SAE AS 22759 84D-2017 WIRE ELECTRICAL POLYTETRAFLUOROETHYLENE POLYMIDE INSULATED NORMAL WEIGHT NICKEL COATED COPPER CONDUCTOR 260 600 VOLT ROHS.pdf

1、 AEROSPACE STANDARD WIRE, ELECTRICAL, POLYTETRAFLUOROETHYLENE/ POLYMIDE INSULATED, NORMAL WEIGHT, NICKEL COATED, COPPER CONDUCTOR, 260 C, 600 VOLT, ROHS AS22759/84Copyright 2017 SAE International All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or tran

2、smitted, 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: CustomerServicesae.org SA

3、E WEB ADDRESS: http:/www.sae.org ISSUED2000-06REVISED2017-09THIRD ANGLE PROJECTION CUSTODIAN: AE-8/AE-8D REV.D FEDERAL SUPPLY CLASS 6145 AS22759 /84 SHEET 1 OF 5 REV. D PROCUREMENT SPECIFICATION: NONE SAE Technical Standards Board Rules provide that: “This report is published by SAEtoadvance thestat

4、e of technicaland engineering sciences. The useof this report is entirely voluntary, and its applicability andsuitability for any particularuse, includingany patent infringement arisingtherefrom,is thesole responsibility of theuser.” SAE reviews eachtechnical reportatleast every fiveyears at whichti

5、me it may be revised, reaffirmed, stabilized, or cancelled. SAE invites your written comments and suggestions.SAE values your input. To provide feedback on this Technical Report, please visit http:/standards.sae.org/AS22759/84D RATIONALE SPECIFICATION UPDATED TO INCLUDE AS29606 CONDUCTOR REQUIREMENT

6、S, ROHS RESTRICTIONS AND AS22759 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. C

7、ONDUCTOR REQUIREMENTS WERE ORIGINALLY 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 PRO

8、DUCING TIGHT TOLERANCE CONDUCTORS 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

9、SIZE CONDUCTORS (SIZE 8 THROUGH 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

10、 SIGNIFICANT CONCERN. SEVERAL 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 FAIL

11、URES. THESE NEW LIMITS WERE 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 CONDUCTO

12、R SPECIFICATION. BEFORE THE 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 - 2000 TIME FRAME. SINCE THE EPL NO LONGER HAD LEGAL STANDING AFTER THE CONVERSION, WIRE PRODU

13、CERS DID NOT HAVE TO ABIDE 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 AD

14、OPT MIL-W-29606 (NOW AS29606) 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 PERCENT. THE COMMITTEE

15、 EVALUATED SEVERAL METHODS OF INCORPORATING 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 PRIMAR

16、ILY USED FOR PRIMARY POWER DISTRIBUTION 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 WE

17、IGHT RANGES MEET THE DESIGN REQUIREMENTS OF LEGACY APPLICATIONS. NOTICE THE COMPLETE REQUIREMENTS FOR PROCURING THE PRODUCT DESCRIBED HEREIN SHALL CONSIST OF THIS DOCUMENT AND THE LATEST ISSUE OF AS22759. THIS SPECIFICATION IS NOT INTENDED FOR USE IN NAVAL AIRCRAFT OR NAVAL AIR SYSTEMS APPLICATIONS.

18、 AEROSPACE STANDARD AS22759 /84 SHEET 2 OF 5 REV. D WIRE, ELECTRICAL, POLYTETRAFLUOROETHYLENE/ POLYMIDE INSULATED, NORMAL WEIGHT, NICKEL COATED, COPPER CONDUCTOR, 260 C, 600 VOLT, ROHS FP / POLYIMIDE / FP TAPE FP TAPE FP TAPE META-ARAMID FIBER BRAID TREATED TO PREVENT FRAYING 1/ SIZE 8 THROUGH 6 FP

19、/ POLYIMIDE / FP TAPE FP TAPE FP TAPE FP TAPE META-ARAMID FIBER BRAID TREATED TO PREVENT FRAYING 1/ SIZE 4 THROUGH 04 FP FLUOROCARBON POLYMER MODIFIED POLYTETRAFLUOROETHYLENE (PTFE) CONDUCTOR STRANDED NICKEL COATED COPPER 1/ BRAID: BRIGHT AROMATIC POLYAMIDE YARN, 200 DENIER, 100 FILAMENTS, TIGHTLY F

20、ORMED, UNIFORM IN APPEARANCE, TREATED WITH A CLEAR FINISHER COATING. THE FINISHER COATING SHALL BE COMPATIBLE WITH THE 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 H

21、ANDLING. FIGURE 1 - AS22759/84 CONFIGURATION AEROSPACE STANDARD AS22759 /84 SHEET 3 OF 5 REV. D WIRE, ELECTRICAL, POLYTETRAFLUOROETHYLENE/ POLYMIDE INSULATED, NORMAL WEIGHT, NICKEL COATED, COPPER CONDUCTOR, 260 C, 600 VOLT, ROHS TABLE 1 - CONSTRUCTION DETAILS FOR FINISHED WIRE PART NO. 1/ WIRE SIZE

22、CONDUCTOR 3/ FINISHED WIRE STRANDING (NUMBER OF STRANDS X SIZE GAUGE OF STRANDS) DIAMETER (INCH) RESISTANCE AT 20 C (68 F) (OHMS/1000 FT. MAX.) DIAMETER (INCH) WEIGHT (LB/1000 FT.) 2/ MIN. MAX. MIN. MAX. MIN. TARGET MAX. M22759/84-8 M22759/84-6 M22759/84-4 M22759/84-2-* M22759/84-1-* M22759/84-01-*

23、M22759/84-02-* M22759/84-03-* M22759/84-04-* 8 6 4 2 1 0 00 000 0000 133 X 29 133 X 27 133 X 25 665 X 30 817 X 30 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 .694 .436 .275 .177 .144 .113 .089 .071 .056 .192 .231 .

24、288 .356 .400 .432 .487 .542 .602 .213 .254 .313 .389 .433 .475 .530 .585 .655 59.6 91.1 147 220 271 342 422 534 684 61.7 93.5 151 229 280 355 442 554 706 63.8 95.9 155 238 289 368 462 574 728 1/ PART NUMBER: THE PREFERRED COLOR IS DARK GREEN WITH THE COLOR DESIGNATOR 5D. EXAMPLE: SIZE 2 DARK GREEN

25、- AS22759/84-2-5D. WHITE IS AN ACCEPTABLE ALTERNATE WITH A COLOR DESIGNATOR 9. 2/ THE ACCEPTABLE VALUE FOR THE CPK FOR THE FINISHED WIRE WEIGHT LISTED SHALL BE 1.3, USING A NORMAL (GAUSSIAN) DISTRIBUTION TO OBTAIN THOSE CPK VALUES. 3/ CONDUCTOR SHALL CONFORM TO AS29606 TYPE NCC SMALL DIAMETER NICKEL

26、 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 FIGURE 1 AND TABLES 1, 2, 3, AND 4.

27、 TABLE 2 - WIRE INSULATION MATERIALS TAPE CODE THICKNESS NOMINAL MATERIAL 1 2 3 4 .0020 .0020 .0030 .0010 .0005 (FP)/.0010 (POLYIMIDE)/.0005 (FP) FP (SKIVED) FP (UNSINTERED OR PRESINTERED BONDABLE) FP (SKIVED) TABLE 3 - TAPE OVERLAP REQUIREMENTS 1/ WIRE SIZE WRAP 1 WRAP 2 WRAP 3 WRAP 4 NOMINAL WALL

28、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

29、16.2 2 2 20.5 35.0 1 50.5 55.0 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.

30、0 1 50.5 55.0 3 50.5 54.0 3 50.5 54.0 16.2 1/ WRAP 1 IS 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 /84 SHEET 4 OF

31、 5 REV. D WIRE, ELECTRICAL, POLYTETRAFLUOROETHYLENE/ POLYMIDE INSULATED, NORMAL WEIGHT, NICKEL COATED, COPPER CONDUCTOR, 260 C, 600 VOLT, ROHS 2. WIRE PERFORMANCE RATING: TEMPERATURE RATING: 260 C (500 F) MAXIMUM CONDUCTOR CONTINUOUS TEMPERATURE. VOLTAGE RATING: 600 VOLTS (RMS) AT SEA LEVEL. THIS IN

32、SULATION 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 PROPERTIES: SEE AS2

33、2759 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 - FINISHED WIRE INSU

34、LATION 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 260 C 2 C (500 F 3.6 F) SHRINKAGE 290 C 2 C (554 F 3.6 F) MAXIMU

35、M 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 DURABILITY: N

36、OT 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/ (INCH) TEST LOAD 1/ (LB) COLD BEND LIFE CYCLE/ BEND TEST WRAP COLD BEND LIFE CYCLE

37、/ 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/ TOLERANCE SHALL B

38、E 3% OF THE GIVEN VALUES. AEROSPACE STANDARD AS22759 /84 SHEET 5 OF 5 REV. D WIRE, ELECTRICAL, POLYTETRAFLUOROETHYLENE/ POLYMIDE INSULATED, NORMAL WEIGHT, NICKEL COATED, COPPER CONDUCTOR, 260 C, 600 VOLT, ROHS FINISH WIRE PERFORMANCE CHARACTERISTICS SHALL BE IN ACCORDANCE WITH TABLE 6. TABLE 6 - FIN

39、ISH 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) EXPOSURE 500 HOURS, 290 C

40、 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 APPLICATION NOTES 1. PRODUCT

41、S MANUFACTURED TO THIS SPECIFICATION ARE ROHS COMPLIANT. SPECIFICATION NOTES 1. REVISION INDICATOR: A CHANGE BAR (I) 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.