SAE AS 22759 57-2016 WIRE ELECTRICAL FLUOROPOLYMER-INSULATED CROSS-LINKED MODIFIED ETFE NORMAL WEIGHT NICKEL COATED EXTRA HIGH STRENGTH COPPER ALLOY 200 600 VOLT ROHS.pdf

1、AEROSPACE STANDARDWIRE, ELECTRICAL, FLUOROPOLYMER-INSULATED, CROSS-LINKED MODIFIED ETFE, NORMAL WEIGHT, NICKELCOATED, EXTRA HIGH STRENGTH COPPER ALLOY,200 C, 600 VOLT, ROHSAS22759TM/57Copyright 2016 SAE InternationalAll rights reserved. No part of this publication may be reproduced, stored in a retr

2、ieval 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: Custome

3、rServicesae.org SAE WEB ADDRESS: http:/www.sae.orgISSUED2016-07THIRD ANGLE PROJECTIONCUSTODIAN: AE-8/AE-8DFEDERAL SUPPLY CLASS6145AS22759TM/57SHEET 1 OF 3PROCUREMENT SPECIFICATION: AS22759SAE Technical Standards BoardRules providethat:“This reportis publishedby SAE to advance thestateoftechnical and

4、engineering sciences. The useofthis reportis entirely voluntary, and its applicability and suitability forany particularuse, includingany patent infringement arising therefrom, is thesole responsibility of theuser.”SAE reviews eachtechnical reportatleastevery five years at whichtime it may bereaffir

5、med, revised, stabilized or cancelled. SAE invites your writtencomments and suggestions.SAE values your input. To provide feedbackon this Technical Report, please visit http:/www.sae.org/technical/standards/AS22759/57RATIONALESPECIFICATION DEVELOPED FOR APPLICATIONS REQUIRING HIGHER CONDUCTOR TENSIL

6、E STRENGTH WHILE MAINTAINING ELECTRICAL CONDUCTIVITY. THIS SPECIFICATION USES THE EXTRA HIGH STRENGTH CLASSIFICATION OF NICKEL PLATED COPPER ALLOY CONDUCTOR FROM AS29606.NOTICETHE COMPLETE REQUIREMENTS FOR PROCURING THE PRODUCT DESCRIBED HEREIN SHALL CONSIST OF THIS DOCUMENT AND THE LATEST ISSUE OF

7、AS22759.PRIMARY INSULATION - CROSSLINKED, EXTRUDED, MODIFIED ETFEJACKET - CROSSLINKED, EXTRUDED, MODIFIED ETFEETFE ETHYLENE TETRAFLUOROETHYLENE CONDUCTOR STRANDED NICKEL COATED EXTRA HIGH STRENGTH COPPER ALLOYFIGURE 1 - AS22759/57 CONFIGURATIONTABLE 1 - CONSTRUCTION DETAILS FOR FINISHED WIREPART NO.

8、 1/WIRE SIZESTRANDING (NUMBER OF STRANDS X SIZE GAUGE OF STRANDS) 2/DIAMETER OF STRANDED CONDUCTOR (INCHES) 2/ FINISHED WIRE(MIN) (MAX)RESISTANCE AT 20 C (68 F) (OHMS/1000 FEET) MAXDIAMETER (INCHES)WEIGHT (LB/1000 FEET) (MAX)M22759/57-30-* 30 7 X 38 .0117 .0134 129.6 .032 .002 1.00M22759/57-28-* 28

9、7 X 36 .0147 .0164 79.0 .035 .002 1.20M22759/57-26-* 26 19 X 38 .0184 .0204 49.4 .040 .002 1.70M22759/57-24-* 24 19 X 36 .0231 .0254 30.1 .045 .002 2.30M22759/57-22-* 22 19 X 34 .0293 .0314 18.6 .050 .002 3.30M22759/57-20-* 20 19 X 32 .0373 .0404 11.4 .058 .002 4.801/ PART NUMBER: THE ASTERISKS IN T

10、HE PART NUMBER COLUMN OF TABLE 1 SHALL BE REPLACED BY COLOR CODE DESIGNATORS IN ACCORDANCE WITH MIL-STD-681. EXAMPLE: M22759/57-20-93 IS A 20 AWG WHITE WITH ORANGE STRIPE.2/ CONDUCTOR SHALL CONFORM TO AS29606 TYPE NCS SMALL DIAMETER NICKEL COATED EXTRA HIGH STRENGTH COPPER ALLOY CONDUCTOR.AEROSPACE

11、STANDARDAS22759TM/57SHEET 2 OF 3WIRE, ELECTRICAL, FLUOROPOLYMER-INSULATED, CROSS-LINKED MODIFIED ETFE, NORMAL WEIGHT, NICKELCOATED, EXTRA HIGH STRENGTH COPPER ALLOY,200 C, 600 VOLT, ROHSREQUIREMENT: ALL REQUIREMENTS SHALL CONSIST OF THIS DOCUMENT AND THE LATEST ISSUE OF AS22759.1. WIRE CONSTRUCTION:

12、WIRE CONSTRUCTION SHALL BE IN ACCORDANCE WITH FIGURE 1 AND TABLES 1, 2, 3, AND 4.2. WIRE PERFORMANCE RATING:TEMPERATURE RATING: 200 C (392 F) MAXIMUM CONDUCTOR CONTINUOUS TEMPERATURE.VOLTAGE RATING: 600 VOLTS (RMS) AT SEA LEVEL. THIS INSULATION SYSTEM HAS BEEN USED IN AEROSPACE APPLICATIONS USING 11

13、5 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 PROPERTIES:SEE AS22759 FOR MATERIAL REQUIREMENT. MATERIALS USED IN THE MANUFACTURE O

14、F THESE PRODUCTS SHALL COMPLYWITH THE RESTRICTION OF HAZARDOUS SUBSTANCES DIRECTIVE 2002/95/EC. 4. FINISH WIRE INSULATION PROPERTIES:PRIMARY INSULATION SHALL HAVE A CONTRASTING PIGMENTATION TO THAT OF THE JACKET.PHYSICAL PROPERTIES OF INSULATION: PRIMARY INSULATION SHALL BE SEPARATED FROM THE OUTER

15、JACKET FOR DETERMINATION OF PRIMARY INSULATION TENSILE STRENGTH AND ELONGATION.FINISH WIRE INSULATION PROPERTIES SHALL BE IN ACCORDANCE WITH TABLE 2.TABLE 2 - FINISHED WIRE INSULATION PROPERTIES REQUIREMENTSINSULATION PROPERTIESSPARK TEST VOLTAGE (PRIMARY INSULATION)1500 VOLTS (RMS) AT 60 HERTZIMPUL

16、SE TEST VOLTAGE (PRIMARY INSULATION)6.0 KILOVOLTS (PEAK)HIGH FREQUENCY TEST VOLTAGE (PRIMARY INSULATION)4.2 KILOVOLTS (RMS)IMPULSE TEST VOLTAGE 8.0 KILOVOLTS (PEAK)HIGH FREQUENCY TEST VOLTAGE 5.7 KILOVOLTS (RMS) CROSSLINK PROOF 300 C 3 C (572 F 5.4 F), 7 HOURSINSULATION BLOCKING 230 C 3 C (446 F 5.4

17、 F)SHRINKAGE 230 C 3 C (446 F 5.4 F)MAXIMUM CHANGE .125 INCHESLAYER WICKING 2.25 INCHES (MAX)PROCEDURE: MULTI-LAYER WIREELECTRICAL RESISTANCE (IR) 5000 MEGOHMS (MIN)-1000 FEETELECTRICAL SURFACE RESISTANCE 500 MEGOHMS - INCHES (MIN)WET DIELECTRIC VOLTAGE 2500 VOLTS (RMS), 60 HERTZWALL THICKNESS .003

18、INCH (MIN) FOR PRIMARY INSULATION.004 INCH (MIN) FOR OUTER JACKET.008 INCH (MIN) FOR TOTAL INSULATIONINSULATION TENSILE STRENGTH 5000 LBF/IN2 (MIN) FOR PRIMARY INSULATION5000 LBF/IN2 (MIN) FOR TOTAL INSULATIONINSULATION ELONGATION 125% (MIN) FOR PRIMARY INSULATION 75% (MIN) FOR TOTAL INSULATIONCONTI

19、NUOUS LENGTH SCHEDULE B5. FINISH WIRE IDENTIFICATION:WIRE IDENTIFICATION EXCEPTIONS: NONEWIRE IDENTIFICATION DURABILITY: 125 CYCLES (250 STROKES) WITH 500 GRAMS WEIGHT STRIPE AND BAND DURABILITY: 125 CYCLES (250 STROKES) WITH 500 GRAMS WEIGHTAEROSPACE STANDARDAS22759TM/57SHEET 3 OF 3WIRE, ELECTRICAL

20、, FLUOROPOLYMER-INSULATED, CROSS-LINKED MODIFIED ETFE, NORMAL WEIGHT, NICKELCOATED, EXTRA HIGH STRENGTH COPPER ALLOY,200 C, 600 VOLT, ROHS6. FINISH WIRE PERFORMANCE:FINISH WIRE FIXTURES APPLICABLE TO EACH WIRE SIZE SHALL BE IN ACCORDANCE WITH TABLE 3.TABLE 3 - TEST MANDREL AND TEST LOAD REQUIREMENTS

21、BEND TESTINGPART NO.MANDREL DIAMETER 1/(INCHES)TEST LOAD 1/(LB)CROSSLINKING PROOF, IMMERSION AND LIFE CYCLE TESTSCOLD BEND TESTCROSSLINKING PROOF, IMMERSION AND LIFE CYCLE TESTSCOLD BEND TESTM22759/57-30-* .375 1.00 .250 1.00M22759/57-28-* .375 1.00 .250 2.00M22759/57-26-* .375 1.00 .500 3.00M22759/

22、57-24-* .500 1.00 .750 3.00M22759/57-22-* .500 1.00 1.00 3.00M22759/57-20-* .500 1.00 1.50 4.001/ TOLERANCE SHALL BE 3% OF THE GIVEN VALUES.FINISH WIRE PERFORMANCE CHARACTERISTICS SHALL BE IN ACCORDANCE WITH TABLE 4.TABLE 4 - FINISH WIRE PERFORMANCE CHARACTERISTICSPERFORMANCE CHARACTERISTIC REQUIREM

23、ENTWRAP BACK BEND RESISTANCE TEMPERATURE EXPOSURE 313 C 3 C (595 F 5.4 F)THERMAL SHOCK MECHANICAL RESISTANCE TEMPERATURE EXPOSURE 200 C 3 C (392 F 5.4 F)MAXIMUM CHANGE .060 INCHESTHERMAL MECHANICAL RESISTANCE (LIFE CYCLE)EXPOSURE 500 HOURS, 230 C 3 C (446 F 5.4 F) COLOR RETENTION NOT REQUIREDHUMIDIT

24、Y RESISTANCE (IR) 5000 MEGOHMS (MIN)-1000 FEETFLUID RESISTANCE DIAMETER INCREASE 5% (MAX)SMOKE RESISTANCE 250 C 5 C (482 F 9 F)FLAME RESISTANCE SELF-EXTINGUISH TIME: 3 SECONDSBURN LENGTH 3 INCHES7. REQUIREMENT EXCEPTION TO THE AS22759:NONEAPPLICATION NOTES1. PRODUCTS MANUFACTURED TO THIS SPECIFICATI

25、ON ARE ROHS COMPLIANT. SPECIFICATION NOTES1. 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 THATCONTAIN EDITORIAL CHANGES ONLY.