DLA DSCC-DWG-04039 REV C-2010 WIRE ELECTRICAL COMPOSITE POLYAMIDE BRAID POLYTETRAFLUOROETHYLENE POLYIMIDE INSULATED NORMAL WEIGHT TIN COATED COPPER CONDUCTOR 150 DEGREE C 600 VOLT.pdf

1、REVISIONS LTR DESCRIPTION DATE APPROVED A Technical modifications to agree with SAE-AS22759/85. Editorial changes throughout. Update format. 7/19/2007 Lee Suroweic B Editorial changes throughout. Update format. Added approved supplier. 13 March 2009 Abdo Abdouni C Added approved supplier. 9 Septembe

2、r 2010 Abdo Abdouni Prepared in accordance with ASME Y14.100 Selected item drawing REV PAGE REV STATUS OF PAGES REV C B B B B B B C 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 T

3、ITLE Lee Surowiec WIRE, ELECTRICAL, COMPOSITE, POLYAMIDE BRAID, POLYTETRAFLUOROETHYLENE/POLYIMIDE INSULATED, NORMAL WEIGHT, TIN COATED, COPPER CONDUCTOR, 150C, 600 VOLT APPROVED BY Richard L. Taylor SIZE CAGE CODE DWG. NO. 04039 A 037Z3 REV C PAGE 1 OF 9 AMSC N/A 6145-E097-005 .CURRENT DESIGN ACTIVI

4、TY CAGE CODE 037Z3 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 43218-3990 SIZE CAGE CODE DWG NO. A 037Z3 04039 REV B PAGE 2 8 AWG t

5、hrough 6 AWG 4 AWG through 4/0 AWG FP Florocarbon Polymer, modified Polytetraflouroethylene (PTFE) FIGURE 1. General configuration. CONDUCTOR, STRANDED, SMALL DIAMETER, TIN COATED COPPER FP / POLYIMIDE / FP TAPE FP TAPE AROMATC POLYAMIDE BRAID TREATED TO PREVENT FRAYING CONDUCTOR, STRANDED, SMALL DI

6、AMETER, TIN 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 43218-3990 SIZE CAGE CODE DWG NO. A 037Z3 04039

7、 REV B PAGE 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 stranded conductor. 1.2 Part or Identifying Number (PIN). The complete

8、PIN shall be as specified as follows: 04039 - 01 - 5D 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

9、04039-8-* 8 133 X 29 .158 .169 .701 .196 .216 61.6 04039-6-* 6 133 X 27 .198 .212 .445 .235 .255 93.7 04039-4-* 4 133 X 25 .250 .268 .292 .292 .312 148 04039-2-* 2 665 X 30 .320 .340 .183 .360 .380 227 04039-1-* 1 817 X 30 .366 .380 .149 .400 .420 295 04039-01-* 0 1045 X 30 .395 .425 .116 .442 .462

10、351 04039-02-* 00 1330 X 30 .440 .475 .091 .498 .528 438 04039-03-* 000 1665 X 30 .500 .540 .071 .554 .584 554 04039-04-* 0000 2109 X 30 .565 .605 .056 .615 .655 689 * The asterisks in the PIN column of table I should be replaced by color code designator (see 1.2.1). Example: 04039-26-5D is dark gre

11、en. 1.2.1 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 designators should indicate the color of the braid. The preferred color is should be dark green with the Mun

12、sell color limits of 5Y 3/2 and 5B 2/0.5 color designator 5D. White is an acceptable alternative color, designator 9. Wire size (see table I) DSCC drawing number Insulation color designator (see 1.2.2) Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-

13、DEFENSE SUPPLY CENTER, COLUMBUS COLUMBUS, OH 43218-3990 SIZE CAGE CODE DWG NO. A 037Z3 04039 REV B 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 exten

14、t 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 Insulation Color (Copies of these documents are available online at https:/assist.daps.dla.mil/quicksearc

15、h/ 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 otherwise specified, the issues of these documents are those cited

16、 in the solicitation or contract. ASTM INTERNATIONAL ASTM B33 - Standard Specification for Tin Coated Soft or Annealed Copper Wire for Electrical Purposes ASTM D4591 - Standard Test Method for Determining Temperatures and Heats of Transitions of Fluoropolymers by Differential Scanning Calorimetry (C

17、opies 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 and Test Equipment (Copies of these docume

18、nts 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-AS22759 - Wire, Electrical, Fluoropolymer-Insulated, Copper or Copper Alloy SAE-AS227

19、59/85 - Wire, Electrical, Polytetrafluoroethylene/Polyimide Insulated, Normal Weight, Tin Coated, Copper Conductor, 150C, 600 Volt SAE-AS22759/88 - Wire, Electrical, Polytetrafluoroethylene/Polyimide Insulated, Normal Weight, Tin Coated, Copper Conductor, 150C, 600 Volts (Copies of these documents a

20、re available from http:/www.sae.org/ or SAE International, 400 Commonwealth Drive, Warrendale, PA 15096-0001). 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 0403

21、9 REV B PAGE 5 3. REQUIREMENTS 3.1 DSCC requirements. Items described in this drawing shall meet the requirements of SAE-AS22759, SAE-AS22759/85 (2 - 4/0 AWG) or SAE-AS22759/88 (8 - 4 AWG) except as specified herein. Any requirements included in this drawing shall be in addition to, or supersede tho

22、se requirements included in SAE-AS22759, SAE-AS22759/85 (2 - 4/0 AWG) or SAE-AS22759/88 (8 - 4 AWG). In case of conflict between the requirements in this drawing, SAE-AS22759, SAE-AS22759/85 (2 - 4/0 AWG) or SAE-AS22759/88 (8 - 4 AWG), the requirements of this drawing shall take precedence. 3.2 Desi

23、gn 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 be available upon request for review by the contracting activity, DSCC, or contractor. 3.3 Mater

24、ial. 3.3.1 Conductor. Conductors shall be made of soft annealed copper 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. 3.3.1.1 Pure

25、 tin. The use of pure tin is prohibited both internally and externally. Tin content of wire components, braids, jackets and solder shall not exceed 97 percent. Tin shall be alloyed with a minimum of 3 percent lead (see 6.9). 3.3.2 Braid. The braid shall be made of bright aromatic polyamide yarn, 200

26、 Denier, 100 filaments, tightly formed. The 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 polytetrafluoroet

27、hylene and polytetrafluoroethylene/polyimide tape 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 4 .0020 .0010 .0020 .0030 .0005 FP/.0010 polyimide/.0005 FP FP (Skived) FP (

28、Skived) FP (Unsintered) 1/ Physical properties of PTFE 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) Dielect

29、ric strength 4,000 volts/mil (average min) .0005 FP Layer Distinguishable color (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

30、 COLUMBUS COLUMBUS, OH 43218-3990 SIZE CAGE CODE DWG NO. A 037Z3 04039 REV 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

31、Min Max Min Max Min Max Min Max 8 2 20.5 35 1 50.5 55.0 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

32、 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 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 d

33、oes not include the polyamide braid thickness. 3.5 Performance testing. Wire supplied to this drawing shall be qualified in accordance with SAE-AS22759/85 (2 - 4/0 AWG) or SAE-AS22759/88 (8 - 4 AWG) and shall meet any additional requirements of this drawing. 3.5.1 Solderability (conformance inspecti

34、on test). Not required, this wire is intended for crimp terminations. 3.5.2 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

35、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 outer FP layer when visually exa

36、mined with the unaided eye. The outer surface will be smooth and free of tape edges at the overlap. 3.5.3 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 visibl

37、e tape ridges that can contribute to tearing of the tape. This test is performed on the sintered wire prior to braiding. 3.5.4 Color. Conformity of color to the limits specified in MIL-STD-104 shall not be required after oven exposure. 3.6 Ratings. 3.6.1 Temperature rating. 150C maximum continuous c

38、onductor 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 mark shall not be applied by hot stamp marking or other methods which significantly penetrate the in

39、sulation. 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 43218-3990 SIZE CAGE CODE DWG NO. A 037Z3 04039 REV B PAGE 7 4. VERIFICATION 4.1 Classification of

40、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 equipment and inspection facilities shall be maintained in accordance with NCSL Z540.3 or equivalent.

41、 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-AS22759/85 (2 - 4/0 AWG) or SAE-AS22759/88 (8 - 4 AWG). The requirements in paragraph 3.5 apply. 4.3 Conformance inspection. Conformance ins

42、pection inspection shall be in accordance with SAE-AS22759/85 (2 - 4/0 AWG) or SAE-AS22759/88 (8 4 AWG) and 3.5 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 DS

43、CC, upon request, all pertinent test data indicating compliance to the tests outlined in SAE-AS22759, SAE-AS22759/85 (2 4/0 AWG) or SAE-AS22759/88 (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 samp

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

45、 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 be as specified in the contract or order (see 6.2). When packaging of materiel is to be perform

46、ed 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 Control Points packaging activities within the Military Service or Defense Agency, or within the

47、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 responsible packaging activity. 6 NOTES 6.1 Intended use. Wires conforming to this drawing are intended

48、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 and stock catalog listings. When a military specification exists and the product covered by thi

49、s 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 CENTER, COLUMBUS COLUMBUS, OH 43218-3990 SIZE CAGE CODE DWG NO. A 037Z3 04039 REV C PAGE 8 6.2 Acquisition data. The acquisition document should specify the follo