DLA DSCC-DWG-04040 REV B-2010 WIRE ELECTRICAL COMPOSITE POLYTETRAFLUOROETHYLENE POLYIMIDE INSULATED NORMAL WEIGHT SILVER COATED COPPER CONDUCTOR 200 DEGREE C 600 VOLT.pdf

1、REVISIONS LTR DESCRIPTION DATE APPROVED A Technical modifications to agree with SAE-AS22759/86. Editorial changes throughout. Update format. Added approved supplier. 12 March 2009 Abdo Abdouni B Added approved supplier. 8 September 2010 Abdo Abdouni Prepared in accordance with ASME Y14.100 Selected

2、item drawing REV PAGE REV STATUS OF PAGES REV B A A A A A A A A A B B PAGE 1 2 3 4 5 6 7 8 9 10 11 12 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, POLYTETR

3、AFLUOROETHYLENE/POLYIMIDE INSULATED, NORMAL WEIGHT, SILVER COATED, COPPER CONDUCTOR, 200C, 600 VOLT APPROVED BY Richard L. Taylor SIZE CAGE CODE DWG. NO. 04040 A 037Z3 REV B PAGE 1 OF 12 AMSC N/A 6145-E097-006 .CURRENT DESIGN ACTIVITY CAGE CODE 037Z3 HAS CHANGED NAMES TO: DLA LAND AND MARITIME COLUM

4、BUS, 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 04040 REV A PAGE 2 1 SCOPE 1.1 Scope. This drawing covers the performance characteristics for

5、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 specified on the requirements drawing and constructed using the followin

6、g format: 04040 - 20 - 9 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, system 1, differentiation color coding chassis wiring (3 numbers ma

7、ximum). 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. Wire size (see table I) DSCC drawing number Insulation color designator (see table I) Provided by IHSNot for ResaleNo reproduction or networking permitted wi

8、thout license from IHS-,-,-DEFENSE SUPPLY CENTER, COLUMBUS COLUMBUS, OH 43218-3990 SIZE CAGE CODE DWG NO. A 037Z3 04040 REV A PAGE 3 FP Fluorocarbn Polymer, modified Poltetrafluprpethylene (PTFE) FIGURE 1. General configuration. SIZES 26 THROUGH 10 CONDUCTOR, STRANDED, SMALL DIAMETER, SILVER COATED

9、COPPER FP / POLYIMIDE / FP TAPE FP TAPE CONDUCTOR, STRANDED, SMALL DIAMETER, SILVER COATED COPPER FP / POLYIMIDE / FP TAPE FP TAPE CONDUCTOR, STRANDED, SMALL DIAMETER, SILVER COATED COPPER FP / POLYIMIDE / FP TAPE FP TAPE SIZES 8 THROUGH 6 SIZES 4 THROUGH 4/0 Provided by IHSNot for ResaleNo reproduc

10、tion or networking permitted without license from IHS-,-,-DEFENSE SUPPLY CENTER, COLUMBUS COLUMBUS, OH 43218-3990 SIZE CAGE CODE DWG NO. A 037Z3 04040 REV A PAGE 4 TABLE I. Details of construction. PIN Wire size (AWG) Conductor Finished wire Stranding (number of strands X gauge (AWG) of strands) Dia

11、meter (inches) Resistance at 20C ohms/1000ft (max) Diameter (inches) Weight lb/1000ft. (max) Min Max Min Max 04040-26-* 26 19 X 38 .0175 .0194 38.4 .033 .037 1.55 04040-24-* 24 19 X 36 .0225 .0244 24.3 .038 .042 2.20 04040-22-* 22 19 X 34 .0285 .0304 15.1 .043 .047 3.00 04040-20-* 20 19 X 32 .0365 .

12、0384 9.19 .051 .055 4.55 04040-18-* 18 19 X 30 .0455 .0484 5.79 .061 .065 6.70 04040-16-* 16 19 X 29 .0515 .0544 4.52 .068 .073 8.60 04040-14-* 14 19 X 27 .0645 .0684 2.88 .081 .086 12.95 04040-12-* 12 37 X 28 .0835 .0874 1.90 .100 .105 20.1 04040-10-* 10 37 X 26 .106 .110 1.19 .122 .127 31.4 04040-

13、8-* 8 133 X 29 .158 .166 .658 .180 .188 57.6 04040-6-* 6 133 X 27 .198 .208 .418 .219 .229 88.3 04040-4-* 4 133 X 25 .250 .263 .264 .276 .288 143 04040-2-* 2 665 X 30 .320 .340 .170 .344 .364 223 04040-1-* 1 817 X 30 .366 .380 .139 .388 .408 289 04040-01-* 0 1045 X 30 .395 .425 .108 .420 .450 345 04

14、040-02-* 00 1330 X 30 .440 .475 .085 .475 .505 432 04040-03-* 000 1665 X 30 .500 .540 .068 .530 .560 542 04040-04-* 0000 2109 X 30 .565 .605 .054 .590 .630 681 * The asterisks in the PIN column of table I should be replaced by color code designators (see 1.2.1). Example: 04040-26-93 is white with an

15、 orange stripe. 2. APPLICABLE DOCUMENTS 2.1 Government documents. 2.2 Specifications, standards, and handbooks. 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 cite

16、d 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 MIL-STD-2223 - Test Methods for Insulated Electric Wire (Copies of these documents are available online

17、 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. The following documents form a part of this document to the extent specified herein. Unless otherwise specified, the

18、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 Fluoropolymers by Differential Sc

19、anning 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.) Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-DEFENSE

20、SUPPLY CENTER, COLUMBUS COLUMBUS, OH 43218-3990 SIZE CAGE CODE DWG NO. A 037Z3 04040 REV A PAGE 5 NCSL INTERNATIONAL 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 29

21、95 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-AS22759/86 - Wire, Electrical, Polytetrafluoroethylene/polyimide Insulated, Normal

22、 Weight, Silver 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 spec

23、ified in SAE-AS22759 and SAE-AS22759/86 except as specified herein. Any requirements included in this drawing shall be in addition to, or supersede those requirements included in SAE- AS22759 and SAE-AS22759/86. In case of conflict between the requirements in this drawing, SAE-AS22759 and SAE-AS2275

24、9/86, 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 shall be retained by the manufacturer, and shall be available upon request

25、 for review by the contracting activity, DSCC, or contractor. 3.3 Material. 3.3.1 Conductor. Conductors shall be made of soft annealed copper wire in accordance with ASTM B298 and table I of this drawing. All strands shall be free from lumps, kinks, splits, scarred or corroded surfaces and skin impu

26、rities. Strands shall be silver coated. The silver coating shall not be less than 40 microinches (1.02 m) when tested in accordance with ASTM B298. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-DEFENSE SUPPLY CENTER, COLUMBUS COLUMBUS, OH 43218-399

27、0 SIZE CAGE CODE DWG NO. A 037Z3 04040 REV A PAGE 6 3.3.2 Insulation. Polytetrafluoroethylene 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) Mate

28、rial 1 .0020 .0005 FP/.0010 polyimide/.0005 FP 2 .0010 FP (Skived) 3 .0020 FP (Skived) 4 .0020 FP (Unsintered) 5 .0025 FP (Unsintered) 6 .0030 FP (Unsintered) 1/ Physical properties of PTFE unsintered tape shall be in accordance with SAE-AS22759. TABLE III. Physical properties of FP/Polyimide/FP tap

29、es. 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 color (next to conductor) 3.4 Wire construction and physical dimensions. See figure 1 and t

30、ables I and IV. TABLE IV. Tape overlap requirements. 1/ Wrap 1 Wrap 2 Wrap 3 Wrap 4 Nominal wall thickness (mils) 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 26 1 50.5 54.0 4 50.5 54.0 - - - - - - 7

31、.4 24 1 50.5 54.0 4 50.5 54.0 - - - - - - 7.4 22 1 50.5 54.0 4 50.5 54.0 - - - - - - 7.4 20 1 50.5 54.0 4 50.5 54.0 - - - - - - 7.4 18 1 50.5 54.0 4 50.5 54.0 - - - - - - 7.4 16 1 50.5 54.0 5 50.5 54.0 - - - - - - 8.3 14 1 50.5 54.0 5 50.5 54.0 - - - - - - 8.3 12 1 50.5 54.0 6 50.5 54.0 - - - - - -

32、9.1 10 1 50.5 54.0 6 50.5 54.0 - - - - - - 9.1 8 2 20.5 35 1 50.5 55.0 6 67.0 71.0 - - - 13.2 6 2 20.5 35 1 50.5 55.0 6 67.0 71.0 - - - 13.2 4 3 20.5 35 1 50.5 55.0 6 50.5 54.0 6 50.5 54.0 16.2 2 3 20.5 35 1 50.5 55.0 6 50.5 54.0 6 50.5 54.0 16.2 1 3 20.5 35 1 50.5 55.0 6 50.5 54.0 6 50.5 54.0 16.2

33、1/0 3 20.5 35 1 50.5 55.0 6 50.5 54.0 6 50.5 54.0 16.2 2/0 3 20.5 35 1 50.5 55.0 6 50.5 54.0 6 50.5 54.0 16.2 3/0 3 20.5 35 1 50.5 55.0 6 50.5 54.0 6 50.5 54.0 16.2 4/0 3 20.5 35 1 50.5 55.0 6 50.5 54.0 6 50.5 54.0 16.2 1/ Wrap 1 is innermost tape which is in contact with the conductor. 3.5 Performa

34、nce testing. Wire supplied to this drawing shall be qualified in accordance with SAE-AS22759/86 and shall meet any additional requirements of this drawing shall apply. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-DEFENSE SUPPLY CENTER, COLUMBUS CO

35、LUMBUS, OH 43218-3990 SIZE CAGE CODE DWG NO. A 037Z3 04040 REV A PAGE 7 3.5.1 Wet arc propagation resistance (test required for initial qualification only). When tested in accordance with MIL-STD-2223, method 3006, the following requirements shall apply: a. A minimum of 70 wires shall pass the impul

36、se 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 not more than 1.0 inch (25.4 mm) in length in any bundle when measured along the axis. 3.5.2 Solderability (conformance inspection test). The

37、 conductor shall meet the solderability requirements for stranded conductors in accordance with 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 s

38、hall be tested without steam aging using a type R flux. 3.5.3 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 shall apply: a. Number of specimens

39、: 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. 3.5.4 Insulation state of sinter (quality conformance test). FP layers shall

40、be evaluated with a Differential Scanning Calorimeter in accordance 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.

41、 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. 3.5.5 Lamination sealing (conformance inspection test). When tested in accordance with SAE-AS4373 method 809

42、 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. 3.5.6 Strippability (conformance inspection test). There shall be no evidence of separation or elongation of FP layers when stripped with standard han

43、d held tools designed for such use. No evidence of insulation shall 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. c. The strip fo

44、rce shall be as follows: Wire size (AWG) Minimun force Maximum force 26 - 20 0.25 lbs 6.0 lbs 18 - 14 0.50 lbs 7.0 lbs 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 03

45、7Z3 04040 REV A PAGE 8 3.5.7 Durability (PTFE outer layer) (Test required for initial qualification only). When tested as specified below, the wire shall withstand an average of 100 cycles without failure due to tear or surface cut through of the outer layer. The following details shall apply: a. Wi

46、re 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 an aluminum/Mylar film of similar

47、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 down (perpendicular with the test s

48、pecimen). (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 the rod is level and perpendicular to

49、 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 between the abrading rod and the conductor. (8) Record the number of cycles to failure. (9) Repeat the procedure