. Tester speed shall be 10 inches (254 mm) per minute.

c. A minimum of three samples shall be tested, and the mean value of the peak (maximum)
strip force reported. This value shall equal or exceed the value specified on the applicable
specification sheet.

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SPECIFICATION 62, ISSUE 4 Page 9 of 10

4.4.9 Thermal Stability

A minimum of five tensile specimens shall be prepared per ASTM D 3032, Section 17. These
samples shall be aged in an air-circulating oven at 165º +2º, -0ºC for 168 hours. Upon removal
from the aging oven, the samples shall be conditioned at 20 ± 5ºC for a minimum of four hours
and tested for retention of tensile strength and ultimate elongation per 4.4.5. Minimum
requirements shall be as stated on the applicable specification sheet.

4.4.10 Weight

The weight of each lot of finished cable shall be determined by Procedure I (4.4.10.1). Lots
failing to meet the weight requirement of the applicable specification sheet when tested in
accordance with Procedure I shall be subjected to Procedure II (4.4.10.2). All barrels failing to
meet the requirements of the applicable specification sheet when tested to Procedure II shall be
rejected.

4.4.10.1 Procedure I

A length of cable, sufficient to produce a measured weight to at least 3 significant figures, shall
be weighed and converted to the weight per unit length shown on the applicable specification
sheet.

4.4.10.2 Procedure II

The net weight of the finished cable in each barrel shall be obtained by subtracting the weight
of the barrel from the gross weight of the barrel containing the finished cable. The net weight
of the cable in each barrel shall be divided by the accurately determined length of finished
cable in that barrel and the resultant figure converted to pounds per 1000 feet (kg/km).

5. PREPARATION FOR DELIVERY

5.1 CONTINUOUS LENGTHS

For any shipment of cable, the minimum continuous (unspliced) length shall be 1000 feet (305
m).

5.2 PACKAGING

Unless otherwise specified on the purchase order, all cable shall be supplied in barrels. Each
barrel shall be identified with the following information:

Raychem Part Number

Lot Number
Quantity in Feet (or Meters)
Raychem

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6. NOTES

6.1 ORDERING DATA

Procurement documents should specify the following:

a. Title, number, and date of this specification

b. Applicable specification sheet part number

c. Quantity

d. Special preparation for delivery requirements, if applicable

6.2 ALTERNATIVE UNITS OF MEASURE

Where units of measure in this specification are followed by italicized alternative units of
measure in parentheses, these alternative units may be substituted.

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