DLA DSCC-DWG-04046 REV C-2010 WIRE ELECTRICAL COMPOSITE POLYTETRAFLUOROETHYLENE POLYIMIDE INSULATED LIGHT WEIGHT NICKEL COATED COPPER CONDUCTOR 260 DEGREE C 600 VOLT.pdf

1、REVISIONS LTR DESCRIPTION DATE APPROVED A Corrected D.C. resistance values in table I. 12 April 2005 R. Taylor B Technical modifications to agree with SAE-AS22759/92. Editorial changes throughout. Update format. Added approved supplier. 12 March 2009 Abdo Abdouni C Added approved supplier. 8 Septemb

2、er 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 B C C PAGE 1 2 3 4 5 6 7 8 9 10 PMIC PREPARED BY DEFENSE SUPPLY CENTER, COLUMBUS COLUMBUS, OHIO 43218-3990 William Carpenter Original date of drawing 1 July 2004 CHECKED

3、 BY TITLE Lee Surowiec WIRE, ELECTRICAL, COMPOSITE, POLYTETRAFLUOROETHYLENE/POLYIMIDE INSULATED, LIGHT WEIGHT, NICKEL COATED, COPPER CONDUCTOR, 260C, 600 VOLT APPROVED BY Richard L. Taylor SIZE CAGE CODE DWG. NO. 04046 A 037Z3 REV C PAGE 1 OF 10 AMSC N/A 6145-E096-004 .CURRENT DESIGN ACTIVITY CAGE C

4、ODE 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 04046 REV B PAGE 2 FP Fluorocarbon

5、Polymer, modified Polytetrafluoroethylene (PTFE) FIGURE 1. General configuration. 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 light weight stra

6、nded conductor. 1.2 Part or Identifying Number (PIN). The complete PIN should be as follows: 04046 - 20 - 9 Wire size (see table I) DSCC drawing number Insulation color designator (see table I) CONDUCTOR, STRANDED, SMALL DIAMETER, NICKEL COATED COPPER FP / POLYIMIDE / FP TAPE FP TAPE Provided by IHS

7、Not 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 04046 REV B PAGE 3 TABLE I. Details of construction. PIN Wire size (AWG) Conductor Finished wire Stranding (number of strands X AW

8、G gauge of strands) Diameter (inches) Resistance at 20C ohms/1000ft. (max) Diameter (inches) Weight lb/1000ft. (max) Min Max Min Max 04046-26-* 26 19 X 38 .0175 .0204 42.20 .030 .034 1.43 04046-24-* 24 19 X 36 .0225 .0244 25.90 .034 .038 1.93 04046-22-* 22 19 X 34 .0285 .0314 16.00 .040 .043 2.85 04

9、046-20-* 20 19 X 32 .0365 .0384 9.77 .048 .051 4.38 04046-18-* 18 19 X 30 .0455 .0484 6.10 .056 .060 6.60 04046-16-* 16 19 X 29 .0515 .0544 4.76 .063 .067 8.30 04046-14-* 14 19 X 27 .0645 .0684 3.00 .076 .080 12.6 04046-12-* 12 37 X 28 .0835 .0874 1.98 .096 .100 19.6 04046-10-* 10 37 X 26 .106 .110

10、1.24 .119 .123 30.6 * The asterisks in the PIN column of table I should be replaced by color code designators (see 1.2.2). Example: 04046-26-93 is white with an orange stripe. 1.2.2 Color The wire insulation color should be indicated by the color designator (see 1.2) and as specified in the contract

11、. The insulation color should be in accordance with MIL-STD-681, system 1, differentiation color coding chassis wiring (3 numbers maximum). 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. 2. APPLICABLE DOCUMENTS 2

12、.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 cited in the solicitation or contract. DEPART

13、MENT OF DEFENSE STANDARDS MIL-STD-104 - Limits for Electrical Insulation Color MIL-STD-681 - Identification Coding and Application of Hookup and Lead Wire MIL-STD-2223 - Test Methods for Insulated Electric Wire (Copies of these documents are available online at https:/assist.daps.dla.mil/quicksearch

14、/ or from the Standardization Document Order Desk, 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

15、cited in the solicitation or contract. ASTM INTERNATIONAL ASTM B355 - Standard Specification for Nickel-Coated Soft or Annealed Copper Wire ASTM D3032 - Standard Test Methods for Hookup Wire Insulation ASTM D4591 - Standard Test Method for Determining Temperatures and Heats of Transitions of Fluorop

16、olymers by Differential Scanning Calorimetry (Copies of these documents are available online at http:/www.astm.org or from the ASTM International, P.O. Box C700, 100 Barr Harbor Drive, West Conshohocken, PA 19428-2959.) Provided by IHSNot for ResaleNo reproduction or networking permitted without lic

17、ense from IHS-,-,-DEFENSE SUPPLY CENTER, COLUMBUS COLUMBUS, OH 43218-3990 SIZE CAGE CODE DWG NO. A 037Z3 04046 REV B PAGE 4 NCSL INTERNATIONAL NCSL Z540.3 - Laboratories Calibration and Measuring and Test Equipment (Copies of these documents are available online at http:/www.ncsli.org or from NCSL I

18、nternational 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-AS22759/92 - Wire, Electrical, Polytetrafluoroethylene/polyimide In

19、sulated, Light 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 req

20、uirements of SAE-AS22759 and SAE-AS22759/92 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-AS22759/92. In case of conflict between the requirements in this drawing, SAE-AS22759 and SAE-AS2

21、2759/92, 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 requ

22、est 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 B355 and table I of this drawing. All strands shall be free from lumps, kinks, splits, scarred or corroded surfaces and skin i

23、mpurities. Strands shall be nickel coated. The nickel coating shall not be less than 50 microinches (1.27 m) when tested in accordance with ASTM B355. 3.3.2 Insulation. Insulation shall be polytetrafluoroethylene and polytetrafluoroethylene/polyimide tape in accordance with tables II and III. The po

24、lyimide tape shall be hydrolysis resistant. TABLE II. Wire insulation materials. 1/ Tape code Thickness nominal (inches) Material 1 2 3 .0012 .0020 .0025 .00045 FP/.00065 polyimide/.0001 FP FP (Unsintered) FP (Unsintered) 1/ Physical properties of PTFE unsintered tape shall be in accordance with SAE

25、 AS22759. 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 04046 REV B PAGE 5 TABLE III. Physical properties of FP/Polyimide/FP tapes. Tensile strength 20,000 lb/in

26、2(average min) Tensile modulus 400,000 lb/in2(average min) Elongation 40 percent (average min) Dielectric strength 4,000 volts/mil (average min) .00045 FP Layer Distinguishable color (next to conductor) 3.4 Wire construction and physical dimensions. See figure 1 and tables I and IV. TABLE IV. Tape o

27、verlap requirements. 1/ Wrap 1 Wrap 2 Nominal wall thickness (mils) Wire size Tape code Percent overlap Tape code Percent overlap Min Max Min Max 26 1 50.5 54.0 2 50.5 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

28、 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 innermost tape which is in contact with the conductor with the .00045 inch FP side of the tape against the conductor. 3.5 Performance testing. Wire supplied to th

29、is drawing shall be qualified in accordance with SAE-AS22759/92; the additional requirements of this drawing. 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 mi

30、nimum 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 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 Solderabili

31、ty. Not applicable. This wire is intended for crimped connections. 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 o

32、f specimens: 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. Provided by IHSNot for ResaleNo reproduction or networking permit

33、ted without license from IHS-,-,-DEFENSE SUPPLY CENTER, COLUMBUS COLUMBUS, OH 43218-3990 SIZE CAGE CODE DWG NO. A 037Z3 04046 REV B PAGE 6 3.5.4 Insulation state of sinter (conformance inspection test). FP layers shall be evaluated with a differential scanning calorimeter in accordance with ASTM D45

34、91. 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. No evidence of tape edges or seams shall be present on the outer FP layer when v

35、isually 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 at 260C, there shall be no evidence of tape separation or lifting. There shall

36、be no visible tape ridges that can cause 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 hand held tools designed for such use. No evidence of insulation shall be left on the condu

37、ctor 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 (6.35 mm). c. The strip force shall be as follows: Wire size (AWG) Minimum force Maximum force 26 20 0.2

38、5 lbs 6.0 lbs 18 - 14 0.50 lbs 7.0 lbs 3.5.7 Durability (PTFE outer layer) (Test required for initial qualification only). When tested as specified, 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 ap

39、ply: a. Wire 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 o

40、f similar 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

41、the test specimen). (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 perpen

42、dicular to 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

43、and the conductor. (8) Record the number of cycles to failure. (9) Repeat the procedure a minimum of 10 times (100 times preferred) to generate a statistically significant sample. (10) Average the results. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-

44、,-,-DEFENSE SUPPLY CENTER, COLUMBUS COLUMBUS, OH 43218-3990 SIZE CAGE CODE DWG NO. A 037Z3 04046 REV B PAGE 7 3.5.8 UV laser marking (test required for initial qualification only). When marked with an ultraviolet (UV) laser source at 1.5 J/cm2, white FP tape shall have a contrast level of 65 percent

45、 minimum average and colored FP tape shall have a 62 percent minimum average. This requirement applies to the outer most FP insulation layer. Non-white insulation colors shall meet the Munsell color limit requirements shown in table V. Contrast level is defined as: CL = 3.5.9 Color (conformance insp

46、ection test). Colors shall be in accordance with MIL-STD-104, class 1, except for UV laser markable wire 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

47、 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/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

48、 Same as black Same as black Same as black Same as black 3.5.10 Color striping or banding durability (conformance 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

49、test. a. Weight: 250 grams (8.82 oz). b. Strokes: 250 strokes (125 cycles). 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 mark shall not be applied by hot stamp marking or other metho