SAE AS 22759 85D-2017 WIRE ELECTRICAL POLYTETRAFLUOROETHYLENE POLYMIDE INSULATED NORMAL WEIGHT TIN COATED COPPER CONDUCTOR 150 600 VOLT ROHS.pdf

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1、 AEROSPACE STANDARD WIRE, ELECTRICAL, POLYTETRAFLUOROETHYLENE/ POLYMIDE INSULATED, NORMAL WEIGHT, TIN COATED COPPER CONDUCTOR, 150 C, 600 VOLT, ROHS AS22759/85Copyright 2017 SAE International All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmit

2、ted, 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: CustomerServicesae.org SAE WE

3、B ADDRESS: http:/www.sae.org ISSUED2000-06REVISED2017-09THIRD ANGLE PROJECTION CUSTODIAN: AE-8/AE-8D REV.D FEDERAL SUPPLY CLASS 6145 AS22759 /85 SHEET 1 OF 5 REV. D PROCUREMENT SPECIFICATION: NONE SAE Technical Standards Board Rules provide that: “This report is published by SAEtoadvance thestate of

4、 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 fiveyears at whichtime i

5、t 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/AS22759/85D RATIONALE SPECIFICATION UPDATED TO INCLUDE AS29606 CONDUCTOR REQUIREMENTS, R

6、OHS 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 CREATED IN 1971. CONDU

7、CTOR 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 CONDUCTOR PRODUCERS WERE PRODUCI

8、NG 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 SAME TIME, LARGE GAUGE SIZE

9、 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 ELECTRICAL POWER CAUSED SIG

10、NIFICANT 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 PREVENT THE CRIMP FAILURES

11、. 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 THE REQUIRED CONDUCTOR SP

12、ECIFICATION. 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 - 2000 TIME FRAME. SINCE THE EPL NO LONGER HAD LEGAL STANDING AFTER THE CONVERSION, WIRE PRODUCERS

13、 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 COMMITTEE DECIDED TO ADOPT

14、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 PERCENT. THE COMMITTEE EVA

15、LUATED 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 PRODUCTS ARE PRIMARILY

16、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 THAT THE NEW WEIGHT

17、 RANGES MEET THE DESIGN REQUIREMENTS OF LEGACY APPLICATIONS. NOTICE THE COMPLETE REQUIREMENTS FOR PROCURING THE PRODUCT DESCRIBED HEREIN SHALL CONSIST OF THIS DOCUMENT AND THE LATEST ISSUE OF AS22759. THIS SPECIFICATION IS NOT INTENDED FOR USE IN NAVAL AIRCRAFT OR NAVAL AIR SYSTEMS APPLICATIONS. AER

18、OSPACE STANDARD AS22759 /85 SHEET 2 OF 5 REV. D WIRE, ELECTRICAL, POLYTETRAFLUOROETHYLENE/ POLYMIDE INSULATED, NORMAL WEIGHT, TIN COATED COPPER CONDUCTOR, 150 C, 600 VOLT, ROHS FP / POLYIMIDE / FP TAPE FP TAPE FP TAPE META-ARAMID FIBER BRAID TREATED TO PREVENT FRAYING 1/ SIZE 8 THROUGH 6 FP / POLYIM

19、IDE / FP TAPE FP TAPE FP TAPE FP TAPE META-ARAMID FIBER BRAID TREATED TO PREVENT FRAYING 1/ SIZE 4 THROUGH 04 FP FLUOROCARBON POLYMER MODIFIED POLYTETRAFLUOROETHYLENE (PTFE) CONDUCTOR STRANDED TIN COATED COPPER 1/ BRAID: BRIGHT AROMATIC POLYAMIDE YARN, 200 DENIER, 100 FILAMENTS, TIGHTLY FORMED, UNIF

20、ORM IN APPEARANCE, TREATED WITH A CLEAR FINISHER COATING. THE FINISHER COATING SHALL BE COMPATIBLE WITH THE TEMPERATURE RATING AND PERFORMANCE REQUIREMENTS OF THE INSULATED WIRE. BRAID SHALL GRIP THE UNDERLYING INSULATION SUFFICIENTLY AS TO NOT SLIDE ALONG THE TAPE SURFACE DURING NORMAL HANDLING. FI

21、GURE 1 - AS22759/85 CONFIGURATION AEROSPACE STANDARD AS22759 /85 SHEET 3 OF 5 REV. D WIRE, ELECTRICAL, POLYTETRAFLUOROETHYLENE/ POLYMIDE INSULATED, NORMAL WEIGHT, TIN COATED COPPER CONDUCTOR, 150 C, 600 VOLT, ROHS TABLE 1 - CONSTRUCTION DETAILS FOR FINISHED WIRE PART NO. 1/ WIRE SIZE CONDUCTOR 3/ FI

22、NISHED WIRE STRANDING (NUMBER OF STRANDS X SIZE GAUGE OF STRANDS) DIAMETER (IN) RESISTANCE AT 20 C (68 F) (OHMS/1000 FEET MAX) DIAMETER (IN) WEIGHT (LB/1000 FEET) 2/ MIN MAX MIN MAX MIN TARGET MAX M22759/85-8 M22759/85-6 M22759/85-4 M22759/85-2-* M22759/85-1-* M22759/85-01-* M22759/85-02-* M22759/85

23、-03-* M22759/85-04-* 8 6 4 2 1 0 00 000 0000 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 .158 .198 .250 .320 .360 .395 .440 .500 .565 .169 .212 .268 .340 .380 .425 .475 .540 .605 .701 .445 .280 .183 .149 .116 .091 .071 .056 .192 .231 .288 .356 .400 .432 .487

24、.542 .602 .213 .254 .313 .389 .433 .475 .530 .585 .655 59.0 91.8 144 220 268 339 422 539 654 61.1 94.3 148 229 277 352 442 554 675 63.2 96.8 152 238 286 365 462 569 696 1/ PART NUMBER: THE PREFERRED COLOR IS DARK GREEN WITH THE COLOR DESIGNATOR 5D. EXAMPLE: SIZE 2 DARK GREEN - AS22759/85-2-5D. WHITE

25、 IS AN ACCEPTABLE ALTERNATE WITH A COLOR DESIGNATOR 9. 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 VALUES. 3/ CONDUCTOR SHALL CONFORM TO AS29606 TYPE TCC SMALL DIAMETER TIN COATED COPPER CONDUCTOR FO

26、R WIRE SIZES 8 THROUGH 4 AND GENERAL PURPOSE FOR WIRE SIZES 2 THROUGH 0000. REQUIREMENT: 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

27、MATERIALS TAPE CODE THICKNESS NOMINAL MATERIAL 1 2 3 4 .0020 .0020 .0030 .0010 .0005 (FP)/.0010 (POLYIMIDE)/.0005 (FP) FP (SKIVED) FP (UNSINTERED OR PRESINTERED BONDABLE) FP (SKIVED) TABLE 3 - TAPE OVERLAP REQUIREMENTS 1/ WIRE SIZE WRAP 1 WRAP 2 WRAP 3 WRAP 4 NOMINAL WALL THICKNESS (MILS) 2/ TAPE CO

28、DE PERCENT OVERLAP TAPE CODE PERCENT OVERLAP TAPE CODE PERCENT OVERLAP TAPE CODE PERCENT OVERLAP MIN MAX MIN MAX MIN MAX MIN MAX 8 4 20.5 35.0 1 50.5 55.0 3 67.0 71.0 13.2 6 4 20.5 35.0 1 50.5 55.0 3 67.0 71.0 13.2 4 2 20.5 35.0 1 50.5 55.0 3 50.5 54.0 3 50.5 54.0 16.2 2 2 20.5 35.0 1 50.5 55.0 3 50

29、.5 54.0 3 50.5 54.0 16.2 1 2 20.5 35.0 1 50.5 55.0 3 50.5 54.0 3 50.5 54.0 16.2 1/0 2 20.5 35.0 1 50.5 55.0 3 50.5 54.0 3 50.5 54.0 16.2 2/0 2 20.5 35.0 1 50.5 55.0 3 50.5 54.0 3 50.5 54.0 16.2 3/0 2 20.5 35.0 1 50.5 55.0 3 50.5 54.0 3 50.5 54.0 16.2 4/0 2 20.5 35.0 1 50.5 55.0 3 50.5 54.0 3 50.5 54

30、.0 16.2 1/ WRAP 1 IS INNERMOST TAPE WHICH IS IN CONTACT WITH THE CONDUCTOR. WRAPS 2, 3, AND 4 ARE PROGRESSIVELY FURTHER AWAY FROM THE CONDUCTOR CORE. 2/ NOMINAL WALL THICKNESS DOES NOT INCLUDE THE POLYAMIDE BRAID THICKNESS. AEROSPACE STANDARD AS22759 /85 SHEET 4 OF 5 REV. D WIRE, ELECTRICAL, POLYTET

31、RAFLUOROETHYLENE/ POLYMIDE INSULATED, NORMAL WEIGHT, TIN COATED COPPER CONDUCTOR, 150 C, 600 VOLT, ROHS 2. WIRE PERFORMANCE RATING: TEMPERATURE RATING: 150 C (302 F) MAXIMUM CONDUCTOR CONTINUOUS TEMPERATURE. VOLTAGE RATING: 600 VOLTS (RMS) AT SEA LEVEL. THIS INSULATION SYSTEM HAS BEEN USED IN AEROSP

32、ACE 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 PROPERTIES: SEE AS22759 FOR MATERIAL REQUIREMENT. MATERIAL

33、S 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 - FINISHED WIRE INSULATION PROPERTIES REQUIREMENTS INSULATI

34、ON PROPERTIES IMPULSE TEST VOLTAGE 8.0 KILOVOLTS (PEAK) HIGH FREQUENCY TEST VOLTAGE 5.7 KILOVOLTS (RMS) TAPE OVERLAP TABLE 3 LAMINATION SEALING 260 C 2 C (500 F 3.6 F), 6 HOURS INSULATION BLOCKING 200 C 2 C (392 F 3.6 F) SHRINKAGE 230 C 2 C (446 F 3.6 F) MAXIMUM CHANGE .125 INCHES ELECTRICAL RESISTA

35、NCE (IR) 3000 MEGOHMS (MIN)-1000 FEET WET DIELECTRIC VOLTAGE 2500 VOLTS (RMS), 60 HERTZ CONTINUOUS LENGTH SCHEDULE B 5. FINISH WIRE IDENTIFICATION: WIRE IDENTIFICATION EXCEPTIONS: NONE WIRE IDENTIFICATION DURABILITY: NOT REQUIRED STRIPE AND BAND DURABILITY: NOT REQUIRED 6. FINISH WIRE PERFORMANCE: F

36、INISH WIRE FIXTURES APPLICABLE TO EACH WIRE SIZE SHALL BE IN ACCORDANCE WITH TABLE 5. TABLE 5 - TEST MANDREL AND TEST LOAD REQUIREMENTS WIRE SIZE (AWG) TEST MANDREL DIAMETER 1/ (INCHES) TEST LOAD 1/ (LB) COLD BEND LIFE CYCLE/ BEND TEST WRAP COLD BEND LIFE CYCLE/ BEND TEST 8 6 4 2 1 0 00 000 0000 4.0

37、0 5.00 6.00 8.00 10.00 10.00 12.00 18.00 18.00 3.00 4.00 5.00 6.00 8.00 8.00 10.00 10.00 10.00 .750 1.00 1.25 2.00 2.50 3.00 4.00 5.00 6.00 10.00 10.00 15.00 15.00 15.00 15.00 20.00 30.00 30.00 4.00 4.00 4.50 6.00 6.00 6.00 8.00 10.00 10.00 1/ TOLERANCE SHALL BE 3% OF THE GIVEN VALUES. AEROSPACE STA

38、NDARD AS22759 /85 SHEET 5 OF 5 REV. D WIRE, ELECTRICAL, POLYTETRAFLUOROETHYLENE/ POLYMIDE INSULATED, NORMAL WEIGHT, TIN COATED COPPER CONDUCTOR, 150 C, 600 VOLT, ROHS FINISH WIRE PERFORMANCE CHARACTERISTICS SHALL BE IN ACCORDANCE WITH TABLE 6. TABLE 6 - FINISH WIRE PERFORMANCE CHARACTERISTICS PERFOR

39、MANCE CHARACTERISTIC REQUIREMENT MANDREL BEND RESISTANCE (TAPES/BRAIDS) REQUIRED THERMAL SHOCK MECHANICAL RESISTANCE TEMPERATURE EXPOSURE 200 C 2 C (392 F 3.6 F) MAXIMUM CHANGE .125 INCHES THERMAL MECHANICAL RESISTANCE (LIFE CYCLE) EXPOSURE 500 HOURS, 230 C 2 C (446 F 3.6 F) HUMIDITY RESISTANCE (IR)

40、 3000 MEGOHMS (MIN)-1000 FEET FLUID RESISTANCE DIAMETER INCREASE 5% (MAX) SMOKE RESISTANCE 200 C 5 C (392 F 9 F) FLAME RESISTANCE SELF-EXTINGUISH TIME: 3 SECONDS BURN LENGTH 3 INCHES 7. REQUIREMENT EXCEPTION TO THE AS22759: NONE APPLICATION NOTES 1. PRODUCTS MANUFACTURED TO THIS SPECIFICATION ARE RO

41、HS COMPLIANT. SPECIFICATION NOTES 1. 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 THAT CONTAIN EDITORIAL CHANGES ONLY.