SAE AS 22759 185B-2017 WIRE ELECTRICAL POLYTETRAFLUOROETHYLENE POLYIMIDE INSULATED SMOOTH SURFACE NORMAL WEIGHT TIN-COATED COPPER CONDUCTOR 150 600 VOLTS ROHS.pdf

1、 AEROSPACE STANDARD WIRE, ELECTRICAL, POLYTETRAFLUOROETHYLENE/ POLYIMIDE INSULATED, SMOOTH SURFACE, NORMAL WEIGHT, TIN-COATED COPPER CONDUCTOR, 150 C, 600 VOLTS ROHS AS22759/185Copyright 2017 SAE International All rights reserved. No part of this publication may be reproduced, stored in a retrieval

2、system or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of SAE. TO PLACE A DOCUMENT ORDER: Tel: 877-606-7323 (inside USA and Canada) Tel: +1 724-776-4970 (outside USA) Fax: 724-776-0790 Email: CustomerSer

3、vicesae.org SAE WEB ADDRESS: http:/www.sae.org ISSUED2010-02REVISED2017-09THIRD ANGLE PROJECTION CUSTODIAN: AE-8/AE-8D REV.BFEDERAL SUPPLY CLASS 6145 AS22759/185 SHEET 1 OF 5 REV. B PROCUREMENT SPECIFICATION: NONE SAETechnicalStandardsBoard Rulesprovidethat:“Thisreportispublished bySAEto advance the

4、 state oftechnicaland engineering sciences.The use ofthisreportisentirelyvoluntary,anditsapplicabilityandsuitabilityforanyparticularuse,includinganypatentinfringementarising therefrom,isthe sole responsibilityoftheuser.”SAEreviewseachtechnicalreportatleasteveryfiveyearsatwhich time itmaybe revised,r

5、eaffirmed,stabilized,orcancelled.SAEinvitesyourwritten commentsandsuggestions.SAE values your input. To provide feedback on this Technical Report, please visit http:/standards.sae.org/AS22759/185B RATIONALE SPECIFICATION UPDATED TO INCLUDE AS29606 CONDUCTOR REQUIREMENTS, ROHS RESTRICTIONS AND AS2275

6、9 MODIFICATIONS. THIS CHANGE ALSO INCREASES THE MAXIMUM WEIGHT REQUIREMENTS FOR WIRE SIZES 8 THROUGH 02 TO ACCOUNT FOR INCREASED CIRCULAR MIL AREA (CMA) ADOPTED IN AS29606. AS22759 IS A CONVERTED MILITARY SPECIFICATION ORIGINALLY NOTED AS MIL-W-22759 CREATED IN 1971. CONDUCTOR REQUIREMENTS WERE ORIG

7、INALLY DEFINED BY ASTM B3, B298, AND B355 FOR TIN, SILVER, AND NICKEL PLATE RESPECTIVELY. THESE SPECIFICATIONS CONTROLLED THE CONDUCTOR BY ESTABLISHING STRAND SIZE, CONDUCTOR SIZE, AND MAXIMUM DCR (DIRECT CURRENT RESISTANCE). BY THE LATE 1980S, CONDUCTOR PRODUCERS WERE PRODUCING TIGHT TOLERANCE COND

8、UCTORS WHICH WERE MADE AT THE MINIMUM DIMENSIONAL AND MAXIMUM DCR LIMITS OF THE SPECIFICATION TO REDUCE THE WEIGHT (MASS) OF THE FINALLY INSULATED WIRE. BY THE EARLY 1990S THE TIGHT TOLERANCE CONDUCTORS WERE PREVALENT THROUGHOUT AEROSPACE. ABOUT THE SAME TIME, LARGE GAUGE SIZE CONDUCTORS (SIZE 8 THR

9、OUGH 4/0) STARTED EXHIBITING CRIMP FAILURES IN TERMINAL LUGS MOUNTED ON AIRCRAFT GENERATORS. SINCE THESE CIRCUITS ROUTED PRIMARY ELECTRICAL POWER FROM THE GENERATOR TO THE MAIN POWER DISTRIBUTION CENTERS, CRIMP DEGRADATION RESULTING IN DISRUPTION OF ELECTRICAL POWER CAUSED SIGNIFICANT CONCERN. SEVER

10、AL OEMS AS WELL AS NAVY AND AIR FORCE LABORATORIES INVESTIGATED THE FAILURES AND DETERMINED THAT THE FAILED CRIMPS WERE DUE TO A COMBINATION OF LOW CMA, HIGH VIBRATION, AND THERMAL CYCLING. ADDITIONAL TESTING ESTABLISHED MINIMUM CMA LEVELS WHICH WOULD PREVENT THE CRIMP FAILURES. THESE NEW LIMITS WER

11、E OFFERED TO ASTM, BUT REJECTED. NAVAIR THEN PRODUCED AN ENGINEERING POSITION LETTER (EPL) TO MANDATE THE INCREASED CMAS ON STRANDING USED IN AS22759 CONSTRUCTIONS. NAVAIR THEN CREATED MIL-W-29606 WHICH WAS INTENDED TO REPLACE THE ASTM SPECIFICATIONS AS THE REQUIRED CONDUCTOR SPECIFICATION. BEFORE T

12、HE MIL-W-29606 COULD BE ADDED TO MIL-W-22759, THE SPECIFICATION TRANSITION AND ADOPTION TOOK PLACE CONVERTING THE DOCUMENTS FROM MILITARY SPECIFICATIONS TO AS DOCUMENTS IN THE 1999 TO 2000 TIME FRAME. SINCE THE EPL NO LONGER HAD LEGAL STANDING AFTER THE CONVERSION, WIRE PRODUCERS DID NOT HAVE TO ABI

13、DE BY THE RESTRICTIONS WHICH ALLOWED THIS ISSUE TO CREEP BACK INTO THE PRODUCTS FROM TIME TO TIME. IN 2011, THE SAE AE-8D COMMITTEE OPENED A PROJECT TO UPDATE THE AS22759 AND ITS ASSOCIATED DETAILED SPECIFICATION SHEETS. WHEN LOOKING AT THIS ISSUE, THE COMMITTEE DECIDED TO ADOPT MIL-W-29606 (NOW AS2

14、9606) AND REPLACE THE ASTM REQUIREMENTS WITH THE AS29606 REQUIREMENTS. SINCE THE DIAMETER RANGE OF THE CONDUCTOR STRANDS NEEDED TO SHIFT SLIGHTLY TO THE RIGHT TO MEET THE NEW MINIMUM CMA REQUIREMENTS, OVERALL PRODUCT WEIGHT MAXIMUMS SHIFTED ABOUT 3 TO 5%. THE COMMITTEE EVALUATED SEVERAL METHODS OF I

15、NCORPORATING THIS CHANGE INCLUDING CANCELING AND SUPERSESSION, BUT THE END USERS DID NOT WANT TO CHANGE PART NUMBERS FOR PRODUCTS WHICH HAVE BEEN USED IN AEROSPACE AND INDUSTRY FOR OVER 40 YEARS AND IS CURRENTLY ON THOUSANDS OF DRAWINGS. SINCE THESE PRODUCTS ARE PRIMARILY USED FOR PRIMARY POWER DIST

16、RIBUTION FROM THE GENERATORS TO THE MAIN DISTRIBUTION PANELS, THE WEIGHT INCREASE TO THE ELECTRICAL INTERCONNECT SYSTEM IS CONSIDERED INSIGNIFICANT. SINCE THIS CHANGE DOES AFFECT THE MAXIMUM WEIGHT LIMITS FOR SIZES 8 THROUGH 4/0, END USERS SHOULD VERIFY THAT THE NEW WEIGHT RANGES MEET THE DESIGN REQ

17、UIREMENTS OF LEGACY APPLICATIONS. NOTICE THE COMPLETE REQUIREMENTS FOR PROCURING THE PRODUCT DESCRIBED HEREIN SHALL CONSIST OF THIS DOCUMENT AND THE LATEST ISSUE OF AS22759. AEROSPACE STANDARD AS22759/185 SHEET 2 OF 5 REV. B WIRE, ELECTRICAL, POLYTETRAFLUOROETHYLENE/ POLYIMIDE INSULATED, SMOOTH SURF

18、ACE, NORMAL WEIGHT, TIN-COATED COPPER CONDUCTOR, 150 C, 600 VOLTS ROHS FP / POLYIMIDE / FP TAPE FP TAPE FP TAPE META-ARAMID FIBER BRAID TREATED TO PREVENT FRAYING 1/ SIZE 8 THROUGH 6 FP / POLYIMIDE / FP TAPE FP TAPE FP TAPE FP TAPE META-ARAMID FIBER BRAID TREATED TO PREVENT FRAYING 1/ SIZE 4 THROUGH

19、 04 FP FLUOROCARBON POLYMER MODIFIED POLYTETRAFLUOROETHYLENE (PTFE) CONDUCTOR STRANDED TIN COATED COPPER 1/ BRAID: BRIGHT AROMATIC POLYAMIDE YARN, 200 DENIER, 100 FILAMENTS, TIGHTLY FORMED, UNIFORM IN APPEARANCE, TREATED WITH A CLEAR FINISHER COATING. THE FINISHER COATING SHALL BE COMPATIBLE WITH TH

20、E TEMPERATURE RATING AND PERFORMANCE REQUIREMENTS OF THE INSULATED WIRE. BRAID SHALL GRIP THE UNDERLYING INSULATION SUFFICIENTLY AS TO NOT SLIDE ALONG THE TAPE SURFACE DURING NORMAL HANDLING. FIGURE 1 - AS22759/185 CONFIGURATION AEROSPACE STANDARD AS22759/185 SHEET 3 OF 5 REV. B WIRE, ELECTRICAL, PO

21、LYTETRAFLUOROETHYLENE/ POLYIMIDE INSULATED, SMOOTH SURFACE, NORMAL WEIGHT, TIN-COATED COPPER CONDUCTOR, 150 C, 600 VOLTS ROHS TABLE 1 - CONSTRUCTION DETAILS PART NO. 1/ WIRE SIZE CONDUCTOR 4/ FINISHED WIRE 3/ STRANDING (NUMBER OF STRANDS X SIZE GAUGE OF STRANDS) DIAMETER (IN) RESISTANCE AT 20 C (68

22、F) (OHMS/1000 FEET MAX) DIAMETER (IN) WEIGHT (LB/1000 FEET) 2/ MIN MAX MIN MAX MIN TARGET MAX M22759/185-8-* M22759/185-6-* M22759/185-4-* M22759/185-2-* M22759/185-1-* M22759/185-01-* M22759/185-02-* M22759/185-03-* M22759/185-04-* 8 6 4 2 1 0 00 000 0000 133 X 29 133 X 27 133 X 25 665 X 30 817 X 3

23、0 1045 X 30 1330 X 30 1665 X 30 2109 X 30 .158 .198 .250 .320 .360 .395 .440 .500 .565 .169 .212 .268 .340 .380 .425 .475 .540 .605 .701 .445 .280 .183 .149 .116 .091 .071 .056 .192 .231 .288 .356 .400 .432 .487 .542 .602 .213 .254 .313 .389 .433 .475 .530 .585 .655 59.0 91.8 144 220 268 339 422 539

24、 654 61.1 94.3 148 229 277 352 442 554 675 63.2 96.8 152 238 286 365 462 569 696 1/ PART NUMBER: THE PREFERRED COLOR IS DARK GREEN WITH A COLOR DESIGNATOR OF 5D. EXAMPLE: SIZE 2 DARK GREEN AS22759/185-2-5D. WHITE IS AN ACCEPTABLE ALTERNATIVE WITH A COLOR DESIGNATOR OF 9. 2/ THE ACCEPTABLE VALUE FOR

25、THE CPK FOR THE FINISHED WIRE WEIGHT LISTED SHALL BE 1.3, USING A NORMAL (GAUSSIAN) DISTRIBUTION TO OBTAIN THOSE CPK VALUES. 3/ THE WIRE CONSTRUCTION SHALL HAVE A SMOOTH POLYTETRAFLUOROETHYLENE (PTFE) OUTER LAYER WITH COMPLETE BONDING BETWEEN THE HOMOGENEOUS LAYERS. 4/ CONDUCTOR SHALL CONFORM TO AS2

26、9606 TYPE TCC SMALL DIAMETER TIN COATED COPPER CONDUCTOR FOR WIRE SIZES 8 THROUGH 4 AND GENERAL PURPOSE FOR WIRE SIZES 2 THROUGH 0000. REQUIREMENT: ALL REQUIREMENTS SHALL CONSIST OF THIS DOCUMENT AND THE LATEST ISSUE OF AS22759. 1. WIRE CONSTRUCTION: WIRE CONSTRUCTION SHALL BE IN ACCORDANCE WITH FIG

27、URE 1 AND TABLES 1, 2, 3, AND 4. TABLE 2 - WIRE INSULATION MATERIAL TAPE CODE THICKNESS (NOM) MATERIAL 1 .0020 .0005 (FP)/.0010 (POLYIMIDE)/.0005 (FP) 2 .0020 FP (SKIVED) 3 .0030 FP (UNSINTERED) 4 .0010 FP (SKIVED) TABLE 3 - TAPE OVERLAP REQUIREMENTS 1/ WIRE SIZE WRAP 1 WRAP 2 WRAP 3 WRAP 4 NOMINAL

28、WALL THICKNESS (MILS) 2/ TAPE CODE PERCENT OVERLAP TAPE CODE PERCENT OVERLAP TAPE CODE PERCENT OVERLAP TAPE CODE PERCENT OVERLAP MIN MAX MIN MAX MIN MAX MIN MAX 8 4 20.5 35.0 1 50.5 55.0 3 67.0 71.0 13.2 6 4 20.5 35.0 1 50.5 55.0 3 67.0 71.0 13.2 4 2 20.5 35.0 1 50.5 55.0 3 50.5 54.0 3 50.5 54.0 16.

29、2 2 2 20.5 35.0 1 50.5 55.9 3 50.5 54.0 3 50.5 54.0 16.2 1 2 20.5 35.0 1 50.5 55.0 3 50.5 54.0 3 50.5 54.0 16.2 1/0 2 20.5 35.0 1 50.5 55.0 3 50.5 54.0 3 50.5 54.0 16.2 2/0 2 20.5 35.0 1 50.5 55.0 3 50.5 54.0 3 50.5 54.0 16.2 3/0 2 20.5 35.0 1 50.5 55.0 3 50.5 54.0 3 50.5 54.0 16.2 4/0 2 20.5 35.0 1

30、 50.5 55.0 3 50.5 54.0 3 50.5 54.0 16.2 1/ WRAP 1 IS THE INNERMOST TAPE WHICH IS IN CONTACT WITH THE CONDUCTOR. WRAPS 2, 3, AND 4 ARE PROGRESSIVELY FURTHER AWAY FROM THE CONDUCTOR CORE. 2/ NOMINAL WALL THICKNESS DOES NOT INCLUDE THE POLYAMIDE BRAID THICKNESS. AEROSPACE STANDARD AS22759/185 SHEET 4 O

31、F 5 REV. B WIRE, ELECTRICAL, POLYTETRAFLUOROETHYLENE/ POLYIMIDE INSULATED, SMOOTH SURFACE, NORMAL WEIGHT, TIN-COATED COPPER CONDUCTOR, 150 C, 600 VOLTS ROHS 2. WIRE PERFORMANCE RATING: TEMPERATURE RATING: 150 C (302 F) MAXIMUM CONDUCTOR CONTINUOUS TEMPERATURE. VOLTAGE RATING: 600 VOLTS (RMS) AT SEA

32、LEVEL. THIS INSULATION SYSTEM HAS BEEN USED IN AEROSPACE APPLICATIONS USING 115 VOLTS (PHASE TO NEUTRAL), 400 HERTZ AC AND 28 VOLTS DC. VERIFICATION OF THE SUITABILITY OF THIS PRODUCT FOR USE IN OTHER ELECTRICAL SYSTEM CONFIGURATIONS IS THE RESPONSIBILITY OF THE USER. 3. MATERIALS AND PHYSICAL PROPE

33、RTIES: SEE AS22759 FOR MATERIAL REQUIREMENT. MATERIALS USED IN THE MANUFACTURE OF THESE PRODUCTS SHALL COMPLY WITH THE RESTRICTION OF HAZARDOUS SUBSTANCES DIRECTIVE 2002/95/EC. 4. FINISH WIRE INSULATION PROPERTIES: FINISH WIRE INSULATION PROPERTIES SHALL BE IN ACCORDANCE WITH TABLE 4. TABLE 4 - FINI

34、SHED WIRE INSULATION PROPERTIES REQUIREMENTS INSULATION PROPERTIES IMPULSE TEST VOLTAGE 8.0 KILOVOLTS (PEAK) HIGH FREQUENCY TEST VOLTAGE 5.7 KILOVOLTS (RMS) TAPE OVERLAP TABLE 3 LAMINATION SEALING 260 C 2 C (500 F 3.6 F), 6 HOURS INSULATION BLOCKING 200 C 2 C (392 F 3.6 F) SHRINKAGE 230 C 2 C (446 F

35、 3.6 F) MAXIMUM CHANGE .125 INCHES ELECTRICAL RESISTANCE (IR) 3000 MEGOHMS (MIN)-1000 FEET WET DIELECTRIC VOLTAGE 2500 VOLTS (RMS), 60 HERTZ CONTINUOUS LENGTH SCHEDULE B 5. FINISH WIRE IDENTIFICATION: WIRE IDENTIFICATION EXCEPTIONS: NONE WIRE IDENTIFICATION DURABILITY: NOT REQUIRED STRIPE AND BAND D

36、URABILITY: NOT REQUIRED 6. FINISH WIRE PERFORMANCE: FINISH WIRE FIXTURES APPLICABLE TO EACH WIRE SIZE SHALL BE IN ACCORDANCE WITH TABLE 5. TABLE 5 - TEST MANDREL AND TEST LOAD REQUIREMENTS WIRE SIZE (AWG) TEST MANDREL DIAMETER 1/ (INCHES) TEST LOAD (LB) COLD BEND LIFE CYCLE/ BEND TEST WRAP COLD BEND

37、 LIFE CYCLE/ BEND TEST 8 6 4 2 1 0 00 000 0000 4.00 5.00 6.00 8.00 10.00 10.00 12.00 18.00 18.00 3.00 4.00 5.00 6.00 8.00 8.00 10.00 10.00 10.00 .750 1.00 1.25 2.00 2.50 3.00 4.00 5.00 6.00 10.00 10.00 15.00 15.00 15.00 15.00 20.00 30.00 30.00 4.00 4.00 4.50 6.00 6.00 6.00 8.00 10.00 10.00 1/ TOLERA

38、NCE SHALL BE 3% OF THE GIVEN VALUES. AEROSPACE STANDARD AS22759/185 SHEET 5 OF 5 REV. B WIRE, ELECTRICAL, POLYTETRAFLUOROETHYLENE/ POLYIMIDE INSULATED, SMOOTH SURFACE, NORMAL WEIGHT, TIN-COATED COPPER CONDUCTOR, 150 C, 600 VOLTS ROHS FINISH WIRE PERFORMANCE CHARACTERISTICS SHALL BE IN ACCORDANCE WIT

39、H TABLE 6. TABLE 6 - FINISH WIRE PERFORMANCE CHARACTERISTICS PERFORMANCE CHARACTERISTIC REQUIREMENT MANDREL BEND RESISTANCE (TAPES/BRAIDS) REQUIRED THERMAL SHOCK MECHANICAL RESISTANCE TEMPERATURE EXPOSURE 260 C 2 C (500 F 3.6 F) MAXIMUM CHANGE .125 INCHES THERMAL MECHANICAL RESISTANCE (LIFE CYCLE) E

40、XPOSURE 500 HOURS, 290 C 2 C (554 F 3.6 F) HUMIDITY RESISTANCE (IR) 3000 MEGOHMS (MIN)-1000 FEET FLUID RESISTANCE DIAMETER INCREASE 5% (MAX) SMOKE RESISTANCE 260 C 5 C (500 F 9 F) FLAME RESISTANCE SELF-EXTINGUISH TIME: 3 SECONDS BURN LENGTH 3 INCHES 7. REQUIREMENT EXCEPTION TO THE AS22759: NONE APPL

41、ICATION NOTES 1. PRODUCTS MANUFACTURED TO THIS SPECIFICATION ARE ROHS COMPLIANT. SPECIFICATION NOTES 1. REVISION INDICATOR: A CHANGE BAR (l) LOCATED IN THE LEFT MARGIN IS FOR THE CONVENIENCE OF THE USER IN LOCATING AREAS WHERE TECHNICAL REVISIONS, NOT EDITORIAL CHANGES, HAVE BEEN MADE TO THE PREVIOUS ISSUE OF THIS DOCUMENT. AN (R) SYMBOL TO THE LEFT OF THE DOCUMENT TITLE INDICATES A COMPLETE REVISION OF THE DOCUMENT, INCLUDING TECHNICAL REVISIONS. CHANGE BARS AND (R) ARE NOT USED IN ORIGINAL PUBLICATIONS NOR IN DOCUMENTS THAT CONTAIN EDITORIAL CHANGES ONLY.