DLA DSCC-DWG-04034 REV B-2010 WIRE ELECTRICAL COMPOSITE POLYTETRAFLUOROETHYLENE POLYIMIDE INSULATED LIGHT WEIGHT COPPER CONDUCTOR TIN COATED 150 DEGREE C 600 VOLT.pdf

1、REVISIONS LTR DESCRIPTION DATE APPROVED A Technical modifications to agree with SAE-AS22759/80. Editorial changes throughout. Update format. Added approved supplier. 3/1/2009 Abdo Abdouni B Added approved supplier. 8 September 2010 Abdo Abdouni Prepared in accordance with ASME Y14.100 Selected item

2、drawing REV PAGE REV STATUS OF PAGES REV B A A A A A A A B B PAGE 1 2 3 4 5 6 7 8 9 10 PMIC PREPARED BY DEFENSE SUPPLY CENTER, COLUMBUS COLUMBUS, OHIO 43218-3990 William Carpenter Original date of drawing 12 July 2004 CHECKED BY TITLE Lee Surowiec WIRE, ELECTRICAL, COMPOSITE, POLYTETRAFLUOROETHYLENE

3、/POLYIMIDE INSULATED, LIGHT WEIGHT, COPPER CONDUCTOR, TIN COATED, 150C, 600 VOLT APPROVED BY Richard L. Taylor SIZE CAGE CODE DWG. NO. 04034 A 037Z3 REV B PAGE 1 OF 10 AMSC N/A 6145-E096-001.CURRENT DESIGN ACTIVITY CAGE CODE 037Z3 HAS CHANGED NAMES TO: DLA LAND AND MARITIME COLUMBUS, OHIO 43218-3990

4、 Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-DEFENSE SUPPLY CENTER, COLUMBUS COLUMBUS, OH 43218-3990 SIZE CAGE CODE DWG NO. A 037Z3 04034 REV A PAGE 2 1 SCOPE 1.1 Scope. This drawing covers the performance characteristics for a composite wire usi

5、ng a seamless polytetrafluoroethylene/ hydrolysis resistant polyimide tape wrap insulation system, with a light weight stranded conductor. 1.2 Part or Identifying Number (PIN). The complete PIN should be as follows: 04034 - 20 - 9 FP Fluorocarbon Polymer, modified Polytetrafluoroethylene (PTFE) FIGU

6、RE 1. General configuration. Wire size (see table I) DSCC drawing number FP / POLYIMIDE / FP TAPE Insulation color designator (see table I) FP TAPE CONDUCTOR, STRANDED, SMALL DIAMETER TIN COATED COPPER Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-

7、DEFENSE SUPPLY CENTER, COLUMBUS COLUMBUS, OH 43218-3990 SIZE CAGE CODE DWG NO. A 037Z3 04034 REV A PAGE 3 TABLE I. Details of construction. PIN Wire size (AWG) Conductor Finished wire Stranding (number of strands X gauge (AWG) of strands) Diameter (inches) Resistance at 20C ohms/1000ft. (max) Diamet

8、er (inches) Weight lb/1000ft. (max) Min Max Min Max 04034-26-* 26 19 X 38 .0175 .0204 41.3 .030 .034 1.43 04034-24-* 24 19 X 36 .0225 .0244 26.2 .034 .038 1.93 04034-22-* 22 19 X 34 .0285 .0314 16.2 .040 .043 2.85 04034-20-* 20 19 X 32 .0365 .0394 9.88 .048 .051 4.38 04034-18-* 18 19 X 30 .0455 .049

9、4 6.23 .056 .060 6.60 04034-16-* 16 19 X 29 .0515 .0554 4.81 .063 .067 8.30 04034-14-* 14 19 X 27 .0645 .0694 3.06 .076 .080 12.6 04034-12-* 12 37 X 28 .0835 .0894 2.02 .096 .100 19.6 04034-10-* 10 37 X 26 .106 .112 1.26 .119 .123 30.6 * The asterisks in the PIN column of table I should be replaced

10、by color code designators (see 1.2.2). Example: 04TBD-26-93 is white with an orange stripe. 1.2.1 Color. The wire insulation color should be indicated by the color designator (see 1.2) and as specified in the contract or purchase order. The insulation color should be in accordance with MIL-STD-681,

11、system 1, differentiation color coding chassis wiring (3 numbers maximum). For laser marked wires, color limits should be in accordance with MIL-STD-104, class I, or in accordance with table V of this drawing. 2. APPLICABLE DOCUMENTS 2.1 Government documents. 2.2 Specifications, standards, and handb

12、ooks. The following specifications, standards, and handbooks form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract. DEPARTMENT OF DEFENSE STANDARDS MIL-STD-104 - Limits for Electrical Ins

13、ulation Color MIL-STD-2223 - Test Methods for Insulated Electric Wire (Copies of these documents are available online at https:/assist.daps.dla.mil/quicksearch/ or from the Standardization Document Order 700 Robbins Avenue, Building 4D, Philadelphia, PA 19111-5094.) 2.3 Non-government publications.

14、The following documents form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract. ASTM INTERNATIONAL ASTM B33 - Standard Specification for Tinned Soft or Annealed Copper Wire for Electrical

15、Purposes ASTM D3032 - Standard Test Methods for Hookup Wire Insulation ASTM D4591 - Standard Test Method for Determining Temperatures and Heats of Transitions of Fluoropolymers by Differential Scanning Calorimetry (Copies of these documents are available from http:/www.astm.org/ or ASTM Internationa

16、l, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, Pennsylvania, USA 19428-2959.) Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-DEFENSE SUPPLY CENTER, COLUMBUS COLUMBUS, OH 43218-3990 SIZE CAGE CODE DWG NO. A 037Z3 04034 REV A PAGE 4 NCSL IN

17、TERNATIONAL NCSL-Z540.3 - General Requirements for Calibration of Measuring and Test Equipment (Copies of these documents are available online at http:/www.ncsli.org or from NCSL International 2995 Wilderness Place, Suite 107 Boulder, Colorado 80301-5404.) SAE INTERNATIONAL SAE-AS4373 - Test Methods

18、 for Insulated Electric Wire SAE-AS22759 - Wire, Electrical, Fluoropolymer-Insulated, Copper or Copper Alloy SAE-AS22759/80 - Wire, Electrical, Polytetrafluoroethylene/polyimide Insulated, Lightweight, Tin-coated, copper conductor 150 C, 600 Volts (Copies of these documents are available from http:/

19、www.sae.org/ or SAE International, 400 Commonwealth Drive, Warrendale, PA 15096-0001). 3. REQUIREMENTS 3.1 DSCC requirements. Items described in this shall meet the requirements of SAE-AS22759 and SAE-AS22759/80 except as specified herein. Any requirements included in this drawing shall be in additi

20、on to, or supersede those requirements included in SAE-AS22759 and SAE-AS22759/80. In case of conflict between the requirements in this drawing, SAE-AS22759 and SAE-AS22759/80, the requirements of this drawing shall take precedence. 3.2 Design configuration. The design, construction, and physical di

21、mensions shall be as specified in this drawing. 3.2.1 Design documentation. Design documentation shall be shall be retained by the manufacturer, and shall be available upon request for review by the contracting activity, DSCC, or contractor. 3.3 Material. 3.3.1 Conductor. Conductors shall be made of

22、 soft annealed copper wire in accordance with ASTM B33 and table I of this drawing. All strands shall be free from lumps, kinks, splits, scarred or corroded surfaces and skin impurities. Strands shall be tin coated in accordance with ASTM B33. 3.3.2 Insulation. Insulation shall be polytetrafluoroeth

23、ylene and polytetrafluoroethylene/polyimide tape as specified in tables II and III. The polyimide tape shall be hydrolysis resistant. TABLE II. Wire insulation materials. 1/ Tape code Thickness nominal (inches) Material 1 2 3 .0012 .0020 .0025 .00045 FP/.00065 polyimide/.0001 FP FP (Unsintered) FP (

24、Unsintered) 1/ Physical properties of PTFE unsintered tape shall be in accordance with SAE-AS22759. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-DEFENSE SUPPLY CENTER, COLUMBUS COLUMBUS, OH 43218-3990 SIZE CAGE CODE DWG NO. A 037Z3 04034 REV A PAG

25、E 5 TABLE III. Physical properties of FP/Polyimide/FP tapes. Tensile strength 20,000 lb/in2(average min) Tensile modulus 400,000 lb/in2(average min) Elongation 40 percent (average min) Dielectric strength 4,000 volts/mil (average min) .00045 FP Layer Distinguishable color (next to conductor) 3.4 Wir

26、e construction and physical dimensions. See figure 1 and tables I and IV. TABLE IV. Tape overlap requirements. 1/ Wrap 1 Wrap 2 Nominal wall thickness (mils) Wire size Tape code Percent overlap Tape code Percent overlap Min Max Min Max 26 1 50.5 54.0 2 50.5 54.0 5.8 24 1 50.5 54.0 2 50.5 54.0 5.8 22

27、 1 50.5 54.0 2 50.5 54.0 5.8 20 1 50.5 54.0 2 50.5 54.0 5.8 18 1 50.5 54.0 2 50.5 54.0 5.8 16 1 50.5 54.0 2 50.5 54.0 5.8 14 1 50.5 54.0 2 50.5 54.0 5.8 12 1 50.5 54.0 3 50.5 54.0 6.7 10 1 50.5 54.0 3 50.5 54.0 6.7 1/ Wrap 1 is innermost tape which is in contact with the conductor, with the .00045 i

28、nch FP side of the tape against the conductor. 3.5 Performance testing. Wire supplied to this drawing shall be qualified in accordance with SAE-AS22759/80 and shall meet any additional requirements of this drawing. 3.5.1 Wet arc propagation resistance (test required for initial qualification only).

29、When tested in accordance with MIL-STD-2223, method 3006, the following requirements shall apply: a. A minimum of 68 wires shall pass the impulse dielectric test of SAE-AS22759. b. Not more than two wires shall fail the impulse dielectric test in any one bundle. c. Actual damage to the wire shall be

30、 not more than 1.0 inch (25.4 mm) in length in any bundle when measured along the axis. 3.5.2 Forced hydrolysis (test required for initial qualification only). When tested in accordance with SAE-AS4373, method 602, the minimum average performance shall be 5000 hours at 70C. The following details sha

31、ll apply: a. Number of specimens: 5. b. Wire size to be tested: 20 AWG. c. A specimen is considered “failed” when it can no longer pass the dielectric test method of SAE-AS4373 method 602. d. Average the time to failure for all of the specimens evaluated. Provided by IHSNot for ResaleNo reproduction

32、 or networking permitted without license from IHS-,-,-DEFENSE SUPPLY CENTER, COLUMBUS COLUMBUS, OH 43218-3990 SIZE CAGE CODE DWG NO. A 037Z3 04034 REV A PAGE 6 3.5.3 Insulation state of sinter (quality conformance test). FP layers shall be evaluated with a differential scanning calorimeter in accord

33、ance with ASTM D4591. The FP layers shall meet the following requirements: a. First heat: Less than 25 Joules/gram (J/g). b. Second heat: Maximum 2 J/g change when compared to first heat. c. Bonding between FP layers shall be homogenous. No evidence of tape edges or seams shall be present on the out

34、er FP layer when visually examined with the unaided eye. The outer surface will be smooth and free of tape edges at the overlap. 3.5.4 Lamination sealing (conformance inspection test). When tested in accordance with SAE-AS4373 method 809 at 200C, there shall be no evidence of tape separation or lift

35、ing. There shall be no visible tape ridges that can contribute to tearing of the tape. 3.5.5 Strippability (conformance inspection test). There shall be no evidence of separation or elongation of FP layers when stripped with standard hand held tools designed for such use. No evidence of insulation s

36、hall be left on the conductor when viewed with the naked eye. The following details shall apply: a. Test size: 26 AWG to 14 AWG, in accordance with ASTM D3032, section 27. b. Length of insulation slugs shall be .25 inches (6.35 mm). c. The strip force shall be as follows: Wire size (AWG) Minimum for

37、ce (lbs) Maximum force (lbs) 20 - 26 0.25 6.0 18 to 14 0.50 7.0 3.5.6 Durability (PTFE outer layer) (Test required for initial qualification only). When tested as specified, the wire shall withstand an average of 100 cycles without failure due to tear or surface cut through of the outer layer. The f

38、ollowing details shall apply: a. Wire size: 22 AWG. b. Temperature: 23C. c. Weight: 300 grams (10.6 oz). d. Edged abrading rod diameter: .026 inch (0.66 mm) nominal. e. Test specimens shall be manufactured to emulate the wire construction specified herein, except the polyimide shall be replaced with

39、 an aluminum/Mylar film of similar thickness with the conductive (aluminum) side out. The conductive surface is used in a circuit path to determine when the abrading rod has penetrated the PTFE layer. f. Test method: (1) Install a .026 inch (0.66 mm) edged abrading rod with the edged surface facing

40、down (perpendicular with the test specimen). (2) Remove approximately 1 inch (25.4 mm) of insulation from the end of the specimen and connect the circuit detection clip to the exposed conductor. (3) Apply the appropriate weights to the fixture. (4) Place the abrading rod on the specimen, ensuring th

41、e rod is level and perpendicular to the specimen surface. (5) Zero the counter on the abrasion tester. (6) Turn the tester on. The rod will begin to oscillate over the surface of the specimen with an approximate 1 inch (25.4 mm) stroke. (7) The test will continue until the tester detects continuity

42、between the abrading rod and the conductor. (8) Record the number of cycles to failure. (9) Repeat the procedure a minimum of 10 times (100 times preferred) to generate a statistically significant sample. (10) Average the results. Provided by IHSNot for ResaleNo reproduction or networking permitted

43、without license from IHS-,-,-DEFENSE SUPPLY CENTER, COLUMBUS COLUMBUS, OH 43218-3990 SIZE CAGE CODE DWG NO. A 037Z3 04034 REV A PAGE 7 3.5.7 UV laser marking (test required for initial qualification only). When marked with an ultraviolet (UV) laser source at 1.5 J/cm2, white FP tape shall have a con

44、trast level of 65% minimum average and colored FP tape shall have a 62% minimum average. This requirement applies to the outer most FP insulation layer. Non-white insulation colors shall meet the Munsell color limit requirements shown in table V. Contrast level is defined as: CL = 3.5.8 Color (confo

45、rmance inspection test). Colors shall be in accordance with MIL-STD-104, class 1, except for UV laser markable wire as shown in table V. White is the preferred background insulation color. Color conformity to the limits of MIL-STD-104 shall not be required after oven exposure. TABLE V. Munsell color

46、 limits for UV laser markable wire. Color Hue Value Chroma From To Min Max From To Black 2.5RN 2.5RN 7 8.5 N/A N/A Blue 5PB 7.5B 7 8 4 6 Green 2.5G 7.5G 7 9 2 6 Red 10RP 5R 7 8 4 6 Yellow 5Y 10Y 8 9 4 6 Brown 2.5YR 7.5R 7 9 2 4 Orange 10R 2.5YR 6 7 8 10 Violet 2.5P 7.5R 7 8 4 8 Gray Same as black Sa

47、me as black Same as black Same as black Same as black Same as black 3.5.9 Color striping or banding durability (conformance inspection test). Colored stripes or bands shall meet the durability of color marking requirements specified in SAE AS22759. The following shall apply to the durability of colo

48、r marking test. a. Weight: 250 grams (8.82 oz). b. Strokes: 250 strokes (125 cycles). 3.6 Ratings. 3.6.1 Temperature rating. 150C maximum continuous conductor temperature. 3.6.2 Voltage rating. 600 Vrms at sea level. 3.7 Marking. The finished wire shall be identified by a printed marking applied to

49、the outer surface or the wire. The identification mark shall not be applied by hot stamp marking or other methods which significantly penetrate the insulation. The PIN shall be in accordance with 1.2 herein. (Reflectance of the background insulation - Reflectance of the laser mark) (Reflectance of the background insulation) Provided by IHSNot for ResaleNo reproduction or networking permitted without l