DLA DSCC-DWG-04047 REV C-2010 WIRE ELECTRICAL COMPOSITE POLYTETRAFLUOROETHYLENE POLYIMIDE INSULATED 30 28 26 AWG 600 VOLT.pdf

1、REVISIONS LTR DESCRIPTION DATE APPROVED A Technical revisions to be consistent with SAE-AS22759. Editorial changes throughout. 7/16/07 Abdo Abdouni B Added approved supplier. Technical changes throughout. Updated format. 30 March 2009 Abdo Abdouni C Added approved supplier. 8 September 2010 Abdo Abd

2、ouni 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 B B B B C PAGE 1 2 3 4 5 6 7 8 9 10 11 12 13 14 PMIC PREPARED BY DEFENSE SUPPLY CENTER, COLUMBUS COLUMBUS, OHIO 43218-3990 William Carpenter Original date of drawing 12 July 2004 CH

3、ECKED BY TITLE Lee Surowiec WIRE, ELECTRICAL, COMPOSITE, POLYTETRAFLUOROETHYLENE/POLYIMIDE INSULATED, 30, 28, 26 AWG, 600 VOLT APPROVED BY Richard L. Taylor SIZE CAGE CODE DWG. NO. 04047 A 037Z3 REV C PAGE 1 OF 14 AMSC N/A 6145-E097-010 .CURRENT DESIGN ACTIVITY CAGE CODE 037Z3 HAS CHANGED NAMES TO:

4、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 04047 REV B PAGE 2 FP Fluorocarbon Polymer, modified Polytetrafluor

5、oethylene (PTFE) FIGURE 1. General configuration. 1 SCOPE 1.1 Scope. This drawing covers the performance characteristics for 30, 28, 26 AWG light weight composite wire using a seamless polytetrafluoroethylene/hydrolysis resistant polyimide tape wrap insulation system. 1.2 Part or Identifying Number

6、(PIN). The complete PIN should be as specified on the requirements drawing and constructed using the following format: 04047 - 30 A - 9 Insulation color designator (see 1.2.2) Wire size (see table I) DSCC drawing number Conductor designator (see table II) CONDUCTOR, STRANDED, SMALL DIAMETER, SILVER,

7、 NICKEL, OR TIN PLATED COPPER FP / POLYIMIDE / FP TAPE FP TAPE 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 04047 REV B PAGE 3 TABLE I. Details of construction.

8、 PIN. Wire size Conductor Finished wire Stranding (number of strands X AWG gauge of strands) Diameter (in.) Resistance at 20C (68F) ohms/1000ft. (max) Diameter (in.) Weight lb/1000ft. (max) Min Max Min Max 04047-30A-* 30 7 X 38 .0110 .0130 117.4 .022 .026 0.75 04047-28A-* 28 7 X 36 .0140 .0160 74.4

9、.025 .029 1.00 04047-26A-* 26 19 X 38 .0175 .0204 44.8 .030 .034 1.43 * The asterisks in the PIN column of table I should be replaced by color code designators (see 1.2.2). Example: 04047-26-93 is white with an orange stripe. 1.2.2 Color. The color of the finished wire should be as indicated by the

10、insulation color designator (see 1.2) of the wire part number and the color specified in the contract or order. The first digit of the designator should indicate the colors of the stripes, bands, or tracers. The insulation color designator of the wire should be listed in MIL-STD-681, system I (diffe

11、rentiation color coding for chassis wiring). The preferred color and any applicable restrictions on available colors are indicated in the individual specification sheet. The color of the background insulation and the colors of any stripes, bands, or tracers, if used, should be in accordance with MIL

12、-STD-104, class I or table VI for laser marked wires. The color of the background, stripes or bands should be in accordance with MIL-STD-681 and should be capable of withstanding the durability (3.5.9) or color marking test (3.5.12) using the number of strokes and the weight specified herein (see 3.

13、7). 1.2.3 Conductor designators. Conductor designators should be as specified in table II. TABLE II. Conductor designator/temperature rating. 1/ Designator Conductor description Temperature rating A Silver plated copper alloy (SPA) 200C B Nickel plated copper alloy (NPA) 260C C Tin plated copper (TP

14、C) 150C D Silver plated copper (SPC) 200C E Nickel plated copper (NPC) 260C 1/ For a complete description of conductor material see 3.3.1 2. APPLICABLE DOCUMENTS 2.1 Government documents. 2.1.1 Specifications, standards, and handbooks. The following specifications, standards, and handbooks form a pa

15、rt 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 Insulation Color MIL-STD-202 - Test Method Standard Electronic and Electr

16、ical Component Parts MIL-STD-2223 - Test 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.) 2.2 Non-government publica

17、tions. 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 in the solicitation or contract. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-DEF

18、ENSE SUPPLY CENTER, COLUMBUS COLUMBUS, OH 43218-3990 SIZE CAGE CODE DWG NO. A 037Z3 04047 REV B PAGE 4 ASTM INTERNATIONAL ASTM B33 - Standard Specification for Tin Coated Soft or Annealed Copper Wire for Electrical Purposes ASTM B298 - Standard Specification for Silver Coated Soft or Annealed Copper

19、 Wire for Electronic Purposes ASTM B355 - Standard Specification for Nickel Coated Soft or Annealed Copper Wire ASTM B624 - Standard Specification for High Strength, High Conductivity Copper Alloy Wire for Electronic Application ASTM D3032 - Standard Test Methods for Hookup Wire Insulation ASTM D459

20、1 - Standard Test Method 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 1942

21、8-2959.) NCSL INTERNATIONAL 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 National Conference of Standards Laboratories (NCSL), 2995 Wilderness Place, Suite 107, Boulder, CO 80301-5404.) NATI

22、ONAL ELECTRICAL MANUFACTURERS ASSOCIATION NEMA WC 52 - High-Temperature and Electronic Insulated Wire - Impulse Dielectric Testing (Copies of these documents are available from http:/www.nema.org/ or .NEMA, 1300 North 17thStreet, Suite 1847, Rosslyn, VA 22209-3801). SAE INTERNATIONAL SAE-AS4373 - Te

23、st Methods for Insulated Electric Wire SAE-AS22759 - Wire, Electrical, Fluoropolymer-Insulated, Copper or Copper Alloy SAE-AS22759/80 - Wire, Electrical, Polytetrafluoroethylene/polyimide Insulated, Light Weight, Tin Coated, Copper Conductor, 150 deg. C, 600 volts SAE-AS22759/81 - Wire, Electrical,

24、Polytetrafluoroethylene/polyimide Insulated, Light Weight, Silver Coated, High Strength or Ultra High Strength Copper Alloy, 200C, 600 Volts SAE-AS22759/82 - Wire, Electrical, Polytetrafluoroethylene/polyimide Insulated, Light Weight, Nickel Coated, High Strength or Ultra High Strength Copper Alloy,

25、 260C, 600 Volts SAE-AS22759/91 - Wire, Electrical, Polytetrafluoroethylene/polyimide Insulated, Light Weight, Silver Coated, Copper Conductor, 200C, 600 Volts SAE-AS22759/92 - Wire, Electrical, Polytetrafluoroethylene/polyimide Insulated, Light Weight, Silver Coated, Copper Conductor, 200C, 600 Vol

26、ts (Copies of these documents are 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

27、 CAGE CODE DWG NO. A 037Z3 04047 REV B PAGE 5 3. REQUIREMENTS 3.1 DSCC requirements. Items shall meet the requirements specified in SAE-AS22759, SAE-AS22759/80, SAE-AS22759/81, SAE-AS22759/82, SAE-AS22759/91, and SAE-AS22759/92 except as specified herein. Any requirements included in this drawing sh

28、all be in addition to, or supersede those requirements included in SAE-AS22759, SAE-AS22759/80, SAE-AS22759/81, SAE-AS22759/82, SAE-AS22759/91, and SAE-AS22759/92. In case of conflict between the requirements in this drawing and those in SAE-AS22759 and SAE-AS22759/80, SAE-AS22759/81, SAE-AS22759/82

29、, SAE-AS22759/91, and SAE-AS22759/92, 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

30、shall be available upon request for review by the contracting activity, DSCC, or contractor. 3.3 Material. 3.3.1 Conductors. 3.3.1.1 Conductor designator A. Conductors shall be made of high strength copper-alloy in accordance with ASTM B624 and table I of this drawing. All strands shall be free from

31、 lumps, kinks, splits, scarred or corroded surfaces and skin impurities. 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. 3.3.1.2 Conductor designator B. Conductors shall be made of high strength copper-alloy

32、wire in accordance with ASTM B624 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 nickel coated. The nickel coating shall not be less than 50 microinches (1.27 m) when tested in accordance with ASTM

33、B355. 3.3.1.3 Conductor designator C. Conductors shall be made of soft annealed copper wire in accordance with ASTM B33 and table I of this drawing. All strands shall be soft annealed copper free from lumps, kinks, splits, scarred or corroded surfaces and skin impurities. Strands shall be tin coated

34、 in accordance with ASTM B33. 3.3.1.4 Conductor designator D. Conductors shall be made of soft annealed copper wire in accordance with ASTM B298 and table I of this drawing. All strands shall be soft annealed copper free from lumps, kinks, splits, scarred or corroded surfaces and skin impurities. St

35、rands shall be silver coated. The silver coating shall not be less than 40 microinches (1.02 m) when tested in accordance with ASTM B298. 3.3.1.5 Conductor designator E. Conductors shall be made of soft annealed copper wire in accordance with ASTM B355 and table I of this drawing. All strands shall

36、be soft annealed copper free from lumps, kinks, splits, scarred or corroded surfaces and skin impurities. 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. Polytetrafluoroethylene (PTFE) and P

37、olytetrafluoroethylene/Polyimide (FP/Polyimide) tapes specified in accordance with tables III and IV. The polyimide tape shall be hydrolysis resistant. TABLE III. Wire insulation materials. 1/ Tape code Thickness nominal (inches) Material 1 2 .0012 .0020 .00045 FP/.00065 polyimide/.0001 FP FP (Unsin

38、tered) 1/ Physical properties of PTFE unsintered tape shall be in accordance with SAE-AS22759 requirements. 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 04047 R

39、EV B PAGE 6 TABLE IV. 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 (average min) Dielectric strength 4,000 volts/mil (average min) .00045 FP Layer Distinguishable color (next to conductor)

40、3.4 Wire construction and physical dimensions. See figure 1 and tables I and V. TABLE V. Tape overlap requirements. 1/ Wrap 1 Wrap 2 Nominal wall thickness (mils) Wire size Tape code Percent overlap Tape code Percent overlap Min Max Min Max 30 1 50.5 54.0 2 50.5 54.0 5.8 28 1 50.5 54.0 2 50.5 54.0 5

41、.8 26 1 50.5 54.0 2 50.5 54.0 5.8 1/ Wrap 1 is innermost tape which is in contact with the conductor. 3.5 Performance testing. Wire supplied to this drawing shall be meet the requirements of SAE-AS22759, SAE-AS22759/80, SAE-AS22759/81, SAE-AS22759/82, SAE-AS22759/91, and SAE-AS22759/92. The addition

42、al performance requirements of this drawing shall apply. 3.5.1 Dielectric tests (continuous performance testing). 100 percent of all wire made to this specification shall withstand either the impulse dielectric test (3.5.1.1) or the high frequency spark test (3.5.1.2). 3.5.1.1 Impulse dielectric tes

43、t. Test in accordance with NEMA WC 52, test voltage 8.0 kilovolts peak. 3.5.1.2 High frequency spark test. Test in accordance with MIL-STD-2223, method 3008, test voltage 5.7 kilovolts (rms). 3.5.2 Blocking (test required for initial qualification only). Adjacent turns or layers of the wire shall no

44、t stick (block) to one another when tested as specified. The following details shall apply: a. One end or a piece of finished wire, of significant length to perform the test, shall be affixed to a metal spool of the barrel diameter (minimum diameter of barrel equals 50 times minimum diameter of fini

45、shed wire). b. The wire shall then be would helically on the spool for at least 3 turns, with the succeeding turns in close contact with one another. c. Tension shall be 3.00 lbs (1.36 kg). d. The winding shall be continued until there are at least three closely wound layers of such helical turns on

46、 the spool. The free end of the wire shall then be affixed to the spool so as to prevent unwinding or loosening of the turns or layers. e. The spool and wire shall be placed for 24 hours in an air oven at the temperatures specified below: (1) Conductor designations A, C, D: 200C 2C (392F 3.6F) (2) C

47、onductor designations B, E: 260C 2C (500F 3.6F) f. At the end of the 24 hour period the spool and wire shall be removed from the oven and allowed to cool to room temperature. g. After cooling, the wire shall be unwound manually, while examining for evidence of adhesion (blocking) of adjacent turns o

48、r layers. Note: A metal mandrel of diameter equal to the specified spool barrel diameter may be used in lieu of a spool for this test. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-DEFENSE SUPPLY CENTER, COLUMBUS COLUMBUS, OH 43218-3990 SIZE CAGE C

49、ODE DWG NO. A 037Z3 04047 REV B PAGE 7 3.5.3 Wet arc propagation resistance (test required for initial qualification only). When tested in accordance with MIL-STD-2223, method 3006, the following requirements shall be met: 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 one bundl