1、_ SAE Technical Standards Board Rules provide that: “This report is published by SAE to advance the state of technical and engineering sciences. The use of this report is entirely voluntary, and its applicability and suitability for any particular use, including any patent infringement arising there
2、from, is the sole responsibility of the user.” SAE reviews each technical report at least every five years at which time it may be revised, reaffirmed, stabilized, or cancelled. SAE invites your written comments and suggestions. Copyright 2014 SAE International All rights reserved. No part of this p
3、ublication may be reproduced, stored in 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: +1 724-776-497
4、0 (outside USA) Fax: 724-776-0790 Email: CustomerServicesae.org SAE WEB ADDRESS: http:/www.sae.orgSAE values your input. To provide feedback on this Technical Report, please visit http:/www.sae.org/technical/standards/AS5419AEROSPACESTANDARDAS5419Issued 2003-02 Reaffirmed 2014-04 Cable, Thermocouple
5、 Extension, Shielded and Unshielded RATIONALE AS5419 has been reaffirmed to comply with the SAE five-year review policy. 1. SCOPE:1.1 Scope:This SAE Aerospace Standard (AS) covers the requirements for thermocouple extension cable. Manufacturers of primary thermocouple wire in accordance with this sp
6、ecification must be qualified to the similar wire type specified in Table 1.1.2 Classification:The cable shall be of the following types and shall be furnished in the basic wire size and basic wire type and shield and jacket styles, as specified.Unjacketed - Two wires spirally laid or duplex paralle
7、led without an overall outer jacketJacketed - Two wires spirally laid or duplex paralleled with an overall outer jacketShielded - Two wires spirally laid or duplex paralleled with one or two overall shieldsShielded and Jacketed - Two wires spirally laid or duplex paralleled with one or two shields a
8、nd one or two jackets1.2.1 Cable Designation: Cable shall be identified by a combination of digits and letters in accordance with the following (see 3.4.1):FIGURE 11.2.1.1 Cable Specification Number: The finished cable shall be identified by the number of this specification.1.2.1.1.1 Cable Configura
9、tion and Braid Shield Coverage: When a minimum shield coverage of 85% is required, specify:“A“ for spiral laid cable configuration“B” for duplex parallel cable configurationWhen a minimum shield coverage of 90% is required, specify:“C” for spiral laid cable configuration“D” for duplex parallel cable
10、 configuration1.2.1.2 Conductor Size: The basic wire size shall be identified. All wires used in the cable shall be of the same size.1.2.1.3 Basic Wire Construction: A letter symbol shall be used to designate the insulation type specification in accordance with the applicable slant sheet in Table 1.
11、TABLE 1 - Component Wire ConstructionSAE INTERNATIONAL AS5419 Page 2 of 28_ 1.2.1.4 EMF Designator: A letter symbol shall be used to designate the EMF type as defined per the individual wire specification.1.2.1.5 Shield Style and Material: The shield style and material of the overall shields shall b
12、e designated by a single letter as follows:TABLE 2 - Shield Style and Material1.2.1.6 Jacket Material and Temperature Rating: The single jacket symbol shall be used for cables with an outer jacket only. The double jacket symbol shall be used in conjunction with a double shield symbol to describe con
13、structions with a jacket in between two shields with another jacket over the outer shield. The single jacket symbol shall be used in conjunction with the double shield symbol to describe constructions with two overlaid shields with a single outer jacket. Unless otherwise specified (see 6.2.1f), jack
14、et colors shall be as specified under the jacket materials as follows:SAE INTERNATIONAL AS5419 Page 3 of 28_ TABLE 3 - Jacket Style and MaterialSAE INTERNATIONAL AS5419 Page 4 of 28_ 2. APPLICABLE DOCUMENTS:The following publications form a part of this document to the extent specified herein. The l
15、atest issue of SAE publications shall apply. The applicable issue of other publications shall be the issue in effect on the date of the purchase order. In the event of conflict between the text of this document and references cited herein, the text of this document takes precedence. Nothing in this
16、document, however, supersedes applicable laws unless a specific exemption has been obtained.2.1 SAE Publications:Available from SAE, 400 Commonwealth Drive, Warrendale, PA 15096-0001.AS4373 Test Methods for Insulated Electric WireAS22759 Wire, Electrical, Fluoropolymer-Insulated, Copper or Copper Al
17、loyAS81044 Wire, Electrical, Crosslinked Polyalkene, Crosslinked Alkane-Imide Polymer, or Polyarylene Insulated, Copper or Copper Alloy2.2 U.S. Government Publications:Available from DODSSP, Subscription Services Desk, Building 4D, 700 Robbins Avenue, Philadelphia, PA 19111-5094.MIL-DTL-25038 Wire E
18、lectrical, High Temperature, Fire Resistant, and Flight CriticalMIL-DTL-81381 Wire, Electric, Polyimide-Insulated, Copper or Copper AlloyMIL-W-29606 Wire, Electric, Stranded, Uninsulated Copper, Copper Alloy or Aluminum, or Thermocouple ExtensionWC 27500 Cable, Power, Electrical and Cable Special Pu
19、rpose, Electrical Shielded and UnshieldedFED-STD-228 Cable and Wire, Insulated; Methods of TestingMIL-STD-104 Limit for Electrical Insulation ColorMIL-STD-202 Test Methods for Electronic and Electrical Component PartsMIL-STD-686 Cable and Cord, Electrical; Identification Marking and Color Coding ofS
20、AE INTERNATIONAL AS5419 Page 5 of 28_ 2.3 ANSI Publications:Available from ANSI, 25 West 43rd Street, New York, NY 10036-8002.ANSI-MC96.1 Temperature Measurement ThermocouplesANSI/ASQC Z1.4 Sampling Procedures and Tables for Inspection by AttributesANSI/ASTM B 3 Soft or Annealed Copper WireANSI/ASTM
21、 B 33 Standard Specification for Tinned Soft or Annealed Copper Wire for Electrical PurposesANSI/ASTM B 298 Silver Coated Soft or Annealed Copper WireANSI/ASTM B 355 Nickel Coated Soft or Annealed Copper Wire2.4 ASTM Publications:Available from ASTM, 100 Barr Harbor Drive, West Conshohocken, PA 1942
22、8-2959.ASTM A 313 Wire, Steel, Corrosion-ResistingASTM B 170 Oxygen Free Electrolyte Copper Refinery ShapesASTM B 272 Copper Flat Copper Products With Finished (Rolled or Drawn) Edges (Flat Wire and Strip)ASTM B 624 High Strength, High Conductivity Copper Alloy Wire for Electronic Application Standa
23、rd Specification forASTM D 3032 Hookup Wire Insulation, Standard Methods of TestingASTM D 4591 Determining Temperatures and Heats of Transitions of Fluoropolymers by Differential Scanning Calorimetry2.5 National Bureau of Standards Publications:Available from Superintendent of Documents, U.S. Govern
24、ment Printing Office, Washington, DC 20402.H4-1 Federal Supply Code for Manufacturers, United States and Canada, Name to CodeH4-2 Federal Supply Code for Manufacturers, United States and Canada, Code to NameNBS HDBK 100 International Annealed Copper Standard (IACS)SAE INTERNATIONAL AS5419 Page 6 of
25、28_ 3. REQUIREMENTS:3.1 Materials:3.1.1 Copper Shield Round Strand Material: Before shielding, the copper strands used in shields shall be annealed or soft-drawn copper wire from commercially pure copper and shall conform to ASTM B 3. Nickel plated strands shall conform to ASTM B 3 or ASTM B 170. It
26、 shall be possible to solder or crimp the material to approved terminals. Wire shall be free from lumps, kinks, splints, abrasions, scraped or corroded surfaces and skin impurities.3.1.2 Stainless Steel Shield Material: Before shielding, the stainless steel strands shall conform to ASTM A 313. It sh
27、all be possible to crimp the wire to approved terminals. The wire shall be free from kinks, abrasions, or scraped surfaces.3.1.3 High Strength Copper Alloy Shield Round Strands: Before shielding, the high strength copper alloy strands shall conform to ASTM B 624 except that the minimum tensile stren
28、gth shall be 55,000 lbf/in2, the minimum elongation shall be 6%, and the conductivity shall be 80% (minimum) as stated in NBS Handbook 100.3.2 Construction:Construction shall comply with the classification given in 1.2. Combinations of shield style and material, basic wire specification and jacket m
29、aterials shall be restricted to those allowed in Table 5 unless otherwise approved by the preparing activity of this standard.3.2.1 Basic Wire: The basic wire (primary) shall meet all the requirements as defined herein. Unless otherwise specified the cable manufacturer is responsible for assuring th
30、at the basic wire requirements are as specified.3.2.2 Cable Layup: The required number of wires for multiconductor construction determined by the cable designation shall be cabled with a left-hand lay. The lay of the individual wires shall be not less than 6 nor more than 16 times the outside major
31、axis diameter of the unshielded, unjacketed cable as calculated in 4.5. The basic wire shall not be spliced. When cables are cut, wires will maintain proper sequence and shall not splay more than twice the diameter of the cable.3.2.2.1 Fillers and Binder Tapes: Fillers and binder tapes, if used, sha
32、ll be of a fungus resistant material with a temperature equivalent to the cable rating without fillers and tape. Fillers and binders shall also be easily removable from the finished cable without adherence to the underlying insulation.SAE INTERNATIONAL AS5419 Page 7 of 28_ 3.2.3 Shield: When the cab
33、le designation specifies that a shield is to be incorporated in the cable construction, either a closely woven braid using round strand or a closely woven braid of flat strand shall be applied over the basic cable.3.2.3.1 Braided Round Shields:3.2.3.1.1 Braided Round Wire: Before application to the
34、cable, individual tin, silver, or nickel coated copper strands shall have a minimum elongation of 6%.3.2.3.1.2 Round Copper or Copper Alloy Strand Size: Cables with braided shields using round copper or round copper alloy strands shall conform to Shield Group A or B. The core diameter referred to in
35、 Group A or B shall be the nominal outside core diameter of the unshielded, unjacketed cable equal to the basic wire diameter multiplied by a factor of 1.64. The following component wires Type RC, Type ML, Type SW, Type WC and Type WJ shall conform to Shield Group B. All other braided shields with r
36、ound shield strands shall conform to Shield Group A.TABLE 4 - Shield Size3.2.3.1.3 Coating:3.2.3.1.3.1 Tin Coated Copper Strands: When the cable designation specifies a tin coated shield, the individual strands shall be coated uniformly with a smooth, continuous layer of commercially pure tin. Prior
37、 to braiding, the strands shall meet the requirements of ASTM B 33. The thickness of the tin coating shall be 250 in maximum.3.2.3.1.3.2 Silver Coated Copper and High Strength Alloy Strands: When the cable designation specifies a silver coated copper shield, the individual strands shall be coated un
38、iformly with a smooth continuous layer of commercially pure silver. Prior to braiding, silver coated copper strands shall meet the requirements of ASTM B 298. Silver coated high strength copper alloy strands shall meet the requirements of 3.1.3 and the adhesion and continuity of coating requirements
39、 of ASTM B 298. The thickness of the silver shall be not less than 40 in.3.2.3.1.3.3 Nickel Coated Copper and High Strength Alloy Strands: When the cable designation specifies a nickel coated shield, the individual strands shall be coated uniformly with a smooth, continuous layer of commercially pur
40、e nickel having a coating thickness of not less than 50 in nor greater than 250 in. The wire shall meet the coating requirements of ASTM B 355 prior to braiding.SAE INTERNATIONAL AS5419 Page 8 of 28_ 3.2.3.1.3.4 Nickel Clad Copper Strands: When the cable designation specifies a nickel clad copper sh
41、ield, the individual strands shall have a nickel coating having a cross-sectional area that is 27% minimum of the total cross-sectional area of the drawn strand. The wire shall meet the coating requirements of ASTM B 355 prior to braiding.3.2.3.1.4 Stainless Steel Shield:3.2.3.1.4.1 Stainless Steel
42、Strand Size: On cable with outside diameter (under the shield) of less than 0.060 in (1.52 mm), the strand size shall be AWG 40. On cable with an outside diameter of 0.060 to 0.120 in (3.05 mm), the strand size shall be AWG 38. On cable with outside diameter of 0.121 in (3.07 mm) and larger, the str
43、and size shall be AWG 36.3.2.3.2 Braided Flattened Wire Strands: Flat wire shields shall be braided of copper, high strength copper alloy, or nickel chromium alloy. The flattened wire shall be 0.0015 in 0.0004 in (0.040 mm 0.010 mm) in thickness.3.2.3.2.1 Copper Wire, Flattened: Copper flattened wir
44、e shall meet the requirements of ASTM B 272 except the wire shall be made by flattening round wire.3.2.3.2.2 Flattened High Strength Copper Alloy Flat Wire: Flattened high strength copper alloy wire shall be made by flattening round wire. The flattened wire tensile strength shall be not less than 55
45、,000 lbf/in2and the elongation shall be 1% minimum after flattening.3.2.3.2.3 Coating of Flattened Wire Strands:3.2.3.2.3.1 Tin Coated Copper Flattened Wire: Tin coated copper strands before flattening shall conform to ASTM B 33. Flattened wire strands shall meet the continuity of coating test of AS
46、TM B 33. The thickness of coating shall be 250 in maximum.3.2.3.2.3.2 Silver Coated Copper or Silver Coated High Strength Copper Alloy Flattened Wire: Silver coated copper or silver coated high strength copper alloy strands shall conform to ASTM B 298 after flattening. The flattened wire strands sha
47、ll have a minimum coating thickness of 40 in and shall meet the continuity of coating requirements of ASTM B 298 after flattening.3.2.3.2.3.3 Nickel Coated Copper or Nickel Coated High Strength Copper Alloy Flattened Wire: Nickel coated copper or nickel coated high strength copper alloy strands shall conform to ASTM B 355 after flattening. The flattened wire stra
