1、AEROSPACE STANDARDCopyright 1964 by Society of Automotive Engineers, Inc. Printed in U.S.A.SOCIETY OF AUTOMOTIVE ENGINEERS, Inc.485 LEXINGTON AVENUENEW YORK 17, N.Y.AS 654Issued 10-30-64RevisedSection8.3oftheSAETechnicalBoardrulesprovidethat:“Alltechnicalreports,includingstandardsapprovedandpractice
2、srecommended,areadvisoryonly.Theirusebyanyoneengagedinindustryortradeisentirelyvoluntary.ThereisnoagreementtoadheretoanySAEstandardorrecommendedpractice,andnocommitmenttoconformtoorbeguidedbyanytechnicalreport.Informulatingandapprovingtechnicalreports,theBoardanditsCommitteeswillnotinvestigateorcons
3、iderpatentswhichmayapplytothesubjectmatter.Prospectiveusersofthereportareresponsibleforprotectingthemselvesagainstliabilityforinfringementofpatents.”CABLE, SPECIAL PURPOSE, ELECTRICAL:WIRE, ELECTRICAL (IGNITION, HIGH-TENSION)1. SCOPE - This Aerospace Standard covers insulated, high-tension, shielded
4、, special purpose cable and unshielded electrical cable for ignition systems of internal combustion engines for aircraft.2. CLASSIFICATION - Cable shall be of the following types, grades, classes, and sizes, as specified (see 6.2).Type I - UnshieldedType II - ShieldedGrade A - Temperature range of +
5、250 to -35FGrade B - Temperature range of +450 to -65FGrade C - Temperature range of +250 to -65FGrade D - Temperature range of +600 to -65FClass 1 - Copper conductor (19 strands min.)Class 2 - Copper conductor (37 strands min.)Class 3 - Corrosion-resistant steel conductor (7 strands min.)Size 5 - 5
6、 millimeter outside diameterSize 7 - 7 millimeter outside diameter3. APPLICABLE DOCUMENTS3.1 The following specifications and standards of the issue in effect on the date of invitation for bids form a part of this standard.3.1.1 Federal SpecificationsO-A-548 - Antifreeze, Ethylene Glycol, InhibitedQ
7、Q-W-343 - Wire, Electrical and Nonelectrical, Copper (Uninsulated)3.1.2 Military SpecificationsMIL-J-5161 - Jet Fuel, RefereeMIL-A-6091 - Fluid; Anti-Icing (Isopropyl Alcohol)MIL-L-6082 - Lubricating Oil; Aircraft-EngineMIL-L-7808 - Lubricating Oil; Aircraft Turbine Engine Synthetic BaseMIL-I-13811
8、- Insulating Compound, Electrical, IgnitionMIL-F-13927 - Fungus Resistance Test; Automotive Electrical Components, General Specification forAS 654Issued 10-30-64RevisedCABLE, SPECIAL PURPOSE, ELECTRICAL:WIRE, ELECTRICAL (IGNITION, HIGH-TENSION)- 2 -3.1.3 Military StandardsMIL-Std-105 - Sampling Proc
9、edures and Tables for Inspection by AttributesMIL-Std-129 - Marking for Shipment and Storage3.2 Other Publications - The following documents form a part of this standard. Unless otherwise specified, the issue in effect on date of invitation for bids shall apply.Consolidated Freight Classification Ru
10、les and Container Specifications(Application for copies should be addressed to the Consolidated Classification Committee, 202 Chicago Union Station, Chicago 6, Illinois.)National Motor Freight Classification Rules and Container Specifications(Application for copies should be addressed to the Nationa
11、l Classification Board, 1424 Sixteenth Street, N. W., Washington 6, D.C.)4. REQUIREMENTS4.1 Qualification - Cable furnished under this standard shall be a product which has been tested and has passed the qualification tests specified herein. Subsequent to such qualification, no change shall be made
12、in materials, design, or construction of a considered type, grade, class, and size of cable without approval of the purchaser. Upon request by the purchaser, the manufacturer shall furnish a certified report showing results of complete qualification testing.4.2 Extension of Qualification - Qualifica
13、tion of cable of a given type, class, grade, and size submitted by a manufacturer may serve to qualify other cable or similar construction by the same manufacturer. Extension of qualification shall apply as follows:AS 654CABLE, SPECIAL PURPOSE, ELECTRICAL:WIRE, ELECTRICAL (IGNITION, HIGH-TENSION) Is
14、sued 10-30-64Revised- 3 -4.3 Materials - The materials used in the manufacture and testing of cable covered by this standard shall be as specified herein and in the applicable specification forming a part of this standard. Materials not specifically covered by this standard or the applicable specifi
15、cations shall be suitable for the intended purpose and free of defects which may affect the serviceability and appearance of the finished cable.4.4 Construction4.4.1 Type I (Unshielded Cable) - Type I cable shall consist of a stranded conductor, insulation, layer of braid and a sheath.4.4.2 Type II
16、(Shielded Cable) - Type II cable shall consist of Type I cable covered with a closely woven metal shielding.4.5 Components4.5.1 Conductor - The conductor shall be composed of wires of composition, quality, and tempers suitable for stranding and insulating. It shall be continuous throughout its lengt
17、h, without weld, splice, or joint, except that individual wires may be spliced as specified in 4.5.4. The conductor shall be uniformly circular in cross section, and shall be free of abrasions, kinks, and flats. The number of individual wires, the diameter of the wire and the diameter of the conduct
18、or shall be as specified in Table I.SAMPLEType IIGradeABCDClass123Size57QUALIFIEDTYPE I 7mm, 34 kilovolts.TABLE IIOutside Diameters, Type I Cable.Diameter(Nom)MillimetersActual(Min)InchesDiameter(Max)Inches570.1960.2700.2060.285AS 654CABLE, SPECIAL PURPOSE, ELECTRICAL:WIRE, ELECTRICAL (IGNITION, HIG
19、H-TENSION) Issued 10-30-64Revised- 7 -4.11.2.2 Dielectric Flaws - Type I cable and Type II cable before shielding is applied, shall be subjected to test specified in 5.3.1. After test, cable shall be inspected for flaws and for sections having insulation defects, which shall be removed from the cabl
20、e. Completed cable shall be certified as having passed the dielectric-flaws test, as specified, and that flaws and defective sections have been removed.4.11.2.3 Capacitance - The dielectric constant of the cable insulation shall be such that the capacitance of the completed cable does not exceed the
21、 values shown in Table III when tested as specified in 5.3.5.4.11.3 Resistance to Life Cycle Test - When subjected to tests specified in 5.3.7 (5.3.7.1 thru 5.3.7.7), Type I cable Type II cable before shield is applied shall show no evidence of sheath decomposition or other damage and shall meet the
22、 requirements of 4.11.2.1.4.11.4 Low-Temperature Resistance - When subjected to tests specified in 5.3.8, cable shall show no evidence of cracking, breaking, or separation and shall resist specified high potential without dielectric or other resultant failure.4.11.5 Hot-Oil Resistance - When subject
23、ed to tests specified in 5.3.9, cable shall show no evidence of cracking, rupture, decomposition, loss of specified dielectric strength, or other resultant damage, and cable diameter shall not swell more than 20% (30% for Grade B) (see 5.3.9.4).4.11.6 High-Temperature Resistance - When subjected to
24、tests specified in 5.3.10 (5.3.10.1 thru 5.3.10.2), cable shall show no sheath or insulation breakdown, and the conductor shall not be corroded.4.11.7 Flammability - When tested as specified in 5.3.12, no burning or charred particles shall fall from the cable, and the flame shall not travel along th
25、e cable at a rate of more than 1/2 inch per minute.4.11.8 Fungus Resistance - When tested as specified in 5.3.13, cable shall show no evidence of damage affecting its performance, and thereafter shall meet the requirements of 4.11.2.1.TABLE IIICAPACITANCECable SizeMillimetersClass 1PicofaradsCapacit
26、ance per foot of cableClass 2PicofaradsClass 3Picofarads575045-523733AS 654Issued 10-30-64RevisedCABLE, SPECIAL PURPOSE, ELECTRICAL:WIRE, ELECTRICAL (IGNITION, HIGH-TENSION)- 8 -4.11.9 Corona Effect - When subjected to the tests specified in 5.3.6, cable shall not deteriorate, crack, or burn over th
27、e ends, and shall resist specified high potential without dielectric or other resultant failure.4.12 Identification of Completed Cable4.12.1 Cable - The type, grade, class, and nominal size of cable, manufacturers name or trade-mark, manufacturers designation, and the date of manufacture shall be ap
28、plied to the exterior surface of the sheath of Type I cable at intervals of not more than 2 feet. The date of manufacture shall be indicated, unless otherwise specified, by two numbers separated by a dash, the first number being the quarter and the second the calender year of manufacture. Additional
29、 marking shall conform to requirements on applicable drawings or in procurement documents (see 6.2).4.12.2 Spools or reels - Each spool or reel shall be plainly marked on both ends with the information listed below, and any other information specified (see 6.2). If paper labels are used, they shall
30、be protected by a compound conforming to Specification MIL-I-13811 to prevent deterioration of marking.Cable: Ignition, High-TensionSpecification AS _Type _ Grade _Class _ Size _Length, feet _Order No. _Stock No. _Date of Manufacture _Manufacturers Name or Trademark _4.13 Age - Bulk cable, on spools
31、, reels, or coils shall be not more than four quarters old, succeeding the quarter marked on the cable, at the time of acceptance by the purchaser.4.14 Workmanship - Cable shall be free of imperfections of manufacture which will materially affect the appearance or serviceability or will prevent sati
32、sfaction of requirements specified herein.5. QUALITY ASSURANCE PROVISIONS5.1 Acceptance Inspection - The acceptance inspection shall consist of Groups I and II tests, and process control tests.5.1.1 Inspection Lot - Unless otherwise specified, a lot shall consist of all cables of one type, grade, cl
33、ass and size offered for inspection at one time, except that the inspection lot shall not exceed 100,000 feet or one weeks production, whichever is less. The inspection lot shall be expressed in units of thousands of feet (total footage in inspection lot divided by 1000).AS 654CABLE, SPECIAL PURPOSE
34、, ELECTRICAL:WIRE, ELECTRICAL (IGNITION, HIGH-TENSION) Issued 10-30-64Revised- 9 -5.1.1.1 Sample - A sample shall be defined as a group of individual lengths of cable chosen at random from any one inspection lot for the purpose of inspection. The sample size or number of lengths to be chosen from ea
35、ch inspection lot is determined by the sampling plan.5.1.1.2 Sample Unit - A sample unit shall be defined as one of the individual lengths of the sample. Each sample unit shall be of sufficient length to permit the performance of all applicable examinations and tests.5.1.1.3 Specimen - A specimen sh
36、all be defined as a piece of one sample unit upon which a particular examination or test is to be made.5.1.2 Inspection - Acceptance inspection shall consist of the examinations and tests listed in Table IV and described below.5.1.3 Sampling for Group I, II Inspections - For each group of tests, a r
37、andom sample of the size specified shall first be selected from an inspection lot. Then from each sample unit, specimens of sufficient length shall be selected for the specified inspections.5.1.3.1 Group I Inspections - Sampling for Group I inspections shall be in accordance with StandardMIL-STD-105
38、, Inspection Level L7, with an acceptable quality level (AQL) of 4.0 percent for major defects, and 15.0 percent for minor defects.5.1.3.2 Group II Inspections - Sampling for Group II Inspections shall be in accordance with StandardMIL-STD-105, Inspection Level I, except that each sample size repres
39、ented by the sample size code letter shall be used, with an acceptance number of 0 and a rejection number of 1.Table IVAcceptance InspectionGroup TestClassificationof DefectRequirementParagraphTestParagraphI.II.ConstructionDimensionsSurface FinishIdentification of ProductWorkmanshipIncorrect Marking
40、CapacitanceDielectric StrengthCorona EffectFlammabilityTensile Loadmajormajormajormajormajorminormajormajormajormajormajor4.4.5.3.54.94.8.24.124.144.12.14.11.2.34.11.2.14.11.94.11.74.11.1-5.3.55.3.115.3.65.3.125.3.4AS 654Issued 10-30-64RevisedCABLE, SPECIAL PURPOSE, ELECTRICAL:WIRE, ELECTRICAL (IGNI
41、TION, HIGH-TENSION)- 10 -5.1.4 Resubmitted Inspection Lots - The paragraph entitled “Resubmitted Lots” of Standard MIL-STD-105 shall apply, except that a resubmitted inspection lot shall be inspected by the contractor, using tightened inspection. Before resubmitting, full particulars concerning the
42、cause of previous rejection and the action taken to correct the defects found in the inspection lot shall be furnished by the contractor to the purchaser.5.1.5 Process Control Inspection - These inspections are of such nature that they cannot be performed on finished wire submitted for inspection an
43、d therefore must be conducted at the most appropriate state of manufacturing operations. The process control inspections shall consist of the tests listed in the Table V.5.1.5.1 Sampling for Process Control Inspection5.1.5.1.1 Conductor Material - From each weeks production of individual strands, or
44、 from every 1000 pounds of finished strand, whichever is less, three 10-foot lengths of strand shall be selected in such a manner as to be representative of the material to be used in the finished insulated cable.5.1.5.1.2 Coating - The sample shall consist of at least 3-1/2 feet of strand, before s
45、tranding, which is representative of the strand to be used in the manufacture of each lot of finished cable.5.1.5.2 Rejection and Retest - When the sample selected from a production run fails in the specified test, no items still on hand or later produced shall be accepted until the extent and cause
46、 of the failure has been determined. After investigation, the contractor shall advise the purchaser of the action taken and, after corrections have been made, shall repeat all the process control tests. Rejection after corrective action will require that the contractor advise the purchaser of the de
47、tails surrounding the retest and cause of rejection.Table VProcess Control InspectionExamination of Test Requirement TestConductor materialSplicesCoating ContinuityFlaws, Finished Wire4.5.24.5.44.5.2.1.14.11.2.25.1.5.1.15.1.5.1.25.3.25.3.1AS 654CABLE, SPECIAL PURPOSE, ELECTRICAL:WIRE, ELECTRICAL (IG
48、NITION, HIGH-TENSION) Issued 10-30-64Revised- 11 -5.1.5.2.1 Acceptance Testing May Continue - For production reasons, acceptance testing may be continued, pending the investigation of the process control inspection failure, but final acceptance of the material shall not be made until it is determined that the lot meets all the requirements of this specification.5.2 Control Tests5.2.1 Sampling for Control Tests - Control test samples shall be selected at the rate of 6 feet of each 100,000 feet produced, except that not less than 6
