SAE AS 22759 196-2016 WIRE ELECTRICAL POLYTETRAFLUOROETHYLENE POLYMIDE INSULATED SMOOTH SURFACE NORMAL WEIGHT NICKEL COATED EXTRA HIGH STRENGTH COPPER ALLOY 260 600 VOLTS ROHS.pdf

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1、AEROSPACE STANDARDWIRE, ELECTRICAL, POLYTETRAFLUOROETHYLENE/POLYMIDE INSULATED, SMOOTH SURFACE, NORMALWEIGHT, NICKEL COATED, EXTRA HIGH STRENGTH COPPER ALLOY, 260 C, 600 VOLTS ROHSAS22759TM/196Copyright 2016 SAE InternationalAll rights reserved. No part of this publication may be reproduced, stored

2、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: +1 724-776-4970 (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/196SHEET 1 OF 4PROCUREMENT SPECIFICATION: AS22759SAE Technical Standards BoardRules providethat:“This reportis publishedby SAE to advance thestateoftec

4、hnical andengineering sciences. The useofthis reportis entirely voluntary, and its applicability and suitability forany particularuse, includingany patent infringement arising therefrom, is thesole 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/AS22759/196RATIONALESPECIFICATION DEVELOPED FOR APPLICATIONS REQUIRING HIGHER CONDU

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

7、T ISSUE OF AS22759.FP / POLYIMIDE / FP TAPE FP TAPEFP FLUOROCARBON POLYMER MODIFIED POLYTETRAFLUOROETHYLENE (PTFE)CONDUCTOR STRANDED NICKEL COATED EXTRA HIGH STRENGTH COPPER ALLOYFIGURE 1 - AS22759/196 CONFIGURATIONTABLE 1 - CONSTRUCTION DETAILS FOR FINISHED WIREPART NO. 1/WIRESIZECONDUCTOR 3/ FINIS

8、HED 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 MAXM22759/196-30-*M22759/196-28-*M22759/196-26-*M22759/196-24-*M22759/196-22-*M22759/196-20-*3028262422207 X 387 X 3619 X 3819

9、X 3619 X 3419 X 320.01170.01470.01840.02310.02930.03730.01340.01640.02040.02540.03140.0404129.679.049.430.118.611.40.0260.0290.0330.0380.0430.0510.0290.0330.0370.0420.0470.0550.750.971.341.872.704.250.831.051.472.042.904.450.911.121.602.203.104.651/ PART NUMBER: THE ASTERISKS IN THE PART NUMBER COLU

10、MN OF TABLE 1 SHALL BE REPLACED BY COLOR CODE DESIGNATORS IN ACCORDANCE WITH MIL-STD-681. EXAMPLES: M22759/196-20-93 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 V

11、ALUES.3/ CONDUCTOR SHALL CONFORM TO AS29606 TYPE NCS SMALL DIAMETER NICKEL COATED EXTRA HIGH STRENGTH COPPER ALLOY CONDUCTOR.AEROSPACE STANDARDAS22759TM/196SHEET 2 OF 4WIRE, ELECTRICAL, POLYTETRAFLUOROETHYLENE/POLYMIDE INSULATED, SMOOTH SURFACE, NORMALWEIGHT, NICKEL COATED, EXTRA HIGH STRENGTH COPPE

12、R ALLOY, 260 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 MATERIALS TAPE CODE THICKNESS (NOM) MATERIAL1 0.0

13、020 0.0005 (FP)/0.0010 (POLYIMIDE)/0.0005 (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 7.428 1 50.5 54.0 2 50.5 54.0 7.426 1 50.5 54.0 2 50.5 54

14、.0 7.424 1 50.5 54.0 2 50.5 54.0 7.422 1 50.5 54.0 2 50.5 54.0 7.420 1 50.5 54.0 2 50.5 54.0 7.41/ WRAP 1 IS INNERMOST TAPE WHICH IS IN CONTACT WITH THE CONDUCTOR. 2. WIRE PERFORMANCE RATING:TEMPERATURE RATING: 260 C (500 F) MAXIMUM CONDUCTOR CONTINUOUS TEMPERATURE.VOLTAGE RATING: 600 VOLTS (RMS) AT

15、 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 RESPONSIBILITY OF THE USER.3. MATERIALS AND PHYSICAL P

16、ROPERTIES: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 PROPERTIES SHALL BE IN ACCORDANCE WITH TABLE 4.TABLE 4 - FIN

17、ISHED 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 260 C 2 C (500 F 3.6 F), 6 HOURSINSULATION BLOCKING

18、260 C 2 C (500 F 3.6 F)SHRINKAGE 290 C 2 C (554 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 REQUIRED FOR WIRE SIZES 30 - 28UV LASER MARKING 62%

19、 MINIMUM AVERAGECONTINUOUS LENGTH SCHEDULE BAEROSPACE STANDARDAS22759TM/196SHEET 3 OF 4WIRE, ELECTRICAL, POLYTETRAFLUOROETHYLENE/POLYMIDE INSULATED, SMOOTH SURFACE, NORMALWEIGHT, NICKEL COATED, EXTRA HIGH STRENGTH COPPER ALLOY, 260 C, 600 VOLTS ROHS5. FINISH WIRE IDENTIFICATION:WIRE IDENTIFICATION E

20、XCEPTIONS: 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 SHALL BE IN ACCORDANCE WITH TABLE 5.TABLE 5 - TEST MAND

21、REL AND TEST LOAD REQUIREMENTSWIRESIZE(AWG)TEST MANDREL DIAMETER 1/(INCHES)TEST LOAD 1/(LB)COLD BENDLIFE CYCLE/BEND TEST WRAP COLD BENDLIFE CYCLE/BEND TEST3028262422201.001.001.001.001.001.000.3750.3750.3750.5000.5000.5000.1250.1250.1250.1250.1250.1252.002.003.003.004.004.00 0.250.250.500.751.001.50

22、1/ TOLERANCE SHALL BE 3% 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/BRAIDS) REQUIREDTHERMAL SHOCK MECHANICAL RESISTANCE TEMPERATU

23、RE EXPOSURE 260 C 2 C (500 F 3.6 F)MAXIMUM CHANGE .091 INCHESTHERMAL MECHANICAL RESISTANCE (LIFE CYCLE)EXPOSURE 500 HOURS, 290 C 2 C (554 F 3.6 F)UV LASER CONTRAST MARKING RESISTANCE AFTER THERMAL AGING: 168 HOURSHUMIDITY RESISTANCE (IR) 5000 MEGOHMS (MIN)-1000 FEETFLUID RESISTANCE DIAMETER INCREASE

24、 5% (MAX)SMOKE RESISTANCE 260 C 5 C (500 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 LESSDRY ARC RESISTANCE MINIMUM 70 WIRES PASS WET DIELECTRIC TE

25、ST2 OR LESS WIRES FAIL IN ONE BUNDLEDAMAGE LENGTH: 1.0 INCHES OF LESSDYNAMIC CUT-THROUGH WIRE SIZE 2610 POUNDS AT 23 C, 8 POUNDS AT 150 C,6 POUNDS AT 200 C, 4 POUNDS AT 260 CWIRE SIZE 2015 POUNDS AT 23 C, 12 POUNDS AT 150 C,10 POUNDS AT 200 C, 6 POUNDS AT 260 CFORCED HYDROLYSIS INSULATION RESISTANCE

26、WIRE SIZE 2070 C 2 C (158 F 3.6 F), 5000 HOURSLONGEVITY RESISTANCE (THERMAL INDEX) 260 C 2 C (500 F 3.6 F), 10000 HOURSABRASION RESISTANCE (NEEDLE) WIRE SIZE 20SAMPLE SIZE 8 READINGS5000 MIN CYCLES, 23 C 2 C (73 F 3.6 F)3000 MIN CYCLES, 70 C 2 C (158 F 3.6 F)1000 MIN CYCLES, 150 C 2 C (302 F 3.6 F)A

27、EROSPACE STANDARDAS22759TM/196SHEET 4 OF 4WIRE, ELECTRICAL, POLYTETRAFLUOROETHYLENE/POLYMIDE INSULATED, SMOOTH SURFACE, NORMALWEIGHT, NICKEL COATED, EXTRA HIGH STRENGTH COPPER ALLOY, 260 C, 600 VOLTS ROHS7. REQUIREMENT EXCEPTION TO THE AS22759:NONEAPPLICATION NOTES1. PRODUCTS MANUFACTURED TO THIS SP

28、ECIFICATION 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.