1、 AEROSPACE STANDARD WIRE, ELECTRICAL, POLYTETRAFLUOROETHYLENE/POLYMIDE INSULATED, SMOOTH SURFACE, NORMAL WEIGHT, SILVER-COATED COPPER CONDUCTOR, 200 C, 600 VOLTS ROHS AS22759/186Copyright 2017 SAE International All rights reserved. No part of this publication may be reproduced, stored in a retrieval
2、 system or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of SAE. TO PLACE A DOCUMENT ORDER: Tel: 877-606-7323 (inside USA and Canada) Tel: +1 724-776-4970 (outside USA) Fax: 724-776-0790 Email: CustomerSe
3、rvicesae.org SAE WEB ADDRESS: http:/www.sae.org ISSUED2010-02REVISED2017-09THIRD ANGLE PROJECTION CUSTODIAN: AE-8/AE-8D REV.B FEDERAL SUPPLY CLASS 6145 AS22759 /186 SHEET 1 OF 6 REV. B PROCUREMENT SPECIFICATION: NONE SAE Technical Standards Board Rules provide that: “This report is published by SAEt
4、oadvance thestate of technicaland engineering sciences. The useof this report is entirely voluntary, and its applicability andsuitability for any particularuse, includingany patent infringement arisingtherefrom,is thesole responsibility of theuser.” SAE reviews eachtechnical reportatleast every five
5、years at whichtime it may be revised, reaffirmed, stabilized, or cancelled. SAE invites your written comments and suggestions.SAE values your input. To provide feedback on this Technical Report, please visit http:/standards.sae.org/AS22759/186B RATIONALE SPECIFICATION UPDATED TO INCLUDE AS29606 COND
6、UCTOR REQUIREMENTS, ROHS RESTRICTIONS, AND AS22759 MODIFICATIONS. THIS CHANGE ALSO INCREASES THE MAXIMUM WEIGHT REQUIREMENTS FOR WIRE SIZES 8 THROUGH 02 TO ACCOUNT FOR INCREASED CIRCULAR MIL AREA (CMA) ADOPTED IN AS29606. AS22759 IS A CONVERTED MILITARY SPECIFICATION ORIGINALLY NOTED AS MIL-W-22759
7、CREATED IN 1971. CONDUCTOR REQUIREMENTS WERE ORIGINALLY DEFINED BY ASTM B3, B298, AND B355 FOR TIN, SILVER, AND NICKEL PLATE RESPECTIVELY. THESE SPECIFICATIONS CONTROLLED THE CONDUCTOR BY ESTABLISHING STRAND SIZE, CONDUCTOR SIZE, AND MAXIMUM DCR (DIRECT CURRENT RESISTANCE). BY THE LATE 1980S CONDUCT
8、OR PRODUCERS WERE PRODUCING TIGHT TOLERANCE CONDUCTORS WHICH WERE MADE AT THE MINIMUM DIMENSIONAL AND MAXIMUM DCR LIMITS OF THE SPECIFICATION TO REDUCE THE WEIGHT (MASS) OF THE FINALLY INSULATED WIRE. BY THE EARLY 1990S THE TIGHT TOLERANCE CONDUCTORS WERE PREVALENT THROUGHOUT AEROSPACE. ABOUT THE SA
9、ME TIME, LARGE GAUGE SIZE CONDUCTORS (SIZE 8 THROUGH 4/0) STARTED EXHIBITING CRIMP FAILURES IN TERMINAL LUGS MOUNTED ON AIRCRAFT GENERATORS. SINCE THESE CIRCUITS ROUTED PRIMARY ELECTRICAL POWER FROM THE GENERATOR TO THE MAIN POWER DISTRIBUTION CENTERS, CRIMP DEGRADATION RESULTING IN DISRUPTION OF EL
10、ECTRICAL POWER CAUSED SIGNIFICANT CONCERN. SEVERAL OEMS AS WELL AS NAVY AND AIR FORCE LABORATORIES INVESTIGATED THE FAILURES AND DETERMINED THAT THE FAILED CRIMPS WERE DUE TO A COMBINATION OF LOW CMA, HIGH VIBRATION AND THERMAL CYCLING. ADDITIONAL TESTING ESTABLISHED MINIMUM CMA LEVELS WHICH WOULD P
11、REVENT THE CRIMP FAILURES. THESE NEW LIMITS WERE OFFERED TO ASTM, BUT REJECTED. NAVAIR THEN PRODUCED AN ENGINEERING POSITION LETTER (EPL) TO MANDATE THE INCREASED CMAS ON STRANDING USED IN AS22759 CONSTRUCTIONS. NAVAIR THEN CREATED MIL-W-29606 WHICH WAS INTENDED TO REPLACE THE ASTM SPECIFICATIONS AS
12、 THE REQUIRED CONDUCTOR SPECIFICATION. BEFORE THE MIL-W-29606 COULD BE ADDED TO MIL-W-22759, THE SPECIFICATION TRANSITION AND ADOPTION TOOK PLACE CONVERTING THE DOCUMENTS FROM MILITARY SPECIFICATIONS TO AS DOCUMENTS IN THE 1999 TO 2000 TIME FRAME. SINCE THE EPL NO LONGER HAD LEGAL STANDING AFTER THE
13、 CONVERSION, WIRE PRODUCERS DID NOT HAVE TO ABIDE BY THE RESTRICTIONS WHICH ALLOWED THIS ISSUE TO CREEP BACK INTO THE PRODUCTS FROM TIME TO TIME. IN 2011, THE SAE AE-8D COMMITTEE OPENED A PROJECT TO UPDATE THE AS22759 AND ITS ASSOCIATED DETAILED SPECIFICATION SHEETS. WHEN LOOKING AT THIS ISSUE, THE
14、COMMITTEE DECIDED TO ADOPT MIL-W-29606 (NOW AS29606) AND REPLACE THE ASTM REQUIREMENTS WITH THE AS29606 REQUIREMENTS. SINCE THE DIAMETER RANGE OF THE CONDUCTOR STRANDS NEEDED TO SHIFT SLIGHTLY TO THE RIGHT TO MEET THE NEW MINIMUM CMA REQUIREMENTS, OVERALL PRODUCT WEIGHT MAXIMUMS SHIFTED ABOUT 3 TO 5
15、%. THE COMMITTEE EVALUATED SEVERAL METHODS OF INCORPORATING THIS CHANGE INCLUDING CANCELING AND SUPERSESSION, BUT THE END USERS DID NOT WANT TO CHANGE PART NUMBERS FOR PRODUCTS WHICH HAVE BEEN USED IN AEROSPACE AND INDUSTRY FOR OVER 40 YEARS AND IS CURRENTLY ON THOUSANDS OF DRAWINGS. SINCE THESE PRO
16、DUCTS ARE PRIMARILY USED FOR PRIMARY POWER DISTRIBUTION FROM THE GENERATORS TO THE MAIN DISTRIBUTION PANELS, THE WEIGHT INCREASE TO THE ELECTRICAL INTERCONNECT SYSTEM IS CONSIDERED INSIGNIFICANT. SINCE THIS CHANGE DOES AFFECT THE MAXIMUM WEIGHT LIMITS FOR SIZES 8 THROUGH 4/0, END USERS SHOULD VERIFY
17、 THAT THE NEW WEIGHT RANGES MEET THE DESIGN REQUIREMENTS OF LEGACY APPLICATIONS. CORRECTED STATE OF SINTER REQUIREMENT. NOTICE THE COMPLETE REQUIREMENTS FOR PROCURING THE PRODUCT DESCRIBED HEREIN SHALL CONSIST OF THIS DOCUMENT AND THE LATEST ISSUE OF AS22759. AEROSPACE STANDARD AS22759 /186 SHEET 2
18、OF 6 REV. B WIRE, ELECTRICAL, POLYTETRAFLUOROETHYLENE/POLYMIDE INSULATED, SMOOTH SURFACE, NORMAL WEIGHT, SILVER-COATED COPPER CONDUCTOR, 200 C, 600 VOLTS ROHS FP / POLYIMIDE / FP TAPE FP TAPE SIZE 26 THROUGH 10 FP / POLYIMIDE / FP TAPE FP TAPE FP TAPE SIZE 8 THROUGH 6 FP / POLYIMIDE / FP TAPE FP TAP
19、E FP TAPE FP TAPE SIZE 4 THROUGH 04 FP FLUOROCARBON POLYMER MODIFIED POLYTETRAFLUOROETHYLENE (PTFE) CONDUCTOR STRANDED SILVER COATED COPPER FIGURE 1 - AS22759/186 CONFIGURATION AEROSPACE STANDARD AS22759 /186 SHEET 3 OF 6 REV. B WIRE, ELECTRICAL, POLYTETRAFLUOROETHYLENE/POLYMIDE INSULATED, SMOOTH SU
20、RFACE, NORMAL WEIGHT, SILVER-COATED COPPER CONDUCTOR, 200 C, 600 VOLTS ROHS TABLE 1 - CONSTRUCTION DETAILS FOR FINISHED WIRE PART NO. 1/ WIRE SIZE CONDUCTOR 4/ FINISHED WIRE 3/ STRANDING (NUMBER OF STRANDS X SIZE GAUGE OF STRANDS) DIAMETER (INCH) RESISTANCE AT 20 C (68 F) (OHMS/1000 FEET MAX.) DIAME
21、TER (INCH) WEIGHT (LB/1000 FEET) 2/ MIN. MAX. MIN. MAX. MIN. TARGET MAX. M22759/186-26-* M22759/186-24-* M22759/186-22-* M22759/186-20-* M22759/186-18-* M22759/186-16-* M22759/186-14-* M22759/186-12-* M22759/186-10-* M22759/186-8-* M22759/186-6-* M22759/186-4-* M22759/186-2-* M22759/186-1-* M22759/1
22、86-01-* M22759/186-02-* M22759/186-03-* M22759/186-04-* 26 24 22 20 18 16 14 12 10 8 6 4 2 1 0 00 000 0000 19 X 38 19 X 36 19 X 34 19 X 32 19 X 30 19 X 29 19 X 27 37 X 28 37 X 26 133 X 29 133 X 27 133 X 25 665 X 30 817 X 30 1045 X 30 1330 X 30 1665 X 30 2109 X 30 .0175 .0225 .0285 .0365 .0455 .0515
23、.0645 .0835 .106 .158 .198 .250 .320 .366 .395 .440 .500 .565 .0194 .0244 .0304 .0384 .0484 .0544 .0684 .0874 .110 .166 .208 .263 .340 .380 .425 .475 .540 .605 38.4 24.3 15.1 9.19 5.79 4.52 2.88 1.90 1.19 .658 .418 .264 .170 .139 .108 .085 .068 .054 .033 .038 .043 .051 .061 .068 .081 .100 .122 .180
24、.219 .276 .344 .388 .420 .475 .530 .590 .037 .042 .047 .055 .065 .073 .086 .105 .127 .188 .229 .288 .364 .408 .450 .505 .560 .630 1.29 1.87 2.70 4.25 6.40 8.20 12.4 18.9 29.3 55.9 86.9 141 217 265 335 419 528 676 1.42 2.04 2.90 4.48 6.65 8.50 12.9 19.7 30.8 57.8 89.4 145 225 274 349 438 548 698 1.55
25、 2.20 3.10 4.70 6.90 8.80 13.4 20.4 31.6 59.7 91.9 149 233 283 363 457 568 720 1/ PART NUMBER: THE ASTERISKS IN THE PART NUMBER COLUMN OF TABLE 1 SHALL BE REPLACED BY THE COLOR CODE DESIGNATORS IN ACCORDANCE WITH MIL-STD-681. M22759/186-20-93 IS A 20 AWG WHITE WITH ORANGE STRIPE. 2/ THE ACCEPTABLE V
26、ALUE FOR THE CPK FOR THE FINISHED WIRE WEIGHT LISTED SHALL BE 1.3, USING A NORMAL (GAUSSIAN) DISTRIBUTION TO OBTAIN THOSE CPK VALUES. 3/ THE WIRE CONSTRUCTION SHALL HAVE A SMOOTH POLYTETRAFLUOROETHYLENE (PTFE) OUTER LAYER WITH COMPLETE BONDING BETWEEN THE HOMOGENEOUS LAYERS. 4/ CONDUCTOR SHALL CONFO
27、RM TO AS29606 TYPE SCC SMALL DIAMETER SILVER COATED COPPER CONDUCTOR FOR WIRE SIZES 26 THROUGH 4 AND GENERAL PURPOSE FOR WIRE SIZES 2 THROUGH 0000. REQUIREMENT: ALL REQUIREMENTS SHALL CONSIST OF THIS DOCUMENT AND THE LATEST ISSUE OF AS22759. 1. WIRE CONSTRUCTION: WIRE CONSTRUCTION SHALL BE IN ACCORD
28、ANCE WITH FIGURE 1 AND TABLES 1, 2, 3, AND 4. TABLE 2 - WIRE INSULATION MATERIAL TAPE CODE THICKNESS (NOM) MATERIAL 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) AEROSPACE STANDARD AS227
29、59 /186 SHEET 4 OF 6 REV. B WIRE, ELECTRICAL, POLYTETRAFLUOROETHYLENE/POLYMIDE INSULATED, SMOOTH SURFACE, NORMAL WEIGHT, SILVER-COATED COPPER CONDUCTOR, 200 C, 600 VOLTS ROHS TABLE 3 - TAPE OVERLAP REQUIREMENTS 1/ WIRE SIZE WRAP 1 WRAP 2 WRAP 3 WRAP 4 NOMINAL WALL THICKNESS (MILS) TAPE CODE PERCENT
30、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 7.4 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
31、.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 9.1 10 1 50.5 54.0 6 50.5 54.0 9.1 8 2 20.5 35.0 1 50.5 55.0 6 67.0 71.0 13.2 6 2 20.5 35.0 1 50.5 55.0 6 67.0 71.0 13.2 4 3 20.5 35.0 1 50.5 55.0 6 50.5 54.0 6 50.5 54.0 16.2 2 3 20.5 35.0 1 50.5 55.9 6 50.5 54.0 6 50.5 54.0 16.2
32、 1 3 20.5 35.0 1 50.5 55.0 6 50.5 54.0 6 50.5 54.0 16.2 1/0 3 20.5 35.0 1 50.5 55.0 6 50.5 54.0 6 50.5 54.0 16.2 2/0 3 20.5 35.0 1 50.5 55.0 6 50.5 54.0 6 50.5 54.0 16.2 3/0 3 20.5 35.0 1 50.5 55.0 6 50.5 54.0 6 50.5 54.0 16.2 4/0 3 20.5 35.0 1 50.5 55.0 6 50.5 54.0 6 50.5 54.0 16.2 1/ WRAP 1 IS THE
33、 INNERMOST TAPE WHICH IS IN CONTACT WITH THE CONDUCTOR. WRAPS 2, 3, AND 4 ARE PROGRESSIVELY FURTHER AWAY FROM THE CONDUCTOR CORE. 2. WIRE PERFORMANCE RATING: TEMPERATURE RATING: 200 C (392 F) MAXIMUM CONDUCTOR CONTINUOUS TEMPERATURE. VOLTAGE RATING: 600 VOLTS (RMS) AT SEA LEVEL. THIS INSULATION SYST
34、EM HAS BEEN USED IN AEROSPACE APPLICATIONS USING 115 VOLTS (PHASE TO NEUTRAL), 400 HERTZ AC AND 28 VOLTS DC. VERIFICATION OF THE SUITABILITY OF THIS PRODUCT FOR USE IN OTHER ELECTRICAL SYSTEM CONFIGURATIONS IS THE RESPONSIBILITY OF THE USER. 3. MATERIALS AND PHYSICAL PROPERTIES: SEE AS22759 FOR MATE
35、RIAL REQUIREMENT. MATERIALS USED IN THE MANUFACTURE OF THESE PRODUCTS SHALL COMPLY WITH THE RESTRICTION OF HAZARDOUS SUBSTANCES DIRECTIVE 2002/95/EC. 4. FINISH WIRE INSULATION PROPERTIES: FINISH WIRE INSULATION PROPERTIES SHALL BE IN ACCORDANCE WITH TABLE 4. AEROSPACE STANDARD AS22759 /186 SHEET 5 O
36、F 6 REV. B WIRE, ELECTRICAL, POLYTETRAFLUOROETHYLENE/POLYMIDE INSULATED, SMOOTH SURFACE, NORMAL WEIGHT, SILVER-COATED COPPER CONDUCTOR, 200 C, 600 VOLTS ROHS TABLE 4 - FINISHED WIRE INSULATION PROPERTIES REQUIREMENTS INSULATION PROPERTIES IMPULSE TEST VOLTAGE 8.0 KILOVOLTS (PEAK) HIGH FREQUENCY TEST
37、 VOLTAGE 5.7 KILOVOLTS (RMS) INSULATION STATE OF SINTER 3.0 JOULES PER GRAM MAXIMUM WIRE SIZES 26 10 NOT REQUIRED FOR WIRE SIZES 8 AND LARGER TAPE OVERLAP TABLE 3 LAMINATION SEALING 260 C 2 C (500 F 3.6 F), 6 HOURS INSULATION BLOCKING 200 C 2 C (392 F 3.6 F) SHRINKAGE 230 C 2 C (446 F 3.6 F) MAXIMUM
38、 CHANGE .091 INCHES WIRE SIZES 26 -10 MAXIMUM CHANGE .125 INCHES WIRE SIZE 8 - 0000 ELECTRICAL RESISTANCE (IR) 5000 MEGOHMS (MIN)-1000 FEET WIRE SIZES 26 - 10 3000 MEGOHMS (MIN)-1000 FEET WIRE SIZES 8 - 0000 WET DIELECTRIC VOLTAGE 2500 VOLTS (RMS), 60 HERTZ INSULATION STRIP FORCE .25 - 6.0 POUNDS: W
39、IRE SIZES 26 - 20 .50 - 7.0 POUNDS: WIRE SIZES 18 - 14 UV LASER MARKING 62% MINIMUM AVERAGE CONTINUOUS LENGTH SCHEDULE B 5. FINISH WIRE IDENTIFICATION: WIRE IDENTIFICATION EXCEPTIONS: NONE WIRE IDENTIFICATION DURABILITY: 125 CYCLES (250 STROKES) WITH 250 GRAMS WEIGHT STRIPE AND BAND DURABILITY: 125
40、CYCLES (250 STROKES) WITH 250 GRAMS WEIGHT 6. FINISH WIRE PERFORMANCE: FINISH WIRE FIXTURES APPLICABLE TO EACH WIRE SIZE SHALL BE IN ACCORDANCE WITH TABLE 5. TABLE 5 - TEST MANDREL AND TEST LOAD REQUIREMENTS WIRE SIZE (AWG) TEST MANDREL DIAMETER 1/ (INCHES) TEST LOAD (LB) COLD BEND LIFE CYCLE/ BEND
41、TEST WRAP COLD BEND LIFE CYCLE/ BEND TEST 26 24 22 20 18 16 14 12 10 8 6 4 2 1 0 00 000 0000 1.00 1.00 1.00 1.00 1.50 1.50 2.00 2.00 3.00 4.00 5.00 6.00 8.00 10.00 10.00 12.00 18.00 18.00 .375 .500 .500 .500 .750 1.00 1.00 1.50 2.00 3.00 4.00 5.00 6.00 8.00 8.00 10.00 10.00 10.00 .125 .125 .125 .125
42、 .250 .250 .375 .375 .375 .750 1.00 1.25 2.00 2.50 3.00 4.00 5.00 6.00 3.00 3.00 4.00 4.00 5.00 5.00 5.00 5.00 6.00 10.00 10.00 15.00 15.00 15.00 15.00 20.00 30.00 30.00 .50 .75 1.00 1.50 2.00 2.00 3.00 3.00 3.00 4.00 4.00 4.50 6.00 6.00 6.00 8.00 10.00 10.00 1/ TOLERANCE SHALL BE 3% OF THE GIVEN VA
43、LUES. FINISH WIRE PERFORMANCE CHARACTERISTICS SHALL BE IN ACCORDANCE WITH TABLE 6. AEROSPACE STANDARD AS22759 /186 SHEET 6 OF 6 REV. B WIRE, ELECTRICAL, POLYTETRAFLUOROETHYLENE/POLYMIDE INSULATED, SMOOTH SURFACE, NORMAL WEIGHT, SILVER-COATED COPPER CONDUCTOR, 200 C, 600 VOLTS ROHS TABLE 6 - FINISH W
44、IRE PERFORMANCE CHARACTERISTICS PERFORMANCE CHARACTERISTIC REQUIREMENT MANDREL BEND RESISTANCE (TAPES/BRAIDS) REQUIRED THERMAL SHOCK MECHANICAL RESISTANCE TEMPERATURE EXPOSURE 200 C 2 C (392 F 3.6 F) MAXIMUM CHANGE .091 INCHES WIRE SIZES 26 - 10 MAXIMUM CHANGE .125 INCHES WIRE SIZE 8 - 0000 THERMAL
45、MECHANICAL RESISTANCE (LIFE CYCLE) EXPOSURE 500 HOURS, 230 C 2 C (446 F 3.6 F) UV LASER CONTRAST MARKING RESISTANCE AFTER THERMAL AGING: 168 HOURS HUMIDITY RESISTANCE (IR) 5000 MEGOHMS (MIN)-1000 FEET WIRE SIZES 26 - 10 3000 MEGOHMS (MIN)-1000 FEET WIRE SIZES 8 - 0000 FLUID RESISTANCE DIAMETER INCRE
46、ASE 5% (MAX.) SMOKE RESISTANCE 200 C 5 C (392 F 9 F) FLAME RESISTANCE SELF-EXTINGUISH TIME: 3 SECONDS BURN LENGTH 3 INCHES WET ARC RESISTANCE MINIMUM 70 WIRES PASS WET DIELECTRIC TEST 2 OR LESS WIRES FAIL IN ONE BUNDLE DAMAGE LENGTH: 1.0 INCHES OF LESS DRY ARC RESISTANCE MINIMUM 70 WIRES PASS WET DI
47、ELECTRIC TEST 2 OR LESS WIRES FAIL IN ONE BUNDLE DAMAGE LENGTH: 1.0 INCHES OF LESS DYNAMIC CUT-THROUGH WIRE SIZE 26 10 POUNDS AT 23 C, 8 POUNDS AT 150 C, 6 POUNDS AT 200 C WIRE SIZE 20 25 POUNDS AT 23 C, 20 POUNDS AT 150 C, 15 POUNDS AT 200 C WIRE SIZE 16 25 POUNDS AT 23 C, 20 POUNDS AT 150 C, 15 PO
48、UNDS AT 200 C FORCED HYDROLYSIS INSULATION RESISTANCE WIRE SIZE 20 70 C 2 C (158 F 3.6 F), 5000 HOURS LONGEVITY RESISTANCE (THERMAL INDEX) 200 C 2 C (392 F 3.6 F), 10000 HOURS ABRASION RESISTANCE (NEEDLE) WIRE SIZE 20 SAMPLE SIZE 8 READINGS 5000 MIN CYCLES, 23 C 2 C (73 F 3.6 F) 3000 MIN CYCLES, 70
49、C 2 C (158 F 3.6 F) 1000 MIN CYCLES, 150 C 2 C (302 F 3.6 F) 7. REQUIREMENT EXCEPTION TO THE AS22759: NONE 8. APPLICATION NOTES: PRODUCTS MANUFACTURED TO THIS SPECIFICATION ARE ROHS COMPLIANT. SPECIFICATION NOTES 1. REVISION INDICATOR: A CHANGE BAR (I) LOCATED IN THE LEFT MARGIN IS FOR THE CONVENIENCE OF THE USER IN LOCATING AREAS WHERE TECHNICAL REVISIONS, NOT EDITORIAL CHANGES, HAVE BEEN MADE T
