DLA DSCC-DWG-04038 REV C-2010 WIRE ELECTRICAL COMPOSITE POLYAMIDE BRAID POLYTETRAFLUOROETHYLENE POLYIMIDE INSULATED NORMAL WEIGHT NICKEL COATED COPPER CONDUCTOR 260 DEGREE C 600 VO.pdf

1、REVISIONS LTR DESCRIPTION DATE APPROVED A Technical modifications to agree with SAE-AS22759/84. Editorial changes throughout. 6/11/07 Abdo Abdouni B Editorial changes throughout. Update format. Added approved supplier. 6 March 2009 Abdo Abdouni C Added approved supplier. 8 September 2010 Abdo Abdoun

2、i Prepared in accordance with ASME Y14.100 Selected item drawing REV PAGE REV STATUS OF PAGES REV C B B B B B B B C 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

3、WIRE, ELECTRICAL, COMPOSITE, POLYAMIDE BRAID, POLYTETRAFLUOROETHYLENE/POLYIMIDE INSULATED, NORMAL WEIGHT, NICKEL COATED, COPPER CONDUCTOR, 260C, 600 VOLT APPROVED BY Richard L. Taylor SIZE CAGE CODE DWG. NO. 04038 A 037Z3 REV C PAGE 1 OF 9 AMSC N/A 6145-E097-004 CURRENT DESIGN ACTIVITY CAGE CODE 037

4、Z3 HAS CHANGED NAMES TO: DLA LAND 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 43216-5000 SIZE CAGE CODE DWG NO. A 037Z3 04038 REV B PAGE 2 8 AWG through 6 AWG 4 A

5、WG through 4/0 AWG FP Fluorocarbon Polymer, modified Polytetrafluoroethylene (PTFE) FIGURE 1. General configuration. CONDUCTOR, STRANDED, SMALL DIAMETER, NICKEL COATED COPPER FP / POLYIMIDE / FP TAPE FP TAPE AROMATC POLYAMIDE BRAID TREATED TO PREVENT FRAYING CONDUCTOR, STRANDED, SMALL DIAMETER, NICK

6、EL COATED COPPER FP / POLYIMIDE / 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 43216-5000 SIZE CAGE CODE DWG NO. A 037Z3 04038 REV B PA

7、GE 3 1 SCOPE 1.1 Scope. This drawing covers the performance characteristics for a composite wire using a seamless polytetrafluoroethylene/ hydrolysis resistant, polyimide tape wrap insulation system, with a normal weight nickel coated copper stranded conductor. 1.2 Part or Identifying Number (PIN).

8、The complete PIN shall be as follows: 04038 - 01 - 5D 1.2.1 Alloy conductor. Nickel coated copper conductor in accordance with ASTM B355 and in table I. TABLE I. Details of construction. PIN Wire size (AWG) Conductor Finished wire Stranding (number of strand X gauge (AWG) of strands) Diameter (inche

9、s) Resistance at 20C ohms/1000ft. (max) Diameter (inches) Weight lb/1000ft. (max) Min Max Min Max 04038-8-* 8 133 X 29 .158 .166 .694 .196 .216 61.6 04038-6-* 6 133 X 27 .198 .208 .436 .235 .255 93.7 04038-4-* 4 133 X 25 .250 .263 .275 .292 .312 148 04038-2-* 2 665 X 30 .320 .340 .177 .360 .380 227

10、04038-1-* 1 817 X 30 .366 .380 .144 .400 .420 295 04038-01-* 0 1045 X 30 .395 .425 .113 .442 .462 351 04038-02-* 00 1330 X 30 .440 .475 .089 .498 .528 438 04038-03-* 000 1665 X 30 .500 .540 .071 .554 .584 554 04038-04-* 0000 2109 X 30 .565 .605 .056 .615 .655 689 * The asterisks in the part number c

11、olumn of table I should be replaced by color code designator I (see 1.2.2). Example: 04038-26-5D is dark green. 1.2.2 Color. The color of the finished wire should be as indicated by the insulation color designator (see 1.2) of the wire PIN and the color specified in the contract or order. The color

12、designators should indicate the color of the braid. The preferred color shall be dark green with the Munsell color limits of 5Y 3/2 and 5B 2/0.5, color designator 5D. White is an acceptable alternative color, designator 9. 2. APPLICABLE DOCUMENTS 2.1 Government documents. Wire size (see table I) DSC

13、C drawing number Insulation color designator (see 1.2.2) Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-DEFENSE SUPPLY CENTER, COLUMBUS COLUMBUS, OH 43216-5000 SIZE CAGE CODE DWG NO. A 037Z3 04038 REV B PAGE 4 2.1.1 Specifications, standards, and ha

14、ndbooks. 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

15、Insulation Color (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.) 2.2 Non-government publications. The following documents form a part of this document

16、to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract. ASTM INTERNATIONAL ASTM B355 - Standard Specification for Nickel Coated Soft or Annealed Copper Wire ASTM D4591 - Standard Test Method for Determining Temperatur

17、es and Heats of Transitions of Fluoropolymers 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 R

18、equirements 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 for Insulated Electric Wire SAE-AS

19、22759 - Wire, Electrical, Fluoropolymer-Insulated, Copper or Copper Alloy SAE-AS22759/84 - Wire, Electrical, Polytetrafluoroethylene/polyimide Insulated, Normal Weight, Nickel Coated, Copper conductor, 260C, 600 Volts SAE-AS22759/87 - Wire, electrical, Polytetrafluoroethylene/Polyimide, Insulated, N

20、ormal Weight, Nickel Coated, Copper Conductor, 260C, 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

21、 of SAE-AS22759 and SAE-AS22759/84 except as specified herein. Any requirements included in this drawing shall be in addition to, or supersede those requirements included in SAE-AS22759, SAE-AS22759/84 (2 - 4/0 AWG) or SAE-AS22759/87 (8 - 4 AWG). In case of conflict between the requirements in this

22、drawing, SAE-AS22759, SAE-AS22759/84 (2 - 4/0 AWG) or SAE-AS22759/87 (8 4 AWG), the requirements of this drawing shall take precedence. 3.2 Design configuration. The design, construction, and physical dimensions shall be as specified in this drawing. 3.2.1 Design documentation. Design documentation

23、shall be retained by the manufacturer and shall be available upon request for review by the contracting activity, DSCC, or contractor. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-DEFENSE SUPPLY CENTER, COLUMBUS COLUMBUS, OH 43216-5000 SIZE CAGE C

24、ODE DWG NO. A 037Z3 04038 REV B PAGE 5 3.3 Material. 3.3.1 Conductor. Conductors shall be made of soft annealed copper in accordance with ASTM B355 and table I of this drawing. All strands shall free from lumps, kinks, splits, scarred or corroded surfaces and skin impurities. Strands shall be nickel

25、 coated. The nickel coating shall not be less than 50 microinches (1.27 m) when tested in accordance with ASTM B355. 3.3.2. Braid. The braid shall be made of bright aromatic polyamide yarn, 200 denier, 100 filaments, tightly formed. The braid shall be uniform in appearance and treated with a clear f

26、inisher coating. The finisher coating shall be compatible with the temperature rating and performance requirements of the insulated wire. 3.3.3 Insulation. The insulation shall be polytetrafluoroethylene and polytetrafluoroethylene/polyimide tape as specified in tables II and III. The polyimide tape

27、 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 or presintered bondable) 1/ Physical properties of PTFE unsintered tape shall

28、 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 Layer Distinguishable co

29、lor (next to conductor) 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 43216-5000 SIZE CAGE CODE DWG NO. A 037Z3 04038 REV

30、B 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 55.0 4 67.0 71 - - - 13.2

31、 6 2 20.5 35 1 50.5 55.0 4 67.0 71 - - - 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 35 1 50.5 55.0 4 50.5 54.0 4

32、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. 3.5 Performance testing. Wire sup

33、plied to this drawing shall be qualified in accordance with SAE-AS22759/84 (2 - 4/0 AWG) or SAE AS22759/87 (8 - 4 AWG) and shall meet any additional requirements of this drawing. 3.5.1 Insulation state of sinter (conformance inspection test). FP layers shall be evaluated with a Differential Scanning

34、 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 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 sha

35、ll 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 smooth and free of tape edges at the overlap. 3.5.2 Lamination sealing (conformance inspection test). When tested in accordance with SAE-

36、AS4373 method 809 at 260C, 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. This test is performed on the sintered wire prior to braiding. 3.5.3 Color. Conformity of color to the limits of MIL-STD-104 shall no

37、t be required after oven exposure. 3.6 Ratings. 3.6.1 Temperature rating. 260C 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 the outer surface or the wire. The identification m

38、ark 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. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-DEFENSE SUPPLY CENTER, COLUMBUS COLUMBUS, OH

39、43216-5000 SIZE CAGE CODE DWG NO. A 037Z3 04038 REV B PAGE 7 4. VERIFICATION 4.1 Classification of inspections. The inspection requirements 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 eq

40、uipment and inspection facilities shall be maintained in accordance with NCSL Z540.3 or equivalent. 4.2 Qualification inspection. The product manufactured under this drawing shall be currently listed on the qualified products list QPL-22759 for wire type SAE-AS22759/84 (2 4/0 AWG) or SAE-AS22759/87

41、(8 4 AWG). The requirements in 3.5 shall apply. 4.3 Conformance inspection. Conformance inspection shall be in accordance with SAE-AS22759, SAE-AS22759/84 (2 4/0 AWG) or SAE-AS22759/87 (8 4 AWG) and 3.6 herein. 4.4 Certification. In order to be certified and listed as an approved source of supply fo

42、r wire manufactured to this drawing, a manufacturer shall: a. Agree to make available to DSCC, upon request, all pertinent test data indicating compliance to the tests outlined in SAE-AS22759, SAE-AS22759/84 (2 - 4/0 AWG) or SAE-AS22759/87 (8 - 4 AWG), and this drawing. b. Provide to DSCC-VAI, or it

43、s designated agent, upon request, free of change and without obligation, current production samples of the types and 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)

44、. (2) Be in current production of the subject part. 4.5 Certificate of compliance. A certificate of compliance shall 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

45、be as specified in the contract or order (see 6.2). When packaging of materiel is to be performed by DoD or in-house contractor personnel, these personnel need to contact the responsible packaging activity to ascertain packaging requirements. Packaging requirements are maintained by the Inventory Co

46、ntrol Points packaging activities within the Military Service or Defense Agency, or within the military services system commands. Packaging data retrieval is available from the managing Military Departments or Defense Agencys automated packaging files, CD-ROM products, or by contacting the responsib

47、le packaging activity. 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 duplicate specifications, drawings

48、and stock catalog listings. When a military specification exists and the product covered by this drawing has been qualified for listing on QPL-22759, this drawing will be inactivated. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-DEFENSE SUPPLY CEN

49、TER, COLUMBUS COLUMBUS, OH 43216-5000 SIZE CAGE CODE DWG NO. A 037Z3 04038 REV B PAGE 8 6.2 Acquisition data. The acquisition document should specify the following: a. Complete PIN (see 1.2). b. Requirements for delivery of a copy of the conformance inspection inspection data for the lot being supplied, if applicable. This data should be supplied with each s