1、AEROSPACE STANDARD WIRE, ELECTRICAL, FLUOROPOLYMER-INSULATED CROSSLINKED MODIFIED ETFE, LOW FLUORIDE, LIGHTWEIGHT, 80 MICROINCH SILVER-COATED COPPER, 200 C, 600 VOLTAS22759/48Copyright 2011 SAE International All rights reserved. No part of this publication may be reproduced, stored in a retrieval sy
2、stem 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: CustomerServi
3、cesae.org SAE WEB ADDRESS: http:/www.sae.org ISSUED 2011-08THIRD ANGLE PROJECTION CUSTODIAN: AE-8/AE-8D FEDERAL SUPPLY CLASS 6145 AS22759/48SHEET 1 OF 3PROCUREMENT SPECIFICATION: AS22759SAE Technical Standards Board Rules provide that: “This report ispublishedby SAE toadvance thestate of technicalan
4、dengineering sciences. Theuse ofthis report is entirely voluntary, andits applicability and suitability forany particular use,including any patent infringement arising therefrom, isthe soleresponsibilityofthe user.”SAE reviews eachtechnicalreport at least every five years at which time itmay bereaff
5、irmed, revised, orcancelled. SAE invites yourwrittencomments andsuggestions. SAE values your input. To provide feedbackon this Technical Report, please visit http:/www.sae.org/technical/standards/AS22759/48RATIONALE THE INDUSTRY HAS IDENTIFIED FLUORIDE OFFGASSING AS A POTENTIAL SERIOUS ISSUE IN ENCL
6、OSED ENVIRONMENTS SUCH AS SPACECRAFT AND MISSILES. THE EVOLUTION OF FLUORIDE GAS CAN ACCELERATE CORROSION OF METAL SURFACES AND ETCHING OF OPTICS. IT CAN ASLO ACCELERATE COPPER OXIDATION. THE INDUSTRY HAS ALSO IDENTIFIED ADDITIONAL AEROSPACE CRITICAL TESTS SINCE THE LEGACY CROSS-LINKED MODIFED ETFE
7、DETAILED SPECIFICATIONS SHEETS WERE ORIGNATED. THESE TESTS INCLUDE UV LASER MARKING AND UV LASER CONTRAST AFTER THERMAL AGING AND THE REQUIREMENTS HAVE BEEN INCLUDED IN THIS DETAILED SPECIFICATION SHEET. NOTICE THE REQUIREMENTS FOR ACQUIRING THE PRODUCT DESCRIBED HEREIN SHALL CONSIST OF THIS SPECIFI
8、CATION SHEET AND THE ISSUE OF THE FOLLOWING SPECIFICATION LISTED IN THAT ISSUE OF THE DEPARTMENT OF DEFENSE QUALIFIED PRODUCTS DATABASE (QPD) SPECIFIED IN THE SOLICITATION: AS22759 FIGURE 1 GENERAL CONFIGURATION TABLE 1 CONSTRUCTION DETAILS PART NO. 1/WIRESIZESTRANDING (NUMBER OF STANDS X AWG GAUGE
9、OF STRANDS) 2/DIAMETER OF STRANDEDCONDUCTOR (INCHES FINISHED WIRE (MIN) (MAX) RESISTANCE AT 20 C (68 F) (OHMS/1000 FT) MAXDIAMETER(INCHES) WEIGHT (LBS/1000FT) (MAX) M22759/48-28-* 28 7 X 36 .0135 .0154 63.8 .027 .002 0.91 M22759/48-26-* 26 19 X 38 .0175 .0194 38.4 .032 .002 1.4 M22759/48-24-* 24 19
10、X 36 .0225 .0244 24.3 .037 .002 2.0 M22759/48-22-* 22 19 X 34 .0285 .0304 15.1 .043 .002 2.8 M22759/48-20-* 20 19 X 32 .0365 .0384 9.19 .050 .002 4.3 M22759/48-18-* 18 19 X 30 .0455 .0484 5.79 .060 .002 6.5 M22759/48-16-* 16 19 X 29 .0515 .0544 4.52 .068 .002 8.3 M22759/48-14-* 14 19 X 27 .0645 .068
11、4 2.88 .085 .003 13.0 M22759/48-12-* 12 37 X 28 .0835 .0874 1.90 .103 .003 19.7 1/ PART NUMBER: THE ASTERISKS IN THE PART NUMBER COLUMN, TABLES 1 AND 2, SHALL BE REPLACED BY COLOR CODE DESIGNATORS IN ACCORDANCE WITH MIL-STD-681. EXAMPLES: SIZE 20, WHITE-M22759/48-20-9; WHITE WITH ORANGE STRIPE M2275
12、9/48-20-93. PRINTING OF COLOR CODE DESIGNATOR ON SURFACE OF WIRE INSULATION IS NOT REQUIRED. 2/ CONDUCTOR SHALL CONFORM TO MIL-DTL-29606A, TYPE SCC1 80 MICROINCH SILVER PLATED COPPER CONDUCTOR Copyright SAE International Provided by IHS under license with SAENot for ResaleNo reproduction or networki
13、ng permitted without license from IHS-,-,-AEROSPACE STANDARD AS22759/48SHEET 2 OF 3WIRE, ELECTRICAL, FLUOROPOLYMER-INSULATED CROSSLINKED MODIFIED ETFE, LOW FLUORIDE, LIGHTWEIGHT, 80 MICROINCH SILVER-COATED COPPER, 200 C, 600 VOLT TABLE 2 PERFORMANCE DETAILS PART NO. BEND TESTING MANDREL DIAMETER (IN
14、CHES (3%) TEST LOAD (LBS) (3%) CROSSLINKING PROOF, IMMERSION AND LIFE CYCLE TESTS COLDBENDTESTCROSSLINKING PROOF, IMMERSION AND LIFE CYCLE TESTS COLDBENDTESTM22759/48-28-* .250 .375 .125 .500 M22759/48-26-* .375 .500 .125 .500 M22759/48-24-* .500 .500 .250 1.00 M22759/48-22-* .500 .750 .375 1.00 M22
15、759/48-20-* .500 .750 .500 1.00 M22759/48-18-* .500 1.00 .500 1.00 M22759/48-16-* .750 1.00 .750 1.00 M22759/48-14-* 1.00 1.50 1.00 3.00 M22759/48-12-* 1.50 2.00 1.50 3.00 RATINGS: TEMPERATURE RATING: 200 C (392 F) MAXIMUM CONTINUOUS CONDUCTOR TEMPERATURE. VOLTAGE RATING: 600 VOLTS (RMS) AT SEA LEVE
16、L. 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 ONFIGURATIONS IS THE RESPONSIBILITY OF THE USER. ADDITIONAL REQUIREMENTS: SILVER PLAT
17、ED CONDUCTOR: SHALL MEET QUALITY CONFORMANCE TEST FOR CONDUCTOR MATERIAL AND REQUIREMENTS OF MIL-W-29606A AS DEFINED FOR SCC1 TYPE CONDUCTORS. BLOCKING: 230 C 3 C (446 F 5.4 F). COLOR: IN ACCORDANCE WITH MIL-STD-104, CLASS 1; WHITE PREFERRED. CONFORMITY OF COLOR TO THE LIMITS OF MIL-STD-104 SHALL NO
18、T BE REQUIRED AFTER CROSSLINKING PROOF TEST OR LIFE CYCLE OVEN EXPOSURE. COLOR STRIPING OR BANDING DURABILITY: 125 CYCLES (250 STROKES) (MIN), 500 GRAMS WEIGHT. NOT REQUIRED FOR SIZES 2 AND LARGER CROSSLINKING PROOF TEST: 7 HOURS AT 300 C 3 C (572 F 5.4 F). QUALITY CONFORMANCE TEST, GROUP II. REQUIR
19、EMENTS AND PROCEDURES AS FOR LIFE CYCLE EXCEPT FOR TIME AND TEMPERATURE. DIELECTRIC TEST AFTER IMMERSION: 2500 VOLTS (RMS), 60 HZ. DRY ARC PROPAGATION RESISTANCE: NOT REQUIRED. DYNAMIC CUT-THROUGH: NOT REQUIRED. FLAMMABILITY: QUALITY CONFORMANCE TEST, GROUP II. FOR REQUIREMENTS AND PROCEDURES SEE BE
20、LOW. TEST IN ACCORDANCE WITH AS4373, METHOD 801. REQUIREMENTS: DURATION AFTER-FLAME 3.0 SECONDS (MAXIMUM) FLAME TRAVEL 3.0 INCHES (MAXIMUM) NO FLAMING OF TISSUE FLUORIDE OFFGASSING TEST: (GROUP 1 QUALITY CONFORMANCE TEST) FLUORIDE EXTRACTION LEVEL SHALL NOT EXCEED 20 PPM IN ACCORDANCE WITH AS4737 ME
21、THOD 608. HIGH FREQUENCY SPARK TEST: (WHEN USED IN LIEU OF THE IMPULSE DIELECTRIC TEST) 5.7 KILOVOLTS (RMS). 100 PERCENT TEST HUMIDITY RESISTANCE: AFTER HUMIDITY EXPOSURE, WIRE SHALL MEET THE REQUIREMENTS FOR INITIAL INSULATION RESISTANCE. IDENTIFICATION OF PRODUCT: REQUIRED. SEE AS22759 FOR RESTRIC
22、TIONS. Copyright SAE International Provided by IHS under license with SAENot for ResaleNo reproduction or networking permitted without license from IHS-,-,-AEROSPACE STANDARD AS22759/48SHEET 3 OF 3WIRE, ELECTRICAL, FLUOROPOLYMER-INSULATED CROSSLINKED MODIFIED ETFE, LOW FLUORIDE, LIGHTWEIGHT, 80 MICR
23、OINCH SILVER-COATED COPPER, 200 C, 600 VOLT IDENTIFICATION DURABILITY: 125 CYCLES (250 STROKES) (MIN), 500 GRAMS WEIGHT. IMMERSION: FOR PROCEDURE SEE BELOW. IMPULSE DIELECTRIC TEST: 8.0 KILOVOLTS (PEAK), 100 PERCENT TEST. INSULATION RESISTANCE, INITIAL: 5000 MEGOHMS FOR 1000 FEET (MIN). INSULATION T
24、HICKNESS: 0.005 INCH (MIN) LIFE CYCLE: 500 HOURS AT 230 C 3 C (446 F 5.4 F). DIELECTRIC TEST, 2500 VOLTS (RMS), 60 HZ. PROCEDURE TO USE MANDRELS COATED WITH POLYTETRAFLUOROETHYLENE IN THE FORM OF EITHER ENAMEL OR WRAPPED TAPE, SUCH THAT THE DIAMETER OF THE MANDRELS, AFTER COATING, STILL CONFORM TO T
25、HE REQUIREMENTS OF PERFORMANCE DETAILS, TABLE 2. LOW TEMPERATURE (COLD BEND): BEND TEMPERATURE, -65 C 3 C (-85 F 5.4 F). DIELECTRIC TEST, 2500 VOLTS (RMS), 60 HZ. NEEDLE ABRASION: NOT REQUIRED. PHYSICAL PROPERTIES OF INSULATION: PULLED AT 2 INCHES PER MINUTE. TENSILE STRENGTH, 5000 LBF/IN2 (MIN), EL
26、ONGATION, 75 PERCENT (MIN). SHRINKAGE: 0.125 INCH (MAX) AT 230 C 3 C (446 F 5.4 F). SMOKE: 250 C 5 C (482 F 9 F); NO VISIBLE SMOKE. SOLDERABILITY: ALL CONDUCTORS SHALL BE TESTED IN ACCORDANCE WITH AS4373, METHOD 105 WITHOUT STEAM AGING. SPARK TEST OF PRIMARY INSULATION: NOT APPLICABLE SURFACE RESIST
27、ANCE: 500 MEGOHMS - INCHES (MIN), INITIAL AND FINAL READINGS. THERMAL SHOCK RESISTANCE: OVEN TEMPERATURE, 200 C 3 C (392 F 5.4 F). MAXIMUM CHANGE IN MEASUREMENT, 0.060 INCH. UV LASER MARKING: (GROUP I QUALITY CONFORMANCE TEST) TEST IN ACCORDANCE WITH AS4373, METHOD 1001. CONTRAST SHALL BE A 75 PERCE
28、NT MINIMUM AVERAGE ON SIX READINGS. UV LASER CONTRAST AFTER THERMAL AGING: (INITIAL QUALIFICATION AND RETENTION OF QUALIFICATION) WIRE SIZE 20 ONLY. PREPARE SAMPLE IN ACCORDANCE WITH AS4373 METHOD 1001. PLACE SAMPLE IN AN AIR CIRCULATING OVEN AT 230 C 2 C (554 F 3.6 F) FOR 168 HOURS. MINIMUM AVERAGE
29、 CONTRAST AFTER AGING SHALL NOT BE LESS THAN 60 PERCENT. WET ARC PROPAGATION RESISTANCE: NOT REQUIRED. WICKING: NOT APPLICABLE. WIRE LENGTH REQUIREMENTS: SCHEDULE B. WRAP BACK TEST.: OVEN TEMPERATURE, 313 C 3 C (595 F 5.4 F). IMMERSION PROCEDURE: A 24-INCH SPECIMEN, FOR EACH TEST FLUID LISTED IN AS2
30、2759, SHALL HAVE ITS DIAMETER MEASURED AND SHALL THEN BE IMMERSED TO WITHIN 6 INCHES OF EACH END FOR THE TIME AND TEMPERATURE SPECIFIED. DURING IMMERSION, THE RADIUS OF BEND OF THE WIRE SHALL BE NOT LESS THAN 14 NOR MORE THAN 35 TIMES THE SPECIFIED MAXIMUM DIAMETER OF THE WIRE UNDER TEST. UPON REMOV
31、AL FROM THE TEST FLUID, THE SPECIMEN SHALL BE WIPED DRY AND THEN REMAIN FOR 1 HOUR IN FREE AIR AT ROOM TEMPERATURE. THE DIAMETER SHALL BE MEASURED AND COMPARED TO THE INITIAL DIAMETER. THE INSULATION SHALL BE REMOVED FOR A DISTANCE OF 1/2 INCH FROM EACH END OF THE SPECIMEN. THE SPECIMEN SHALL THEN B
32、E SUBJECTED TO THE BEND TEST AND DIELECTRIC TEST SPECIFIED IN THE PROCEDURE FOR LIFE CYCLE TESTING. QUALIFICATION OF WIRE: FOR QUALIFICATION, A SOURCE IS REQUIRED TO SUBMIT DATA ON QUALITY CONFORMANCE TESTS AND ANY FINISHED WIRE TESTS AS REQUIRED BY THE QUALIFICATION AUTHORIZATION LETTER. ALL OTHER
33、TESTING WILL BE PERFORMED BY THE QUALIFYING ACTIVITY AT THE SOURCES EXPENSE. APPLICATION NOTES: THE INDUSTRY HAS IDENTIFIED FLUORIDE OFFGASSING AS A SERIOUS ISSUE IN ENCLOSED ENVIRONMENTS. THE EVOLUTION OF FLUORIDE GAS CAN ACCELERATE CORROSION OF METAL SURFACES AND ETCHING OF OPTICS. IT CAN ALSO ACCELERATE COPPER OXIDATION. IF ENCLOSED ENVIRONMENTS IS NOT AN ISSUE CONSIDER USING AS22759/ 44. Copyright SAE International Provided by IHS under license with SAENot for ResaleNo reproduction or networking permitted without license from IHS-,-,-
