DLA DSCC-DWG-04045 REV C-2010 WIRE ELECTRICAL COMPOSITE POLYTETRAFLUOROETHYLENE POLYIMIDE INSULATED LIGHT WEIGHT SILVER COATED COPPER CONDUCTOR 200 DEGREE C 600 VOLT.pdf

1、REVISIONS LTR DESCRIPTION DATE APPROVED A Technical modifications to agree with SAE-AS22759/89. Editorial changes throughout. Update format. 6/11/07 Lee Suroweic B Added approved supplier. Editorial changes throughout. 12 March 2009 Abdo Abdouni C Added approved supplier. 8 September 2010 Abdo Abdou

2、ni 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 B C PAGE 1 2 3 4 5 6 7 8 9 10 PMIC * PREPARED BY DEFENSE SUPPLY CENTER, COLUMBUS COLUMBUS, OHIO 43218-39900 William Carpenter Original date of drawing 12 July 2004 CHECKED BY TITLE Lee

3、Surowiec WIRE, ELECTRICAL, COMPOSITE, POLYTETRAFLUOROETHYLENE/POLYIMIDE INSULATED, LIGHT WEIGHT, SILVER COATED, COPPER CONDUCTOR, 200C, 600 VOLT APPROVED BY Richard L. Taylor SIZE CAGE CODE DWG. NO. 04045 A 037Z3 REV C PAGE 1 OF 10 AMSC N/A 6145-E097-009 CURRENT DESIGN ACTIVITY CAGE CODE 037Z3 HAS C

4、HANGED 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 04045 REV B PAGE 2 FP Fluorocarbon Polymer, modifi

5、ed Polytetrafluoroethylene (PTFE) FIGURE 1. General configuration. 1 SCOPE 1.1 Scope. This drawing covers the performance characteristics for a composite wire using a hydrolysis resistant, PTFE/polyimide tape wrap insulation system, with a light weight stranded conductor. 1.2 Part or Identifying Num

6、ber (PIN). The complete PIN should be as follows: 04045 - 20 - 9 Insulation color designator (see table I) Wire size (see table I) DSCC drawing number CONDUCTOR, STRANDED, SMALL DIAMETER, SILVER COATED COPPER FP / POLYIMIDE / FP TAPE FP TAPE Provided by IHSNot for ResaleNo reproduction or networking

7、 permitted without license from IHS-,-,-DEFENSE SUPPLY CENTER, COLUMBUS COLUMBUS, OH 43218-3990 SIZE CAGE CODE DWG NO. A 037Z3 04045 REV B 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) Res

8、istance at 20C ohms/1000ft. (max) Diameter (inches) Weight lb/1000ft. (max) Min Max Min Max 04045-26-* 26 19 X 38 .0175 .0194 38.4 .030 .034 1.43 04045-24-* 24 19 X 36 .0225 .0244 24.3 .034 .038 1.93 04045-22-* 22 19 X 34 .0285 .0304 15.1 .040 .043 2.85 04045-20-* 20 19 X 32 .0365 .0384 9.19 .048 .0

9、51 4.38 04045-18-* 18 19 X 30 .0455 .0484 5.79 .056 .060 6.60 04045-16-* 16 19 X 29 .0515 .0544 4.52 .063 .067 8.30 04045-14-* 14 19 X 27 .0645 .0684 2.88 .076 .080 12.6 04045-12-* 12 37 X 28 .0835 .0874 1.90 .096 .100 19.6 04045-10-* 10 37 X 26 .106 .110 1.19 .119 .123 30.6 * The asterisks in the P

10、IN column should be replaced by color code designators (see 3.3.1.1). Example: 04045-26-93 is white with an orange stripe. 2. APPLICABLE DOCUMENTS 2.1 General. The documents listed in this section are specified in sections 3, 4, or 5 of this specification. This section does not include documents cit

11、ed in other sections of this specification or recommended for additional information or as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all specified requirements documents cited in sections 3, 4, or 5 of this sp

12、ecification, whether or not they are listed. 2.2 Government documents. 2.2.1 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 tho

13、se 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 MIL-STD-681 - Identification Coding and application of Hookup and Lead Wire MIL-STD-2223 - Test

14、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.) Provided by IHSNot for ResaleNo reproduction or networking permitte

15、d without license from IHS-,-,-DEFENSE SUPPLY CENTER, COLUMBUS COLUMBUS, OH 43218-3990 SIZE CAGE CODE DWG NO. A 037Z3 04045 REV B PAGE 4 2.3 Non-Government publications. The following documents form a part of this document to the extent specified herein. Unless otherwise specified, the issues of the

16、se documents are those cited in the solicitation or contract. ASTM INTERNATIONAL ASTM B298 - Standard Specification for Silver Coated Soft or Annealed Copper Wire for Electronic Purposes ASTM D3032 - Wire, Insulation, Hookup Wire, Copper, Silver-Coated Soft or Annealed ASTM D4591 - Standard Test Met

17、hod 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 International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, Pennsylvania, USA 19428-2959.) NCSL INTERNA

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

19、lectric Wire SAE-AS22759 - Wire, Electrical, Fluoropolymer-Insulated, Copper or Copper Alloy SAE-AS22759/91 - Wire, Electrical, Polytetrafluoroethylene/polyimide Insulated, Light Weight, Silver Coated, Copper Conductor, 200C, 600 Volts (Copies of these documents are available from http:/www.sae.org/

20、 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 04045 REV B PAGE 5 3. REQUIREMENTS 3.1 D

21、SCC requirements. Items described in this drawing shall meet the requirements of SAE-AS22759 and SAE-AS22759/91 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-AS22759/91. In case of confli

22、ct between the requirements in this drawing, SAE-AS22759 and SAE-AS22759/91, 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 sha

23、ll 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 soft annealed copper wire in accordance with ASTM B298 and table I of this drawing. All strands shall be free

24、 from lumps, kinks, splits, scarred or corroded surfaces and skin impurities. Strands shall be silver coated. The silver coating shall not be less than 50 microinches (1.27 m) when tested in accordance with ASTM B298. 3.3.1.1 Color. The wire insulation color shall be indicated by the color designato

25、r (see 1.2) and as specified in the contract or purchase order. The insulation color shall be in accordance with MIL-STD-681, system 1, differentiation color coding chassis wiring (3 numbers maximum). For laser marked wires, color limits shall be in accordance with MIL-STD-104, class I, or specified

26、 in table V of this drawing. 3.3.2 Insulation. Insulation shall be polytetrafluoroethylene and polytetrafluoroethylene/polyimide tape specified in tables II and III. TABLE II. Wire insulation materials. 1/ Tape code Thickness nominal (inches) Material 1 2 3 .0012 .0020 .0025 .00045 FP/.00065 polyimi

27、de/.0001 FP FP (Unsintered) 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 20,000 lb/in2(average min) Tensile modulus 400,000 lb/in2(average min) Elongation 40 percent (

28、average min) Dielectric strength 4,000 volts/mil (average min) .00045 FP Layer Distinguishable color (next to conductor) 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

29、037Z3 04045 REV B PAGE 6 3.4 Wire construction and physical dimensions. See figure 1 and table I and table IV. TABLE IV. Tape overlap requirements. 1/ Wrap 1 Wrap 2 Nominal wall thickness (mils) Wire size (AWG) Tape code Percent overlap Tape code Percent overlap Min Max Min Max 26 1 50.5 54.0 2 50.5

30、 54.0 5.8 24 1 50.5 54.0 2 50.5 54.0 5.8 22 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 the innermost tape which is i

31、n contact with the conductor, with the .00045 inch FP side of the tape against the conductor. 3.5 Performance testing. Wire supplied to this drawing shall be qualified in accordance with SAE-AS22759/91 and shall meet any additional requirements of this drawing. 3.5.1 Wet arc propagation resistance (

32、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 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 on

33、e 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 conductor shall meet the solderability requirements for stranded conductors in accordance with MIL-STD-202, me

34、thod 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 type R flux. 3.5.3 Forced hydrolysis (test required for initial qual

35、ification 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: 5. b. Wire size to be tested: 20 AWG. c. Average the time to failure for all of the specimens evaluated. 3.5.

36、4 Insulation state of sinter (conformance inspection test). FP layers shall 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 3 J/g change wh

37、en compared to first heat. c. Bonding between FP layers shall be homogenous. 3.5.5 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. Provided by IHSNot for ResaleNo reproduction o

38、r networking permitted without license from IHS-,-,-DEFENSE SUPPLY CENTER, COLUMBUS COLUMBUS, OH 43218-3990 SIZE CAGE CODE DWG NO. A 037Z3 04045 REV B PAGE 7 3.5.6 Strippability (conformance inspection test). There shall be no evidence of separation or elongation of FP layers when stripped with stan

39、dard hand 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 20 AWG, in accordance with ASTM D3032, section 27. b. Length of insulation slugs shall be .25 inches. c. The

40、 strip force shall be as follows: Wire size (AWG) Minimum force (lbs) Maximum force (lbs) 26 20 0.25 6.0 3.5.7 Ultraviolet (UV) laser marking (test required for initial qualification only). White FP materials shall be formulated in such a manner to achieve a 55% minimum contrast level when marked by

41、 an ultraviolet (UV) laser source operating at a fluence of 0.9 0.1 J/cm2. Non-white insulation colors shall meet the Munsell color limit requirements shown in table V. 3.5.8 Color (conformance inspection test). Colors shall be in accordance with MIL-STD-104, class 1, except for UV laser markable wi

42、re 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 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/

43、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 Same as black Same as black Same as black Same as black Same as black 3.5.9 Color striping or banding durability (c

44、onformance 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 color marking test. a. Weight: 250 grams (8.82 oz). b. Strokes: 250 strokes (125 cycles). 3.6 Ratings. 3.6.1 Temperat

45、ure rating. 200C 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 mark shall not be applied by hot stamp marking or other methods

46、 which significantly penetrate the insulation. The PIN shall be specified in 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 04045 REV B PAGE 8 4. VERI

47、FICATION 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 equipment and inspection facilities shall be maintained in accordance

48、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-AS22759/91. The requirements in 3.5 apply. 4.3 Conformance inspection. Conformance inspection shall be in acc

49、ordance with SAE-AS22759, SAE-AS22759/91 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 DSCC, upon request, all pertinent test data indicating compliance to the tests outlined in SAE-AS22759, SAE-AS227