SAE AS 22759 193-2016 WIRE ELECTRICAL POLYTETRAFLUOROETHYLENE POLYMIDE INSULATED SMOOTH SURFACE LIGHT WEIGHT SILVER COATED EXTRA HIGH STRENGTH COPPER ALLOY 200 600 VOLTS ROHS.pdf

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1、AEROSPACE STANDARDWIRE, ELECTRICAL, POLYTETRAFLUOROETHYLENE/ POLYMIDEINSULATED, SMOOTH SURFACE, LIGHT WEIGHT, SILVER COATED,EXTRA HIGH STRENGTH COPPER ALLOY, 200 C, 600 VOLTS ROHSAS22759TM/193Copyright 2016 SAE InternationalAll rights reserved. No part of this publication may be reproduced, stored i

2、n 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: +1 724-776-4970 (outside USA)Fax: 724-776-0790 Email:

3、 CustomerServicesae.org SAE WEB ADDRESS: http:/www.sae.orgISSUED2016-07THIRD ANGLE PROJECTIONCUSTODIAN: AE-8/AE-8DFEDERAL SUPPLY CLASS6145AS22759TM/193SHEET 1 OF 4PROCUREMENT SPECIFICATION: AS22759SAE Technical Standards BoardRules providethat:“This reportis publishedby SAE to advance thestateoftech

4、nical andengineering sciences. The useofthis reportis entirely voluntary, and its applicability and suitability forany particularuse, includingany patent infringement arising therefrom, isthe sole responsibility of theuser.”SAE reviews eachtechnical reportatleastevery five years at whichtime it may

5、bereaffirmed, revised, stabilized or cancelled. SAE invites your written commentsand suggestions.SAE values your input. To provide feedbackon this Technical Report, please visit http:/www.sae.org/technical/standards/AS22759/193RATIONALESPECIFICATION DEVELOPED FOR APPLICATIONS REQUIRING HIGHER CONDUC

6、TOR TENSILE STRENGTH WHILE MAINTAINING ELECTRICAL CONDUCTIVITY. THIS SPECIFICATION USES THE EXTRA HIGH STRENGTH CLASSIFICATION OF SILVER PLATED COPPER ALLOY CONDUCTOR FROM AS29606.NOTICETHE COMPLETE REQUIREMENTS FOR PROCURING THE PRODUCT DESCRIBED HEREIN SHALL CONSIST OF THIS DOCUMENT AND THE LATEST

7、 ISSUE OF AS22759.FP / POLYIMIDE / FP TAPE FP TAPEFP FLUOROCARBON POLYMER MODIFIED POLYTETRAFLUOROETHYLENE (PTFE)CONDUCTOR STRANDED SILVER COATED EXTRA HIGH STRENGTH COPPER ALLOYFIGURE 1 - AS22759/193 CONFIGURATIONTABLE 1 - CONSTRUCTION DETAILS FOR FINISHED WIREPART NO. 1/WIRESIZECONDUCTOR 3/ FINISH

8、ED WIRESTRANDING(NUMBER OFSTRANDSX SIZEGAUGE OFSTRANDS)DIAMETER(IN) RESISTANCEAT 20 C(68 F)(OHMS/1000FEET MAX)DIAMETER(IN)WEIGHT(LB/1000 FEET) 2/MIN MAX MIN MAX MIN TARGET MAXM22759/193-30-*M22759/193-28-*M22759/193-26-*M22759/193-24-*M22759/193-22-*M22759/193-20-*3028262422207 X 387 X 3619 X 3819 X

9、 3619 X 3419 X 320.01170.01470.01840.02310.02930.03730.01240.01540.02040.02440.03140.0395117.474.444.828.417.510.70.0220.0250.0300.0340.0400.0480.0260.0290.0340.0380.0430.0510.610.861.211.732.554.070.680.931.331.862.764.250.751.001.461.992.954.441/ PART NUMBER: THE ASTERISKS IN THE PART NUMBER COLUM

10、N OF TABLE 1 SHALL BE REPLACED BY COLOR CODE DESIGNATORS IN ACCORDANCE WITH MIL-STD-681. EXAMPLES: M22759/193-20-93 IS A 20 AWG WHITE WITH ORANGE STRIPE.2/ THE ACCEPTABLE VALUE FOR THE CPK FOR THE FINISHED WIRE WEIGHT LISTED SHALL BE 1.3, USING A NORMAL (GAUSSIAN) DISTRIBUTION TO OBTAIN THOSE CPK VA

11、LUES.3/ CONDUCTOR SHALL CONFORM TO AS29606 TYPE SCS SMALL DIAMETER SILVER COATED EXTRA HIGH STRENGTH COPPER ALLOY CONDUCTOR.AEROSPACE STANDARD AS22759TM/193SHEET 2 OF 4WIRE, ELECTRICAL, POLYTETRAFLUOROETHYLENE/ POLYMIDEINSULATED, SMOOTH SURFACE, LIGHT WEIGHT, SILVER COATED,EXTRA HIGH STRENGTH COPPER

12、 ALLOY, 200 C, 600 VOLTS ROHSREQUIREMENT: ALL REQUIREMENTS SHALL CONSIST OF THIS DOCUMENT AND THE LATEST ISSUE OF AS22759.1. WIRE CONSTRUCTION:WIRE CONSTRUCTION SHALL BE IN ACCORDANCE WITH FIGURE 1 AND TABLES 1, 2, 3, AND 4.TABLE 2 - WIRE INSULATION MATERIALSTAPE CODE THICKNESS (NOM) MATERIAL1 0.001

13、2 0.00045 (FP)/0.00065 (POLYIMIDE)/0.0001 (FP)2 0.0020 FP (UNSINTERED)TABLE 3 - TAPE OVERLAP REQUIREMENTS 1/WIRESIZEWRAP 1 WRAP 2 NOMINALWALLTHICKNESS(MILS)TAPECODEPERCENTOVERLAP TAPECODEPERCENTOVERLAPMIN MAX MIN MAX30 1 50.5 54.0 2 50.5 54.0 5.828 1 50.5 54.0 2 50.5 54.0 5.826 1 50.5 54.0 2 50.5 54

14、.0 5.824 1 50.5 54.0 2 50.5 54.0 5.822 1 50.5 54.0 2 50.5 54.0 5.820 1 50.5 54.0 2 50.5 54.0 5.81/ WRAP 1 IS INNERMOST TAPE WHICH IS IN CONTACT WITH THE CONDUCTOR. THE 0.00045 FP LAYER SHALL BE AGAINST THE CONDUCTOR.2. WIRE PERFORMANCE RATING:TEMPERATURE RATING: 200 C (392 F) MAXIMUM CONDUCTOR CONTI

15、NUOUS TEMPERATURE.VOLTAGE RATING: 600 VOLTS (RMS) AT SEA LEVEL. 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 CONFIGURATIONS IS THE RE

16、SPONSIBILITY OF THE USER.3. MATERIALS AND PHYSICAL PROPERTIES:SEE AS22759 FOR MATERIAL REQUIREMENT. MATERIALS USED IN THE MANUFACTURE OF THESE PRODUCTS SHALL COMPLY WITH THE RESTRICTION OF HAZARDOUS SUBSTANCES DIRECTIVE 2002/95/EC. 4. FINISH WIRE INSULATION PROPERTIES:FINISH WIRE INSULATION PROPERTI

17、ES SHALL BE IN ACCORDANCE WITH TABLE 4.TABLE 4 - FINISHED WIRE INSULATION PROPERTIES REQUIREMENTSINSULATION PROPERTIESIMPULSE TEST VOLTAGE 8.0 KILOVOLTS (PEAK)HIGH FREQUENCY TEST VOLTAGE 5.7 KILOVOLTS (RMS) INSULATION STATE OF SINTER 3.0 JOULES PER GRAM MAXIMUMTAPE OVERLAP TABLE 3LAMINATION SEALING

18、260 C 2 C (500 F 3.6 F), 6 HOURSINSULATION BLOCKING 200 C 2 C (392 F 3.6 F)SHRINKAGE 230 C 2 C (446 F 3.6 F)MAXIMUM CHANGE .091 INCHESELECTRICAL RESISTANCE (IR) 5000 MEGOHMS (MIN)-1000 FEETWET DIELECTRIC VOLTAGE 2500 VOLTS (RMS), 60 HERTZINSULATION STRIP FORCE .25 - 6.0 POUNDS: WIRE SIZES 26 - 20NOT

19、 REQUIRED FOR WIRE SIZES 30 - 28UV LASER MARKING 62% MINIMUM AVERAGECONTINUOUS LENGTH SCHEDULE BAEROSPACE STANDARD AS22759TM/193SHEET 3 OF 4WIRE, ELECTRICAL, POLYTETRAFLUOROETHYLENE/ POLYMIDEINSULATED, SMOOTH SURFACE, LIGHT WEIGHT, SILVER COATED,EXTRA HIGH STRENGTH COPPER ALLOY, 200 C, 600 VOLTS ROH

20、S5. FINISH WIRE IDENTIFICATION:WIRE IDENTIFICATION EXCEPTIONS: NONEWIRE IDENTIFICATION DURABILITY: 125 CYCLES (250 STROKES) WITH 250 GRAMS WEIGHT STRIPE AND BAND DURABILITY: 125 CYCLES (250 STROKES) WITH 250 GRAMS WEIGHT6. FINISH WIRE PERFORMANCE:FINISH WIRE FIXTURES APPLICABLE TO EACH WIRE SIZE SHA

21、LL BE IN ACCORDANCE WITH TABLE 5.TABLE 5 - TEST MANDREL AND TEST LOAD REQUIREMENTSWIRESIZE(AWG)TEST MANDREL DIAMETER 1/(INCHES)TEST LOAD 1/(LB)COLD BENDLIFE CYCLE/BEND TEST WRAP COLD BENDLIFE CYCLE/BEND TEST3028262422201.001.001.001.001.001.000.3750.3750.3750.5000.5000.5000.1250.1250.1250.1250.1250.

22、1252.002.003.003.004.004.00 0.250.250.500.751.001.501/ TOLERANCE SHALL BE 3 PERCENT OF THE GIVEN VALUES.FINISH WIRE PERFORMANCE CHARACTERISTICS SHALL BE IN ACCORDANCE WITH TABLE 6.TABLE 6 - FINISH WIRE PERFORMANCE CHARACTERISTICSPERFORMANCE CHARACTERISTIC REQUIREMENTMANDREL BEND RESISTANCE (TAPES/BR

23、AIDS) REQUIREDTHERMAL SHOCK MECHANICAL RESISTANCE TEMPERATURE EXPOSURE 200 C 2 C (392 F 3.6 F)MAXIMUM CHANGE .091 INCHESTHERMAL MECHANICAL RESISTANCE (LIFE CYCLE)EXPOSURE 500 HOURS, 230 C 2 C (446 F 3.6 F)UV LASER CONTRAST MARKING RESISTANCE AFTER THERMAL AGING: 168 HOURSHUMIDITY RESISTANCE (IR) 500

24、0 MEGOHMS (MIN)-1000 FEETFLUID RESISTANCE DIAMETER INCREASE 5% (MAX)SMOKE RESISTANCE 200 C 5 C (392 F 9 F)FLAME RESISTANCE SELF-EXTINGUISH TIME: 3 SECONDSBURN LENGTH 3 INCHESWET ARC RESISTANCE MINIMUM 70 WIRES PASS WET DIELECTRIC TEST2 OR LESS WIRES FAIL IN ONE BUNDLEDAMAGE LENGTH: 1.0 INCHES OF LES

25、SDRY ARC RESISTANCE MINIMUM 70 WIRES PASS WET DIELECTRIC TEST2 OR LESS WIRES FAIL IN ONE BUNDLEDAMAGE LENGTH: 1.0 INCHES OF LESSDYNAMIC CUT-THROUGH WIRE SIZE 268 POUNDS AT 23 C, 6 POUNDS AT 150 C, 4 POUNDS AT 200 CWIRE SIZE 2010 POUNDS AT 23 C, 8 POUNDS AT 150 C, 6 POUNDS AT 200 CFORCED HYDROLYSIS I

26、NSULATION RESISTANCEWIRE SIZE 2070 C 2 C (158 F 3.6 F), 5000 HOURSLONGEVITY RESISTANCE (THERMAL INDEX) 200 C 2 C (392 F 3.6 F), 10000 HOURSABRASION RESISTANCE (NEEDLE) WIRE SIZE 20SAMPLE SIZE 8 READINGS2000 MIN CYCLES, 23 C 2 C (73 F 3.6 F)1000 MIN CYCLES, 70 C 2 C (158 F 3.6 F)350 MIN CYCLES, 150 C

27、 2 C (302 F 3.6 F)AEROSPACE STANDARD AS22759TM/193SHEET 4 OF 4WIRE, ELECTRICAL, POLYTETRAFLUOROETHYLENE/ POLYMIDEINSULATED, SMOOTH SURFACE, LIGHT WEIGHT, SILVER COATED,EXTRA HIGH STRENGTH COPPER ALLOY, 200 C, 600 VOLTS ROHS7. REQUIREMENT EXCEPTION TO THE AS22759:NONEAPPLICATION NOTES1. PRODUCTS MANU

28、FACTURED TO THIS SPECIFICATION ARE ROHS COMPLIANT. SPECIFICATION NOTES1. REVISION INDICATOR:A CHANGE BAR (l) LOCATED IN THE LEFT MARGIN IS FOR THE CONVENIENCE OF THE USER IN LOCATING AREAS WHERE TECHNICAL REVISIONS, NOT EDITORIAL CHANGES, HAVE BEEN MADE TO THE PREVIOUS ISSUE OF THIS DOCUMENT. AN (R) SYMBOL TO THE LEFT OF THE DOCUMENT TITLE INDICATES A COMPLETE REVISION OF THE DOCUMENT, INCLUDING TECHNICAL REVISIONS. CHANGE BARS AND (R) ARE NOT USED IN ORIGINAL PUBLICATIONS NOR IN DOCUMENTS THATCONTAIN EDITORIAL CHANGES ONLY.