SAE AS 22759 47-2011 WIRE ELECTRICAL FLUOROPOLYMER-INSULATED CROSSLINKED MODIFIED ETFE LOW FLUORIDE LIGHTWEIGHT 80 MICROINCH SILVER-COATED HIGHSTRENGTH COPPER ALLOY 200 C 600 VOLT《.pdf

1、AEROSPACE STANDARD WIRE, ELECTRICAL, FLUOROPOLYMER-INSULATED, CROSSLINKED MODIFIED ETFE, LOW FLUORIDE, LIGHTWEIGHT, 80 MICROINCH SILVER-COATED HIGH-STRENGTH COPPER ALLOY, 200 C, 600 VOLTAS22759/47Copyright 2011 SAE International All rights reserved. No part of this publication may be reproduced, sto

2、red in a retrieval 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

3、 Email: CustomerServicesae.org SAE WEB ADDRESS: http:/www.sae.org ISSUED 2011-08THIRD ANGLE PROJECTION CUSTODIAN: AE-8/AE-8D FEDERAL SUPPLY CLASS 6145 AS22759/47SHEET 1 OF 4PROCUREMENT SPECIFICATION: AS22759SAE Technical Standards Board Rules provide that: “This report ispublishedby SAE toadvance th

4、estate of technicalandengineering sciences. Theuse ofthis report is entirely voluntary, andits applicability and suitability forany particular use,including any patent infringement arising therefrom, isthe soleresponsibilityofthe user.”SAE reviews eachtechnicalreport at least every five years at whi

5、ch time itmay bereaffirmed, revised, orcancelled. SAE invites yourwrittencomments andsuggestions. SAE values your input. To provide feedbackon this Technical Report, please visit http:/www.sae.org/technical/standards/AS22759/47RATIONALE THE INDUSTRY HAS IDENTIFIED FLUORIDE OFFGASSING AS A POTENTIAL

6、SERIOUS ISSUE IN ENCLOSED ENVIRONMENTS SUCH AS SPACECRAFT AND MISSILES. THE EVOLUTION OF FLUORIDE GAS CAN ACCELERATE CORROSION OF METAL SURFACES AND ETCHING OF OPTICS. IT CAN ASLO ACCELERATE COPPER OXIDATION. THE INDUSTRY HAS ALSO IDENTIFIED ADDITIONAL AEROSPACE CRITICAL TESTS SINCE THE LEGACY CROSS

7、-LINKED MODIFED ETFE DETAILED SPECIFICATIONS SHEETS WERE ORIGNATED. THESE TESTS INCLUDE UV LASER MARKING AND UV LASER CONTRAST AFTER THERMAL AGING AND THE REQUIREMENTS HAVE BEEN INCLUDED IN THIS DETAILED SPECIFICATION SHEET. NOTICE THE REQUIREMENTS FOR ACQUIRING THE PRODUCT DESCRIBED HEREIN SHALL CO

8、NSIST OF THIS SPECIFICATION SHEET AND THE ISSUE OF THE FOLLOWING SPECIFICATION LISTED IN THAT ISSUE OF THE DEPARTMENT OF DEFENSE QUALIFIED PRODUCTS DATABASE (QPD) SPECIFIED IN THE SOLICITATION: AS22759 FIGURE 1 GENERAL CONFIGURATION TABLE 1 CONSTRUCTION DETAILS PART NO. 1/WIRESIZESTRANDING (NUMBER O

9、F STANDS X AWG GAUGE OF STRANDS) 2/DIAMETER OF STRANDEDCONDUCTOR (INCHES FINISHED WIRE (MIN) (MAX) RESISTANCE AT 20 C (68 F) (OHMS/1000 FT) MAXDIAMETER(INCHES) WEIGHT (LBS/1000FT) (MAX) M22759/47-30-* 30 7 X 38 .0105 .0124 117.4 .024 * .002 0.66 M22759/47-28-* 28 7 X 36 .0135 .0154 74.4 .027 * .002

10、0.91 M22759/47-26-* 26 19 X 38 .0175 .0204 44.8 .032 * .002 1.4 M22759/47-24-* 24 19 X 36 .0225 .0244 28.4 .037 * .002 2.0 M22759/47-22-* 22 19 X 34 .0185 .0314 17.5 .043 * .002 2.9 M22759/47-20-* 20 19 X 32 .0365 .0394 10.7 .050 * .002 4.4 1/ PART NUMBER: THE ASTERISKS IN THE PART NUMBER COLUMN, TA

11、BLES 1 AND 2, SHALL BE REPLACED BY COLOR CODE DESIGNATORS IN ACCORDANCE WITH MIL-STD-681. EXAMPLES: SIZE 20, WHITE-M22759/47-20-9; WHITE WITH ORANGE STRIPE M22759/47-20-93. PRINTING OF COLOR CODE DESIGNATOR ON SURFACE OF WIRE INSULATION IS NOT REQUIRED. 2/ CONDUCTOR SHALL CONFORM TO MIL-DTL-29606A,

12、TYPE SCA1 80 MICROINCH SILVER PLATED COPPER CONDUCTOR Copyright SAE International Provided by IHS under license with SAENot for ResaleNo reproduction or networking permitted without license from IHS-,-,-AEROSPACE STANDARD AS22759/47SHEET 2 OF 4WIRE, ELECTRICAL, FLUOROPOLYMER-INSULATED, CROSSLINKED M

13、ODIFIED ETFE, LOW FLUORIDE, LIGHTWEIGHT, 80 MICROINCH SILVER-COATED HIGH-STRENGTH COPPER ALLOY, 200 C, 600 VOLT TABLE 2 PERFORMANCE DETAILS PART NO. BEND TESTING MANDREL DIAMETER (INCHES (3%) TEST LOAD (LBS) (3%) CROSSLINKING PROOF, IMMERSION AND LIFE CYCLE TESTS COLDBENDTESTCROSSLINKING PROOF, IMME

14、RSION AND LIFE CYCLE TESTS COLDBENDTESTM22759/47-30-* .250 .375 .125 .500 M22759/47-28-* .250 .375 .125 .500 M22759/47-26-* .375 .500 .125 .500 M22759/47-24-* 375 .500 .250 1.00 M22759/47-22-* .500 .750 .375 1.00 M22759/47-20-* .500 .750 .500 1.00 RATINGS: TEMPERATURE RATING: 200 C (392 F) MAXIMUM C

15、ONTINUOUS CONDUCTOR TEMPERATURE. VOLTAGE RATING: 600 VOLTS (RMS) AT SEA 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 CONFIGURA

16、TIONS IS THE RESPONSIBILITY OF THE USER. ADDITIONAL REQUIREMENTS: SILVER PLATED CONDUCTOR: SHALL MEET QUALITY CONFORMANCE TEST FOR CONDUCTOR MATERIAL AND REQUIREMENTS OF MIL-W-29606A AS DEFINED FOR SCA1 TYPE CONDUCTORS. BLOCKING: 230 C 3 C (446 F 5.4 F). COLOR: IN ACCORDANCE WITH MIL-STD-104, CLASS

17、1; WHITE PREFERRED. CONFORMITY OF COLOR TO THE LIMITS OF MIL-STD-104 SHALL NOT BE REQUIRED AFTER CROSSLINKING PROOF TEST OR LIFE CYCLE OVEN EXPOSURE. COLOR STRIPING OR BANDING DURABILITY: 125 CYCLES (250 STROKES) (MIN), 500 GRAMS WEIGHT. CROSSLINKING PROOF TEST: 7 HOURS AT 300 C 3 C (572 F 5.4 F). Q

18、UALITY CONFORMANCE TEST, GROUP II. REQUIREMENTS AND PROCEDURES AS FOR LIFE CYCLE EXCEPT FOR TIME AND TEMPERATURE. DIELECTRIC TEST AFTER IMMERSION: 2500 VOLTS (RMS), 60 HZ. DRY ARC PROPAGATION RESISTANCE: NOT REQUIRED. DYNAMIC CUT-THROUGH: NOT REQUIRED. FLAMMABILITY: QUALITY CONFORMANCE TEST, GROUP I

19、I. FOR REQUIREMENTS AND PROCEDURES SEE BELOW. TEST IN ACCORDANCE WITH AS4373, METHOD 801. REQUIREMENTS: DURATION AFTER-FLAME 3.0 SECONDS (MAXIMUM) FLAME TRAVEL 3.0 INCHES (MAXIMUM) NO FLAMING OF TISSUE FLUORIDE OFFGASSING TEST: (GROUP 1 QUALITY CONFORMANCE TEST) FLUORIDE EXTRACTION LEVEL SHALL NOT E

20、XCEED 20 PPM IN ACCORDANCE WITH AS4737 METHOD 608. HIGH FREQUENCY SPARK TEST: (WHEN USED IN LIEU OF THE IMPULSE DIELECTRIC TEST) 5.7 KILOVOLTS (RMS). 100 PERCENT TEST HUMIDITY RESISTANCE: AFTER HUMIDITY EXPOSURE, WIRE SHALL MEET THE REQUIREMENTS FOR INITIAL INSULATION RESISTANCE. IDENTIFICATION OF P

21、RODUCT: REQUIRED. SEE AS22759 FOR RESTRICTIONS. IDENTIFICATION DURABILITY: 125 CYCLES (250 STROKES) (MIN), 500 GRAMS WEIGHT. Copyright SAE International Provided by IHS under license with SAENot for ResaleNo reproduction or networking permitted without license from IHS-,-,-AEROSPACE STANDARD AS22759

22、/47SHEET 3 OF 4WIRE, ELECTRICAL, FLUOROPOLYMER-INSULATED, CROSSLINKED MODIFIED ETFE, LOW FLUORIDE, LIGHTWEIGHT, 80 MICROINCH SILVER-COATED HIGH-STRENGTH COPPER ALLOY, 200 C, 600 VOLT IMMERSION: FOR PROCEDURE SEE BELOW. IMPULSE DIELECTRIC TEST: 8.0 KILOVOLTS (PEAK), 100 PERCENT TEST. INSULATION RESIS

23、TANCE, INITIAL: 5000 MEGOHMS FOR 1000 FEET (MIN). INSULATION THICKNESS: 0.005 INCH (MIN) LIFE CYCLE: 500 HOURS AT 230 C 3 C (446 F 5.4 F). DIELECTRIC TEST, 2500 VOLTS (RMS), 60 HZ. PROCEDURE TO USE MANDRELS COATED WITH POLYTETRAFLUOROETHYLENE IN THE FORM OF EITHER ENAMEL OR WRAPPED TAPE, SUCH THAT T

24、HE DIAMETER OF THE MANDRELS, AFTER COATING, STILL CONFORM TO THE REQUIREMENTS OF PERFORMANCE DETAILS, TABLE 2. LOW TEMPERATURE (COLD BEND): BEND TEMPERATURE, -65 C 3 C (-85 F 5.4 F). DIELECTRIC TEST, 2500 VOLTS (RMS), 60 HZ. NEEDLE ABRASION: NOT REQUIRED. PHYSICAL PROPERTIES OF INSULATION: PULLED AT

25、 2 INCHES PER MINUTE. TENSILE STRENGTH, 5000 LBF/IN2 (MIN). ELONGATION, 75 PERCENT (MIN). SHRINKAGE: 0.125 INCH (MAX) AT 230 C 3 C (446 F 5.4 F). SMOKE: 250 C 5 C (482 F 9 F); NO VISIBLE SMOKE. SOLDERABILITY: ALL CONDUCTORS SHALL BE TESTED IN ACCORDANCE WITH AS4373, METHOD 105 WITHOUT STEAM AGING. S

26、PARK TEST OF PRIMARY INSULATION: NOT APPLICABLE SURFACE RESISTANCE: 500 MEGOHMS - INCHES (MIN), INITIAL AND FINAL READINGS. THERMAL SHOCK RESISTANCE: OVEN TEMPERATURE, 200 C 3 C (392 F 5.4 F). MAXIMUM CHANGE IN MEASUREMENT, 0.060 INCH, UV LASER MARKING: (GROUP I QUALITY CONFORMANCE TEST) TEST IN ACC

27、ORDANCE WITH AS4373, METHOD 1001. CONTRAST SHALL BE A 75 PERCENT MINIMUM AVERAGE ON SIX READINGS. UV LASER CONTRAST AFTER THERMAL AGING: (INITIAL QUALIFICATION AND RETENTION OF QUALIFICATION) WIRE SIZE 20 ONLY. PREPARE SAMPLE IN ACCORDANCE WITH AS4373 METHOD 1001. PLACE SAMPLE IN AN AIR CIRCULATING

28、OVEN AT 230 C 2 C (554 F 3.6 F) FOR 168 HOURS. MINIMUM AVERAGE CONTRAST AFTER AGING SHALL NOT BE LESS THAN 60 PERCENT. WET ARC PROPAGATION RESISTANCE: NOT REQUIRED. WICKING: NOT APPLICABLE. WIRE LENGTH REQUIREMENTS: SCHEDULE B. WRAP BACK TEST.: OVEN TEMPERATURE, 313 C 3 C (595 F 5.4 F). IMMERSION PR

29、OCEDURE: A 24-INCH SPECIMEN, FOR EACH TEST FLUID LISTED IN AS22759 , SHALL HAVE ITS DIAMETER MEASURED AND SHALL THEN BE IMMERSED TO WITHIN 6 INCHES OF EACH END FOR THE TIME AND TEMPERATURE SPECIFIED. DURING IMMERSION, THE RADIUS OF BEND OF THE WIRE SHALL BE NOT LESS THAN 14 NOR MORE THAN 35 TIMES TH

30、E SPECIFIED MAXIMUM DIAMETER OF THE WIRE UNDER TEST. UPON REMOVAL FROM THE TEST FLUID, THE SPECIMEN SHALL BE WIPED DRY AND THEN REMAIN FOR 1 HOUR IN FREE AIR AT ROOM TEMPERATURE. THE DIAMETER SHALL BE MEASURED AND COMPARED TO THE INITIAL DIAMETER. THE INSULATION SHALL BE REMOVED FOR A DISTANCE OF 1/

31、2 INCH FROM EACH END OF THE SPECIMEN. THE SPECIMEN SHALL THEN BE SUBJECTED TO THE BEND TEST AND DIELECTRIC TEST SPECIFIED IN THE PROCEDURE FOR LIFE CYCLE TESTING. QUALIFICATION OF WIRE: FOR QUALIFICATION, A SOURCE IS REQUIRED TO SUBMIT DATA ON QUALITY CONFORMANCE TESTS AND ANY FINISHED WIRE TESTS AS

32、 REQUIRED BY THE QUALIFICATION AUTHORIZATION LETTER. ALL OTHER TESTING WILL BE PERFORMED BY THE QUALIFYING ACTIVITY AT THE SOURCES EXPENSE. Copyright SAE International Provided by IHS under license with SAENot for ResaleNo reproduction or networking permitted without license from IHS-,-,-AEROSPACE S

33、TANDARD AS22759/47SHEET 4 OF 4WIRE, ELECTRICAL, FLUOROPOLYMER-INSULATED, CROSSLINKED MODIFIED ETFE, LOW FLUORIDE, LIGHTWEIGHT, 80 MICROINCH SILVER-COATED HIGH-STRENGTH COPPER ALLOY, 200 C, 600 VOLT APPLICATION NOTES: THE INDUSTRY HAS IDENTIFIED FLUORIDE OFFGASSING AS A SERIOUS ISSUE IN ENCLOSED ENVI

34、RONMENTS. THE EVOLUTION OF FLUORIDE GAS CAN ACCELERATE CORROSION OF METAL SURFACES AND ETCHING OF OPTICS. IT CAN ALSO ACCELERATE COPPER OXIDATION. IF ENCLOSED ENVIRONMENTS IS NOT AN ISSUE CONSIDER USING AS22759/ 33. Copyright SAE International Provided by IHS under license with SAENot for ResaleNo reproduction or networking permitted without license from IHS-,-,-