DLA DSCC-DWG-04037 REV B-2010 WIRE ELECTRICAL COMPOSITE POLYAMIDE BRAID POLYTETRAFLUOROETHYLENE POLYIMIDE INSULATED NORMAL WEIGHT SILVER COATED COPPER CONDUCTOR 200 DEGREE C 600 VO.pdf

1、REVISIONS LTR DESCRIPTION DATE APPROVED A Technical modifications to agree with SAE-AS22759/83 and SAE-AS22759/86. Editorial changes throughout. Updated format. Added approved supplier. 1 March 2009 Abdo Abdouni B Added approved supplier. 8 September 2010 Abdo Abdouni Prepared in accordance with ASM

2、E Y14.100 Selected item drawing REV PAGE REV STATUS OF PAGES REV B A A A A A A B B PAGE 1 2 3 4 5 6 7 8 9 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, PO

3、LYAMIDE BRAID, POLYTETRAFLUOROETHYLENE/POLYIMIDE INSULATED, NORMAL WEIGHT, SILVER COATED, COPPER CONDUCTOR, 200C, 600 VOLT APPROVED BY Richard L. Taylor SIZE CAGE CODE DWG. NO. 04037 A 037Z3 REV A PAGE 1 OF 9 AMSC N/A 6145-E097-003 CURRENT DESIGN ACTIVITY CAGE CODE 037Z3 HAS CHANGED NAMES TO: DLA LA

4、ND AND MARITIME COLUMBUS, OHIO 43218-3990 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 04037 REV A PAGE 2 8 AWG through 6 AWG 4 AWG through 4/0 AWG FP Fluorocar

5、bon Polymer, modified Polytetrafluoroethylene (PTFE) FIGURE 1. General configuration. CONDUCTOR, STRANDED, SMALL DIAMETER, SILVER COATED COPPER FP / POLYIMIDE / FP TAPE FP TAPE AROMATC POLYAMIDE BRAID TREATED TO PREVENT FRAYING CONDUCTOR, STRANDED, SMALL DIAMETER, SILVER COATED COPPER FP / POLYIMIDE

6、 / FP TAPE FP TAPE AROMATC POLYAMIDE BRAID TREATED TO PREVENT FRAYING 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 04037 REV A PAGE 3 1 SCOPE 1.1 Scope. This dr

7、awing covers the performance characteristics for a composite wire using a seamless polytetrafluoroethylene/ hydrolysis resistant polyimide tape wrap insulation system, with a normal weight stranded conductor. 1.2 Part or Identifying Number (PIN). The complete PIN should be as follows: 04037 - 01 - 9

8、 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) Diameter (inches) Weight lb/1000ft. (max) Min Max Min Max 04037-8-* 8 133 X 29 .158 .166 .658 .196 .216 62.0 04

9、037-6-* 6 133 X 27 .198 .208 .418 .235 .255 95.5 04037-4-* 4 133 X 25 .250 .263 .264 .292 .312 150 04037-2-* 2 665 X 30 .320 .340 .170 .360 .380 227 04037-1-* 1 817 X 30 .366 .380 .139 .400 .420 295 04037-01-* 0 1045 X 30 .395 .425 .108 .442 .462 351 04037-02-* 00 1330 X 30 .440 .475 .085 .498 .528

10、438 04037-03-* 000 1665 X 30 .500 .540 .068 .554 .584 554 04037-04-* 0000 2109 X 30 .565 .605 .054 .615 .655 689 * The asterisks in the part number column of table I shall be replaced by color code designator in accordance with 1.2.1. Example: 04TBD-26-9 is white. 1.2.1 Color. The color of the finis

11、hed wire shall be as indicated by the insulation color designator (see 1.2) of the wire part number and the color specified in the contract or order. The color designator should indicate the color of the braid. The preferred color is should be dark green with the Munsell color limits of 5Y 3/2 and 5

12、B 2/0.5 color designator 5D. White is an acceptable alternative color, designator 9. Insulation color designator (3 numbers maximum) (see 1.2.1) Wire size (see table I) DSCC drawing number Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-DEFENSE SUPPL

13、Y CENTER, COLUMBUS COLUMBUS, OH 43218-3990 SIZE CAGE CODE DWG NO. A 037Z3 04037 REV A PAGE 4 2. APPLICABLE DOCUMENTS 2.1 Government documents. 2.1.1 Specifications, standards, and handbooks. The following specifications, standards, and handbooks form a part of this document to the extent specified h

14、erein. 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 Insulation Color MIL-STD-202 - Test Method Standard Electronic and Electrical Component Parts (Copies of these documen

15、ts 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.) 2.2 Non-Government publications. The following documents form a part of this document to the extent specified herein. Unless ot

16、herwise specified, the issues of these documents are those cited in the solicitation or contract. ASTM INTERNATIONAL ASTM B298 - Standard Specification for Silver Coated Soft or Annealed Copper Wire ASTM D4591 - Standard Test Method for Determining Temperatures and Heats of Transitions of Fluoropoly

17、mers by Differential Scanning Calorimetry (Copies of these documents are available from http:/www.astm.org/ or ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, Pennsylvania, USA 19428-2959.) NCSL INTERNATIONAL NCSL Z540.3 - General Requirements for Calibration of Measuring

18、and Test Equipment (Copies of these documents are available from http:/www.ncsli.org or to National Conference of Standards Laboratories (NCSL), 2995 Wilderness Place, Suite 107, Boulder, CO 80301-5404.) SAE INTERNATIONAL SAE AS4373 - Test Methods for Insulated Electric Wire SAE AS22759 - Wire, Elec

19、trical, Fluoropolymer-Insulated, Copper or Copper Alloy SAE AS22759/83 - Wire, Electrical, Polytetrafluoroethylene/Polyimide Insulated, Normal Weight, Silver Coated, Copper Conductor, 200C, 600 Volt SAE AS22759/86 - Wire, Electrical, Polytetrafluoroethylene/Polyimide Insulated, Normal Weight, Silver

20、 Coated, Copper Conductor, 200C, 600 Volts (Copies of these documents are available from http:/www.sae.org/ or SAE International, 400 Commonwealth Drive, Warrendale, PA 15096-0001). 3. REQUIREMENTS 3.1 DSCC requirements. Items described in this drawing shall meet the requirements of SAE AS22759, SAE

21、 AS22759/83 (2 - 4/0 AWG) or SAE AS22759/86 (8 - 4 AWG) except as specified herein. Any requirements included in this drawing shall be in addition to, or supersede those requirements specified in SAE AS22759, SAE AS22759/83 (2 - 4/0 AWG) or SAE AS22759/86 (8 - 4 AWG). In case of conflict between the

22、 requirements in this drawing and those specified in SAE AS22759, SAE AS22759/83 (2 - 4/0 AWG) or SAE AS22759/86 (8 - 4 AWG), the requirements of this drawing shall take precedence. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-DEFENSE SUPPLY CENTE

23、R, COLUMBUS COLUMBUS, OH 43218-3990 SIZE CAGE CODE DWG NO. A 037Z3 04037 REV A PAGE 5 3.2 Design configuration. The design, construction, and physical dimensions shall be as specified in this drawing. 3.2.1 Design documentation. Design documentation shall be retained by the manufacturer, and shall b

24、e available upon request for review by the contracting activity, DSCC, or contractor. 3.3 Material. 3.3.1 Conductor. The conductors shall be made of soft annealed copper in accordance with ASTM B298 and table I of this drawing. All strands shall be free from lumps, kinks, splits, scarred or corroded

25、 surfaces and skin impurities. Strands shall be silver coated. The silver coating shall not be less than 40 microinches (1.02 m) of silver when tested in accordance with ASTM B298. 3.3.2 Braid. The braid shall be made of bright aromatic polyamide yarn, 200 Denier, 100 filaments, tightly formed. The

26、braid shall be uniform in appearance and treated with a clear finisher coating. The finisher coating shall be compatible with the temperature rating and performance requirements of the insulated wire. 3.3.3 Insulation. Insulation shall be polytetrafluoroethylene and polytetrafluoroethylene/polyimide

27、 tape 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 4 .0020 .0010 .0020 .0030 .0005 FP/.0010 polyimide/.0005 FP FP (Skived) FP (Skived) FP (Unsintered) 1/ Physical properties of PTFE

28、 unsintered tape shall be in accordance with SAE AS22759. TABLE III. Physical properties of FP/Polyimide/FP tapes. Tensile strength 19,000 lb/in2(average min) Tensile modulus 350,000 lb/in2(average min) Elongation 40 percent (average min) Dielectric strength 4,000 volts/mil (average min) .0005 FP La

29、yer Distinguishable color (next to conductor) 3.3.4 Wire construction and physical dimensions. See figure 1 and tables I and IV. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-DEFENSE SUPPLY CENTER, COLUMBUS COLUMBUS, OH 43218-3990 SIZE CAGE CODE DW

30、G NO. A 037Z3 04037 REV A PAGE 6 TABLE IV. Tape overlap requirements. 1/ Wrap 1 Wrap 2 Wrap 3 Wrap 4 Nominal wall thickness (mils) 2/ Wire size 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 2 20.5 35 1 50.5 5

31、5.0 4 67.0 71.0 - - - 13.2 6 2 20.5 35 1 50.5 55.0 4 67.0 71.0 - - - 13.2 4 3 20.5 35 1 50.5 55.0 4 50.5 54.0 4 50.5 54.0 16.2 2 3 20.5 35 1 50.5 55.0 4 50.5 54.0 4 50.5 54.0 16.2 1 3 20.5 35 1 50.5 55.0 4 50.5 54.0 4 50.5 54.0 16.2 1/0 3 20.5 35 1 50.5 55.0 4 50.5 54.0 4 50.5 54.0 16.2 2/0 3 20.5 3

32、5 1 50.5 55.0 4 50.5 54.0 4 50.5 54.0 16.2 3/0 3 20.5 35 1 50.5 55.0 4 50.5 54.0 4 50.5 54.0 16.2 4/0 3 20.5 35 1 50.5 55.0 4 50.5 54.0 4 50.5 54.0 16.2 1/ Wrap 1 is innermost tape which is in contact with the conductor. 2/ Nominal wall thickness does not include the polyamide braid thickness. 3.4 P

33、erformance testing. Wire supplied to this drawing shall be qualified in accordance with SAE AS22759/83 (2 4/0 AWG) or SAE AS22759/86 (8 4 AWG); and shall meet any additional requirements of this drawing. 3.4.1 Solderability (conformance inspection test). The requirement for acceptable solder coverag

34、e of the stranded conductor shall be as specified in MIL-STD-202, method 208. The following details shall apply: a. Unless otherwise specified, five specimens shall be prepared and tested for solderability using method 208 of MIL-STD-202. b. The specimens shall be tested without steam aging using a

35、type R flux. 3.4.2 Insulation state of sinter (conformance inspection test). FP layers shall be evaluated with a differential scanning calorimeter in accordance with ASTM D4591. This is performed on the sintered wire prior to braiding. The FP layers shall meet the following requirements: a. First he

36、at: 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 outer FP layer when visually examined with the unaided eye. The outer surface will be smo

37、oth and free of tape edges at the overlap. 3.4.3 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 lifting. There shall be no visible tape ridges that can contribute to tearing of the tape.

38、 This test is performed on the sintered wire prior to braiding. 3.4.4 Color (conformance inspection test). Conformity of color to the limits of MIL-STD-104 shall not be required after oven exposure. 3.5 Ratings. 3.5.1 Temperature rating. 200C maximum continuous conductor temperature. 3.5.2 Voltage r

39、ating. 600 Vrms at sea level. 3.6 Marking. The finished wire shall be identified by a printed marking applied to 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 accorda

40、nce with 1.2 herein. 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 04037 REV A PAGE 7 4. VERIFICATION 4.1 Classification of inspections. The inspection requireme

41、nts specified herein are classified as follows: a. Qualification inspection (see 4.2). b. Conformance inspection (see 4.3). 4.1.1 Equipment calibration. All test equipment and inspection facilities shall be maintained in accordance with NCSL Z540.3 or equivalent. 4.2 Qualification inspection. The pr

42、oduct manufactured under this drawing shall be currently listed on the qualified products list QPL-22759 for wire type SAE AS22759/83 (2 - 4/0 AWG) or SAE AS22759/86 (8 - 4 AWG). The additional performance requirements in paragraph 3.4 shall apply. 4.3 Conformance inspection. Conformance inspection

43、shall be in accordance with SAE AS22759/83 (2 - 4/0 AWG) or SAE AS22759/86 (8 4 AWG) and 3.4 herein. 4.4 Certification. In order to be certified and listed as an approved source of supply for wire manufactured to this drawing, a manufacturer shall: a. Agree to make available to DSCC, upon request, a

44、ll pertinent test data indicating compliance to the tests outlined in SAE AS22759, SAE AS22759/83 (2 4/0 AWG) or SAE AS22759/86 (8 4 AWG), and this drawing. b. Provide to DSCC-VAI, or its designated agent, upon request, free of change and without obligation, current production samples of the types a

45、nd quantities requested. c. Meet one of the following criteria: (1) Currently be listed on QPL-22759 for at least one wire series (not necessarily the one for which this drawing applies). (2) Be in current production of the subject part. 4.5 Certificate of compliance. A certificate of compliance sha

46、ll be required from a manufacturer in order to be listed as an approved source of supply (see 6.7). 5 PACKAGING 5.1 Packaging. For acquisition purposes, the packaging requirements shall be as specified in the contract or order (see 6.2). When packaging of materiel is to be performed by DoD or in-hou

47、se contractor personnel, these personnel need to contact the responsible packaging activity to ascertain packaging requirements. Packaging requirements are maintained by the Inventory Control Points packaging activities within the Military Service or Defense Agency, or within the military services s

48、ystem commands. Packaging data retrieval is available from the managing Military Departments or Defense Agencys automated packaging files, CD-ROM products, or by contacting the responsible packaging activity. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from I

49、HS-,-,-DEFENSE SUPPLY CENTER, COLUMBUS COLUMBUS, OH 43218-3990 SIZE CAGE CODE DWG NO. A 037Z3 04037 REV B PAGE 8 6 NOTES 6.1 Intended use. Wires conforming to this drawing are intended for use when military specifications do not exist for wires that will perform the required function. This drawing is intended to prevent the proliferation of unnecessary duplic