1、REVISIONS LTR DESCRIPTION DATE APPROVED A Technical modifications to agree with SAE-AS22759/86, SAE-AS22759/87, SAE-AS22759/88, SAE-AS22759/89, and SAE-AS22759/90. Editorial changes throughout. Update format. Added approved supplier. 30 March 2009 Abdo Abdouni B Added approved supplier. 8 September
2、2010 Abdo Abdouni Prepared in accordance with ASME Y14.100 Selected item drawing REV PAGE REV STATUS OF PAGES REV B A A A A A A A A A A A A A B PAGE 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 PMIC PREPARED BY DEFENSE SUPPLY CENTER, COLUMBUS COLUMBUS, OHIO 43218-3990 William Carpenter Original date of drawi
3、ng 12 July 2004 CHECKED BY TITLE Lee Surowiec WIRE, ELECTRICAL, COMPOSITE, POLYTETRAFLUOROETHYLENE/POLYIMIDE INSULATED, 26, 20, 18, 16 AWG, 600 VOLT APPROVED BY Richard L. Taylor SIZE CAGE CODE DWG. NO. 04048 A 037Z3 REV B PAGE 1 OF 15 AMSC N/A 6145-E097-011 .CURRENT DESIGN ACTIVITY CAGE CODE 037Z3
4、HAS CHANGED NAMES TO: 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 04048 REV A PAGE 2 FP Fluorocarbon Polymer, m
5、odified Polytetrafluoroethylene (PTFE) FIGURE 1. General configuration. 1 SCOPE 1.1 Scope. This drawing covers the performance characteristics for 26, 20, 18, 16 AWG normal weight composite wire using a seamless polytetrafluoroethylene/hydrolysis resistant polyimide tape wrap insulation system. 1.2
6、Part or Identifying Number (PIN). The complete PIN should be as specified on the requirements drawing and constructed using the following format: 04048 - 20 A - 9 Insulation color designator (see 1.2.2) Wire size (see table I) DSCC drawing number Conductor designator (see table II) CONDUCTOR, STRAND
7、ED, SMALL DIAMETER, SILVER, 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 04048 REV A PAGE 3 TABLE
8、I. Details of construction. 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 04048-26A-* 26 19 X 38 .0175 .0204 44.8 .033 .037 1.55 04048-20F-*
9、20 19 X 32 .0390 .0410 14.6 .053 .057 5.25 04048-18F-* 18 19 X 30 .0490 .0515 8.16 .064 .068 7.70 04048-16F-* 16 19 X 29 .0549 .0580 6.54 .071 .075 9.75 * The asterisks in the PIN column in table I should be replaced by color code designators (see 1.2.2). Example: 04048-26-93 is white with an orange
10、 stripe. 1.2.2 Color. The color of the finished wire should be as indicated by the 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 insul
11、ation color designator of the wire should be listed in MIL-STD-681, system I (differentiation 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
12、colors of any stripes, bands, or tracers, if used, should be in accordance with MIL-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 markin
13、g test (3.5.12) using the number of strokes and the weight specified herein (see 3.7). 1.2.3 Conductor designators. Conductor designators shall be as specified in table II. TABLE II. Conductor designator/temperature rating. 1/ Designator Conductor description Temperature rating A Silver plated coppe
14、r alloy (SPA) 200C B Nickel plated copper alloy (NPA) 260C C Tin plated copper (TPC) 150C D Silver plated copper (SPC) 200C E Nickel plated copper (NPC) 260C F 27% Nickel planted Copper (NPC) 260C 1/ For a complete description of conductor material see 3.3.1 2. APPLICABLE DOCUMENTS 2.1 Government do
15、cuments. 2.1.1 Specifications, standards, and handbooks. The following specifications, standards, and handbooks 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. DEPARTMENT OF DEFENS
16、E STANDARDS MIL-STD-104 - Limits for Electrical Insulation Color MIL-STD-202 - Test Method Standard Electronic and Electrical Component Parts MIL-STD-681 - Identification Coding and Application of Hookup and Lead Wire MIL-STD-2223 - Test Methods for Insulated Electric Wire (Copies of these documents
17、 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.) Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-DEFENSE SUPPLY CENTER, COLUMBUS
18、 COLUMBUS, OH 43218-3990 SIZE CAGE CODE DWG NO. A 037Z3 04048 REV A PAGE 4 2.2 Non-government publications. 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.
19、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 Wire for Electronic Purposes ASTM B355 - Standard Specification for Nickel Coated Soft or Annealed Cop
20、per 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 D4591 - Standard Test Method for Determining Temperatures and Heats of Transitions of Fluoropolymers by Dif
21、ferential 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 19428-2959.) NCSL INTERNATIONAL NCSL-Z540.3 - General Requirements for Calibration of Measuring and Test Eq
22、uipment (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.) NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA) NEMA WC 52 - High-Temperature and Electronic Insulated
23、 Wire - Impulse Dielectric Testing Copies of these documents are available online at http:/www.nema.org or from the National Electrical Manufacturers Association, 1300 North 17thStreet, Suite 1847, Rosslyn VA 22209.) SAE INTERNATIONAL SAE-AS4373 - Test Methods for Insulated Electric Wire SAE-AS22759
24、 - Wire, Electrical, Fluoropolymer-Insulated, Copper or Copper Alloy SAE-AS22759/86 - Wire, Electrical, Polytetrafluoroethylene/polyimide Insulated, Normal Weight, Silver Coated, Copper Conductor, 200 deg. C, 600 volts SAE-AS22759/87 - Wire, Electrical, Polytetrafluoroethylene/polyimide Insulated, N
25、ormal Weight, Nickel Coated, Copper Conductor, 260C, 600 Volts SAE-AS22759/88 - Wire, Electrical, Polytetrafluoroethylene/polyimide Insulated, Normal Weight, Tin Coated, Copper Conductor, 150C, 600 Volts SAE-AS22759/89 - Wire, Electrical, Polytetrafluoroethylene/polyimide Insulated, Normal Weight, S
26、ilver Coated, High Strength or Ultra High Strength Copper Alloy, 200C, 600 Volts SAE-AS22759/90 - Wire, Electrical, Polytetrafluoroethylene/polyimide Insulated, Normal Weight, Nickel Coated, High Strength or Ultra High Strength Copper Alloy, 260C, 600 Volts (Copies of these documents are available f
27、rom 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 CAGE CODE DWG NO. A 037Z3 04048 REV A PAGE 5
28、 3. REQUIREMENTS 3.1 DSCC requirements. Items shall meet the requirements of SAE-AS22759, SAE-AS22759/86, SAE-AS22759/87, SAE-AS22759/88, SAE-AS22759/89, and SAE-AS22759/90 except as specified herein. Any requirements included in this drawing shall be in addition to, or supersede those requirements
29、included in SAE-AS22759, SAE-AS22759/86, SAE-AS22759/87, SAE-AS22759/88, SAE-AS22759/89, and SAE-AS22759/90. In case of conflict between the requirements in this drawing and those in SAE-AS22759, SAE-AS22759/86, SAE-AS22759/87, SAE-AS22759/88, SAE-AS22759/89, and SAE-AS22759/90, the requirements of
30、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 shall be available upon request for review by the contract
31、ing 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 lumps, kinks, splits, scarred or corroded surfaces and skin impurit
32、ies. 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 wire in accordance with ASTM B624 and table I of this drawing. All s
33、trands 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 B355. 3.3.1.3 Conductor designator C. Conductors shall be made of so
34、ft annealed copper wire in accordance with ASTM B33 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 tin coated in accordance with ASTM B33. 3.3.1.4 Conductor designator D. Conductors shall be made of
35、 soft annealed copper wire in accordance with ASTM B298 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 silver coated. The silver coating shall not be less than 40 microinches (1.02 m) when tested in
36、 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 be free from lumps, kinks, splits, scarred or corroded surfaces and skin impurities. Strands shall be nickel c
37、oated. The nickel coating shall not be less than 50 microinches (1.27 m) when tested in accordance with ASTM B355. 3.3.1.6 Conductor designator F. Conductors shall be made of soft annealed copper wire in accordance with ASTM B355 and table I of this drawing. All strands shall be free from lumps, kin
38、ks, splits, scared or corroded surfaces and skin impurities. Strands shall be nickel coated. The nickel coating shall meet the requirements of ASTM B355, class 27. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-DEFENSE SUPPLY CENTER, COLUMBUS COLUMB
39、US, OH 43218-3990 SIZE CAGE CODE DWG NO. A 037Z3 04048 REV A PAGE 6 3.3.2 Insulation. Polytetrafluoroethylene (PTFE) and Polytetrafluoroethylene/Polyimide (FP/Polyimide) tapes specified in tables III and IV. The polyimide tape shall be hydrolysis resistant. TABLE III. Wire insulation materials. 1/ T
40、ape code Thickness nominal (inches) Material 1 2 3 .0020 .0020 .0025 .0005 FP/.001 polyimide/.0005 FP FP (Unsintered) FP (Unsintered) 1/ Physical properties of PTFE unsintered tape shall be in accordance with SAE-AS22759 requirements. TABLE IV. Physical properties of FP/Polyimide/FP tapes. Tensile s
41、trength 19,000 lb/in2(average min) Tensile modulus 350,000 lb/in2(average min) Elongation 40 percent (average min) Dielectric strength 4,000 volts/mil (average min) .0005 FP Layer Distinguishable color (next to conductor) 3.4 Wire construction and physical dimensions. See figure 1 and tables I and V
42、. 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 26 1 50.5 54.0 2 50.5 54.0 7.4 20 1 50.5 54.0 2 50.5 54.0 7.4 18 1 50.5 54.0 2 50.5 54.0 7.4 16 1 50.5 54.0 3 50.5 54.0 8.3 1/ Wrap 1 is
43、innermost tape which is in contact with the conductor. 3.5 Performance testing: Wire supplied to this drawing shall meet the requirements of SAE-AS22759, SAE-AS22759/86, SAE-AS22759/87, SAE-AS22759/88, SAE-AS22759/89, and SAE-AS22759/90 as applicable. The additional performance requirements of this
44、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 test. Test in accordance with NEMA WC 5
45、2, 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 not stick (block) to one another when
46、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 finished wire). b. The wire shall then b
47、e 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). Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-DEFENSE SUPPLY CENTER, COLUMBUS COLUMBUS, OH 432
48、18-3990 SIZE CAGE CODE DWG NO. A 037Z3 04048 REV A PAGE 7 d. The winding shall be continued until there are at least three closely wound layers of such helical turns on 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 laye
49、rs. 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) Conductor designations B, E, F: 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 un
