SAE AS 22759 186B-2017 WIRE ELECTRICAL POLYTETRAFLUOROETHYLENE POLYMIDE INSULATED SMOOTH SURFACE NORMAL WEIGHT SILVER-COATED COPPER CONDUCTOR 200 600 VOLTS ROHS.pdf
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1、 AEROSPACE STANDARD WIRE, ELECTRICAL, POLYTETRAFLUOROETHYLENE/POLYMIDE INSULATED, SMOOTH SURFACE, NORMAL WEIGHT, SILVER-COATED COPPER CONDUCTOR, 200 C, 600 VOLTS ROHS AS22759/186Copyright 2017 SAE International All rights reserved. No part of this publication may be reproduced, stored in a retrieval
2、 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: CustomerSe
3、rvicesae.org SAE WEB ADDRESS: http:/www.sae.org ISSUED2010-02REVISED2017-09THIRD ANGLE PROJECTION CUSTODIAN: AE-8/AE-8D REV.B FEDERAL SUPPLY CLASS 6145 AS22759 /186 SHEET 1 OF 6 REV. B PROCUREMENT SPECIFICATION: NONE SAE Technical Standards Board Rules provide that: “This report is published by SAEt
4、oadvance thestate of technicaland engineering sciences. The useof this report is entirely voluntary, and its applicability andsuitability for any particularuse, includingany patent infringement arisingtherefrom,is thesole responsibility of theuser.” SAE reviews eachtechnical reportatleast every five
5、years at whichtime it may be revised, reaffirmed, stabilized, or cancelled. SAE invites your written comments and suggestions.SAE values your input. To provide feedback on this Technical Report, please visit http:/standards.sae.org/AS22759/186B RATIONALE SPECIFICATION UPDATED TO INCLUDE AS29606 COND
6、UCTOR REQUIREMENTS, ROHS RESTRICTIONS, AND AS22759 MODIFICATIONS. THIS CHANGE ALSO INCREASES THE MAXIMUM WEIGHT REQUIREMENTS FOR WIRE SIZES 8 THROUGH 02 TO ACCOUNT FOR INCREASED CIRCULAR MIL AREA (CMA) ADOPTED IN AS29606. AS22759 IS A CONVERTED MILITARY SPECIFICATION ORIGINALLY NOTED AS MIL-W-22759
7、CREATED IN 1971. CONDUCTOR REQUIREMENTS WERE ORIGINALLY DEFINED BY ASTM B3, B298, AND B355 FOR TIN, SILVER, AND NICKEL PLATE RESPECTIVELY. THESE SPECIFICATIONS CONTROLLED THE CONDUCTOR BY ESTABLISHING STRAND SIZE, CONDUCTOR SIZE, AND MAXIMUM DCR (DIRECT CURRENT RESISTANCE). BY THE LATE 1980S CONDUCT
8、OR PRODUCERS WERE PRODUCING TIGHT TOLERANCE CONDUCTORS WHICH WERE MADE AT THE MINIMUM DIMENSIONAL AND MAXIMUM DCR LIMITS OF THE SPECIFICATION TO REDUCE THE WEIGHT (MASS) OF THE FINALLY INSULATED WIRE. BY THE EARLY 1990S THE TIGHT TOLERANCE CONDUCTORS WERE PREVALENT THROUGHOUT AEROSPACE. ABOUT THE SA
9、ME TIME, LARGE GAUGE SIZE CONDUCTORS (SIZE 8 THROUGH 4/0) STARTED EXHIBITING CRIMP FAILURES IN TERMINAL LUGS MOUNTED ON AIRCRAFT GENERATORS. SINCE THESE CIRCUITS ROUTED PRIMARY ELECTRICAL POWER FROM THE GENERATOR TO THE MAIN POWER DISTRIBUTION CENTERS, CRIMP DEGRADATION RESULTING IN DISRUPTION OF EL
10、ECTRICAL POWER CAUSED SIGNIFICANT CONCERN. SEVERAL OEMS AS WELL AS NAVY AND AIR FORCE LABORATORIES INVESTIGATED THE FAILURES AND DETERMINED THAT THE FAILED CRIMPS WERE DUE TO A COMBINATION OF LOW CMA, HIGH VIBRATION AND THERMAL CYCLING. ADDITIONAL TESTING ESTABLISHED MINIMUM CMA LEVELS WHICH WOULD P
11、REVENT THE CRIMP FAILURES. THESE NEW LIMITS WERE OFFERED TO ASTM, BUT REJECTED. NAVAIR THEN PRODUCED AN ENGINEERING POSITION LETTER (EPL) TO MANDATE THE INCREASED CMAS ON STRANDING USED IN AS22759 CONSTRUCTIONS. NAVAIR THEN CREATED MIL-W-29606 WHICH WAS INTENDED TO REPLACE THE ASTM SPECIFICATIONS AS
12、 THE REQUIRED CONDUCTOR SPECIFICATION. BEFORE THE MIL-W-29606 COULD BE ADDED TO MIL-W-22759, THE SPECIFICATION TRANSITION AND ADOPTION TOOK PLACE CONVERTING THE DOCUMENTS FROM MILITARY SPECIFICATIONS TO AS DOCUMENTS IN THE 1999 TO 2000 TIME FRAME. SINCE THE EPL NO LONGER HAD LEGAL STANDING AFTER THE
13、 CONVERSION, WIRE PRODUCERS DID NOT HAVE TO ABIDE BY THE RESTRICTIONS WHICH ALLOWED THIS ISSUE TO CREEP BACK INTO THE PRODUCTS FROM TIME TO TIME. IN 2011, THE SAE AE-8D COMMITTEE OPENED A PROJECT TO UPDATE THE AS22759 AND ITS ASSOCIATED DETAILED SPECIFICATION SHEETS. WHEN LOOKING AT THIS ISSUE, THE
14、COMMITTEE DECIDED TO ADOPT MIL-W-29606 (NOW AS29606) AND REPLACE THE ASTM REQUIREMENTS WITH THE AS29606 REQUIREMENTS. SINCE THE DIAMETER RANGE OF THE CONDUCTOR STRANDS NEEDED TO SHIFT SLIGHTLY TO THE RIGHT TO MEET THE NEW MINIMUM CMA REQUIREMENTS, OVERALL PRODUCT WEIGHT MAXIMUMS SHIFTED ABOUT 3 TO 5
15、%. THE COMMITTEE EVALUATED SEVERAL METHODS OF INCORPORATING THIS CHANGE INCLUDING CANCELING AND SUPERSESSION, BUT THE END USERS DID NOT WANT TO CHANGE PART NUMBERS FOR PRODUCTS WHICH HAVE BEEN USED IN AEROSPACE AND INDUSTRY FOR OVER 40 YEARS AND IS CURRENTLY ON THOUSANDS OF DRAWINGS. SINCE THESE PRO
16、DUCTS ARE PRIMARILY USED FOR PRIMARY POWER DISTRIBUTION FROM THE GENERATORS TO THE MAIN DISTRIBUTION PANELS, THE WEIGHT INCREASE TO THE ELECTRICAL INTERCONNECT SYSTEM IS CONSIDERED INSIGNIFICANT. SINCE THIS CHANGE DOES AFFECT THE MAXIMUM WEIGHT LIMITS FOR SIZES 8 THROUGH 4/0, END USERS SHOULD VERIFY
17、 THAT THE NEW WEIGHT RANGES MEET THE DESIGN REQUIREMENTS OF LEGACY APPLICATIONS. CORRECTED STATE OF SINTER REQUIREMENT. NOTICE THE COMPLETE REQUIREMENTS FOR PROCURING THE PRODUCT DESCRIBED HEREIN SHALL CONSIST OF THIS DOCUMENT AND THE LATEST ISSUE OF AS22759. AEROSPACE STANDARD AS22759 /186 SHEET 2
18、OF 6 REV. B WIRE, ELECTRICAL, POLYTETRAFLUOROETHYLENE/POLYMIDE INSULATED, SMOOTH SURFACE, NORMAL WEIGHT, SILVER-COATED COPPER CONDUCTOR, 200 C, 600 VOLTS ROHS FP / POLYIMIDE / FP TAPE FP TAPE SIZE 26 THROUGH 10 FP / POLYIMIDE / FP TAPE FP TAPE FP TAPE SIZE 8 THROUGH 6 FP / POLYIMIDE / FP TAPE FP TAP
19、E FP TAPE FP TAPE SIZE 4 THROUGH 04 FP FLUOROCARBON POLYMER MODIFIED POLYTETRAFLUOROETHYLENE (PTFE) CONDUCTOR STRANDED SILVER COATED COPPER FIGURE 1 - AS22759/186 CONFIGURATION AEROSPACE STANDARD AS22759 /186 SHEET 3 OF 6 REV. B WIRE, ELECTRICAL, POLYTETRAFLUOROETHYLENE/POLYMIDE INSULATED, SMOOTH SU
20、RFACE, NORMAL WEIGHT, SILVER-COATED COPPER CONDUCTOR, 200 C, 600 VOLTS ROHS TABLE 1 - CONSTRUCTION DETAILS FOR FINISHED WIRE PART NO. 1/ WIRE SIZE CONDUCTOR 4/ FINISHED WIRE 3/ STRANDING (NUMBER OF STRANDS X SIZE GAUGE OF STRANDS) DIAMETER (INCH) RESISTANCE AT 20 C (68 F) (OHMS/1000 FEET MAX.) DIAME
21、TER (INCH) WEIGHT (LB/1000 FEET) 2/ MIN. MAX. MIN. MAX. MIN. TARGET MAX. M22759/186-26-* M22759/186-24-* M22759/186-22-* M22759/186-20-* M22759/186-18-* M22759/186-16-* M22759/186-14-* M22759/186-12-* M22759/186-10-* M22759/186-8-* M22759/186-6-* M22759/186-4-* M22759/186-2-* M22759/186-1-* M22759/1
22、86-01-* M22759/186-02-* M22759/186-03-* M22759/186-04-* 26 24 22 20 18 16 14 12 10 8 6 4 2 1 0 00 000 0000 19 X 38 19 X 36 19 X 34 19 X 32 19 X 30 19 X 29 19 X 27 37 X 28 37 X 26 133 X 29 133 X 27 133 X 25 665 X 30 817 X 30 1045 X 30 1330 X 30 1665 X 30 2109 X 30 .0175 .0225 .0285 .0365 .0455 .0515
23、.0645 .0835 .106 .158 .198 .250 .320 .366 .395 .440 .500 .565 .0194 .0244 .0304 .0384 .0484 .0544 .0684 .0874 .110 .166 .208 .263 .340 .380 .425 .475 .540 .605 38.4 24.3 15.1 9.19 5.79 4.52 2.88 1.90 1.19 .658 .418 .264 .170 .139 .108 .085 .068 .054 .033 .038 .043 .051 .061 .068 .081 .100 .122 .180
24、.219 .276 .344 .388 .420 .475 .530 .590 .037 .042 .047 .055 .065 .073 .086 .105 .127 .188 .229 .288 .364 .408 .450 .505 .560 .630 1.29 1.87 2.70 4.25 6.40 8.20 12.4 18.9 29.3 55.9 86.9 141 217 265 335 419 528 676 1.42 2.04 2.90 4.48 6.65 8.50 12.9 19.7 30.8 57.8 89.4 145 225 274 349 438 548 698 1.55
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