1、AEROSPACE STANDARDWIRE, ELECTRICAL, POLYTETRAFLUOROETHYLENE/POLYMIDE INSULATED, SMOOTH SURFACE, LIGHT WEIGHT,NICKEL COATED, EXTRA HIGH STRENGTH COPPER ALLOY,260 C, 600 VOLTS ROHSAS22759TM/194Copyright 2016 SAE InternationalAll rights reserved. No part of this publication may be reproduced, stored in
2、 a retrieval 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:
3、CustomerServicesae.org SAE WEB ADDRESS: http:/www.sae.orgISSUED2016-07THIRD ANGLE PROJECTIONCUSTODIAN: AE-8/AE-8DFEDERAL SUPPLY CLASS6145AS22759TM/194SHEET 1 OF 4PROCUREMENT SPECIFICATION: AS22759SAE Technical Standards BoardRules providethat:“This reportis publishedby SAE to advance thestateoftechn
4、ical andengineering sciences. The useofthis reportis entirely voluntary, and its applicability and suitabilityfor any particular use, including any patent infringement arising therefrom, is thesole responsibility of theuser.”SAE reviews eachtechnical reportatleastevery five years at whichtime it may
5、 bereaffirmed, revised, stabilized or cancelled. SAE invites your written comments and suggestions.SAE values your input. To provide feedbackon this Technical Report, please visit http:/www.sae.org/technical/standards/AS22759/194RATIONALESPECIFICATION DEVELOPED FOR APPLICATIONS REQUIRING HIGHER COND
6、UCTOR TENSILE STRENGTH WHILE MAINTAINING ELECTRICAL CONDUCTIVITY. THIS SPECIFICATION USES THE EXTRA HIGH STRENGTH CLASSIFICATION OF NICKEL PLATED COPPER ALLOY CONDUCTOR FROM AS29606.NOTICETHE COMPLETE REQUIREMENTS FOR PROCURING THE PRODUCT DESCRIBED HEREIN SHALL CONSIST OF THIS DOCUMENT AND THE LATE
7、ST ISSUE OF AS22759.FP / POLYIMIDE / FP TAPE FP TAPEFP FLUOROCARBON POLYMER MODIFIED POLYTETRAFLUOROETHYLENE (PTFE)CONDUCTOR STRANDED NICKEL COATED EXTRA HIGH STRENGTH COPPER ALLOYFIGURE 1 - AS22759/194 CONFIGURATIONTABLE 1 - CONSTRUCTION DETAILS FOR FINISHED WIREPART NO. 1/WIRESIZECONDUCTOR 3/ FINI
8、SHED WIRESTRANDING(NUMBER OFSTRANDSX SIZEGAUGE OFSTRANDS)DIAMETER(IN) RESISTANCEAT 20 C(68 F)(OHMS/1000FEET MAX)DIAMETER(IN)WEIGHT(LB/1000 FEET) 2/MIN MAX MIN MAX MIN TARGET MAXM22759/194-30-*M22759/194-28-*M22759/194-26-*M22759/194-24-*M22759/194-22-*M22759/194-20-*3028262422207 X 387 X 3619 X 3819
9、 X 3619 X 3419 X 320.01170.01470.01840.02310.02930.03730.01340.01640.02040.02540.03140.0404129.679.049.430.118.611.40.0220.0250.0300.0340.0400.0480.0260.0290.0340.0380.0430.0510.610.861.211.732.554.070.680.931.331.862.764.250.751.001.461.992.954.441/ PART NUMBER: THE ASTERISKS IN THE PART NUMBER COL
10、UMN OF TABLE 1 SHALL BE REPLACED BY COLOR CODE DESIGNATORS IN ACCORDANCE WITH MIL-STD-681. EXAMPLES: M22759/194-20-93 IS A 20 AWG WHITE WITH ORANGE STRIPE.2/ THE ACCEPTABLE VALUE FOR THE CPK FOR THE FINISHED WIRE WEIGHT LISTED SHALL BE 1.3, USING A NORMAL (GAUSSIAN) DISTRIBUTION TO OBTAIN THOSE CPK
11、VALUES.3/ CONDUCTOR SHALL CONFORM TO AS29606 TYPE NCS SMALL DIAMETER NICKEL COATED EXTRA HIGH STRENGTH COPPER ALLOY CONDUCTOR.AEROSPACE STANDARDAS22759TM/194SHEET 2 OF 4WIRE, ELECTRICAL, POLYTETRAFLUOROETHYLENE/POLYMIDE INSULATED, SMOOTH SURFACE, LIGHT WEIGHT,NICKEL COATED, EXTRA HIGH STRENGTH COPPE
12、R ALLOY,260 C, 600 VOLTS ROHSREQUIREMENT: ALL REQUIREMENTS SHALL CONSIST OF THIS DOCUMENT AND THE LATEST ISSUE OF AS22759.1. WIRE CONSTRUCTION:WIRE CONSTRUCTION SHALL BE IN ACCORDANCE WITH FIGURE 1 AND TABLES 1, 2, 3, AND 4.TABLE 2 - WIRE INSULATION MATERIALS TAPE CODE THICKNESS (NOM) MATERIAL1 0.00
13、12 0.00045 (FP)/0.00065 (POLYIMIDE)/0.0001 (FP)2 0.0020 FP (UNSINTERED)TABLE 3 - TAPE OVERLAP REQUIREMENTS 1/WIRESIZEWRAP 1 WRAP 2 NOMINALWALLTHICKNESS(MILS)TAPECODEPERCENTOVERLAP TAPECODEPERCENTOVERLAPMIN MAX MIN MAX30 1 50.5 54.0 2 50.5 54.0 5.828 1 50.5 54.0 2 50.5 54.0 5.826 1 50.5 54.0 2 50.5 5
14、4.0 5.824 1 50.5 54.0 2 50.5 54.0 5.822 1 50.5 54.0 2 50.5 54.0 5.820 1 50.5 54.0 2 50.5 54.0 5.81/ WRAP 1 IS INNERMOST TAPE WHICH IS IN CONTACT WITH THE CONDUCTOR. THE 0.00045 FP LAYER SHALL BE AGAINST THE CONDUCTOR.2. WIRE PERFORMANCE RATING:TEMPERATURE RATING: 260 C (500 F) MAXIMUM CONDUCTOR CONT
15、INUOUS TEMPERATURE.VOLTAGE RATING: 600 VOLTS (RMS) AT SEA LEVEL. THIS INSULATION SYSTEM 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 R
16、ESPONSIBILITY OF THE USER.3. MATERIALS AND PHYSICAL PROPERTIES:SEE AS22759 FOR MATERIAL 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 PROPERT
17、IES SHALL BE IN ACCORDANCE WITH TABLE 4.TABLE 4 - FINISHED WIRE INSULATION PROPERTIES REQUIREMENTSINSULATION PROPERTIESIMPULSE TEST VOLTAGE 8.0 KILOVOLTS (PEAK)HIGH FREQUENCY TEST VOLTAGE 5.7 KILOVOLTS (RMS) INSULATION STATE OF SINTER 3.0 JOULES PER GRAM MAXIMUMTAPE OVERLAP TABLE 3LAMINATION SEALING
18、 260 C 2 C (500 F 3.6 F), 6 HOURSINSULATION BLOCKING 260 C 2 C (500 F 3.6 F)SHRINKAGE 290 C 2 C (554 F 3.6 F)MAXIMUM CHANGE .091 INCHESELECTRICAL RESISTANCE (IR) 5000 MEGOHMS (MIN)-1000 FEETWET DIELECTRIC VOLTAGE 2500 VOLTS (RMS), 60 HERTZINSULATION STRIP FORCE .25 - 6.0 POUNDS: WIRE SIZES 26 - 20NO
19、T REQUIRED FOR WIRE SIZES 30 - 28UV LASER MARKING 62% MINIMUM AVERAGECONTINUOUS LENGTH SCHEDULE BAEROSPACE STANDARDAS22759TM/194SHEET 3 OF 4WIRE, ELECTRICAL, POLYTETRAFLUOROETHYLENE/POLYMIDE INSULATED, SMOOTH SURFACE, LIGHT WEIGHT,NICKEL COATED, EXTRA HIGH STRENGTH COPPER ALLOY,260 C, 600 VOLTS ROHS
20、5. FINISH WIRE IDENTIFICATION:WIRE IDENTIFICATION EXCEPTIONS: NONEWIRE IDENTIFICATION DURABILITY: 125 CYCLES (250 STROKES) WITH 250 GRAMS WEIGHT STRIPE AND BAND DURABILITY: 125 CYCLES (250 STROKES) WITH 250 GRAMS WEIGHT6. FINISH WIRE PERFORMANCE:FINISH WIRE FIXTURES APPLICABLE TO EACH WIRE SIZE SHAL
21、L BE IN ACCORDANCE WITH TABLE 5.TABLE 5 - TEST MANDREL AND TEST LOAD REQUIREMENTSWIRESIZE(AWG)TEST MANDREL DIAMETER 1/(INCHES)TEST LOAD 1/(LB)COLD BENDLIFE CYCLE/BEND TEST WRAP COLD BENDLIFE CYCLE/BEND TEST3028262422201.001.001.001.001.001.000.3750.3750.3750.5000.5000.5000.1250.1250.1250.1250.1250.1
22、252.002.003.003.004.004.00 0.250.250.500.751.001.501/ TOLERANCE SHALL BE 3% OF THE GIVEN VALUES.FINISH WIRE PERFORMANCE CHARACTERISTICS SHALL BE IN ACCORDANCE WITH TABLE 6.TABLE 6 - FINISH WIRE PERFORMANCE CHARACTERISTICSPERFORMANCE CHARACTERISTIC REQUIREMENTMANDREL BEND RESISTANCE (TAPES/BRAIDS) RE
23、QUIREDTHERMAL SHOCK MECHANICAL RESISTANCE TEMPERATURE EXPOSURE 260 C 2 C (500 F 3.6 F)MAXIMUM CHANGE .091 INCHESTHERMAL MECHANICAL RESISTANCE (LIFE CYCLE)EXPOSURE 500 HOURS, 290 C 2 C (554 F 3.6 F)UV LASER CONTRAST MARKING RESISTANCE AFTER THERMAL AGING: 168 HOURSHUMIDITY RESISTANCE (IR) 5000 MEGOHM
24、S (MIN)-1000 FEETFLUID RESISTANCE DIAMETER INCREASE 5% (MAX)SMOKE RESISTANCE 260 C 5 C (500 F 9 F)FLAME RESISTANCE SELF-EXTINGUISH TIME: 3 SECONDSBURN LENGTH 3 INCHESWET ARC RESISTANCE MINIMUM 70 WIRES PASS WET DIELECTRIC TEST2 OR LESS WIRES FAIL IN ONE BUNDLEDAMAGE LENGTH: 1.0 INCHES OF LESSDRY ARC
25、 RESISTANCE MINIMUM 70 WIRES PASS WET DIELECTRIC TEST2 OR LESS WIRES FAIL IN ONE BUNDLEDAMAGE LENGTH: 1.0 INCHES OF LESSDYNAMIC CUT-THROUGH WIRE SIZE 268 POUNDS AT 23 C, 6 POUNDS AT 150 C,4 POUNDS AT 200 C, 3 POUNDS AT 260 CWIRE SIZE 2010 POUNDS AT 23 C, 8 POUNDS AT 150 C,6 POUNDS AT 200 C, 4 POUNDS
26、 AT 260 CFORCED HYDROLYSIS INSULATION RESISTANCEWIRE SIZE 2070 C 2 C (158 F 3.6 F), 5000 HOURSLONGEVITY RESISTANCE (THERMAL INDEX) 260 C 2 C (500 F 3.6 F), 10000 HOURSABRASION RESISTANCE (NEEDLE) WIRE SIZE 20SAMPLE SIZE 8 READINGS2000 MIN CYCLES, 23 C 2 C (73 F 3.6 F)1000 MIN CYCLES, 70 C 2 C (158 F
27、 3.6 F)350 MIN CYCLES, 150 C 2 C (302 F 3.6 F)AEROSPACE STANDARDAS22759TM/194SHEET 4 OF 4WIRE, ELECTRICAL, POLYTETRAFLUOROETHYLENE/POLYMIDE INSULATED, SMOOTH SURFACE, LIGHT WEIGHT,NICKEL COATED, EXTRA HIGH STRENGTH COPPER ALLOY,260 C, 600 VOLTS ROHS7. REQUIREMENT EXCEPTION TO THE AS22759:NONEAPPLICA
28、TION NOTES1. PRODUCTS MANUFACTURED TO THIS SPECIFICATION ARE ROHS COMPLIANT. SPECIFICATION NOTES1. REVISION INDICATOR:A CHANGE BAR (l) LOCATED IN THE LEFT MARGIN IS FOR THE CONVENIENCE OF THE USER IN LOCATING AREAS WHERE TECHNICAL REVISIONS, NOT EDITORIAL CHANGES, HAVE BEEN MADE TO THE PREVIOUS ISSUE OF THIS DOCUMENT. AN (R) SYMBOL TO THE LEFT OF THE DOCUMENT TITLE INDICATES A COMPLETE REVISION OF THE DOCUMENT, INCLUDING TECHNICAL REVISIONS. CHANGE BARS AND (R) ARE NOT USED IN ORIGINAL PUBLICATIONS NOR IN DOCUMENTS THATCONTAIN EDITORIAL CHANGES ONLY.
