SAE AS 5419 5-2003 WIRE THERMOCOUPLE FLUOROPOLYMER INSULATED CROSSLINKED MODIFIED ETFE NORMAL WEIGHT NICKEL CHROMIUM (KP) NICKEL ALUMINUM MANGANESE (KN) THERMOCOUPLE EXTENSION 200 .pdf

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1、 AEROSPACE STANDARD WIRE, THERMOCOUPLE, FLUOROPOLYMER INSULATED, CROSSLINKED MODIFIED ETFE, NORMAL WEIGHT, NICKEL/ CHROMIUM (KP); NICKEL/ALUMINUM/MANGANESE (KN), THERMOCOUPLE EXTENSION, 200 C AS5419/5Copyright 2014 SAE International All rights reserved. No part of this publication may be reproduced,

2、 stored 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-

3、0790 Email: CustomerServicesae.org SAE WEB ADDRESS: http:/www.sae.org ISSUED 2003-02REAFFIRMED 2014-01THIRD ANGLE PROJECTION CUSTODIAN: AE-8/AE-8D FEDERAL SUPPLY CLASS AS5419/5 SHEET 1 OF 8 SAE Technical Standards Board Rules provide that: “This report ispublishedby SAE toadvance thestate of technic

4、alandengineering sciences. Theuse ofthis report is entirely voluntary, andits applicability and suitability forany particular use,including any patent infringement arising therefrom, isthe soleresponsibilityofthe user.”SAE reviews eachtechnicalreport at least every five years at which time itmay ber

5、evised, reaffirmed, stabilized, orcancelled. SAE invites yourwrittencomments andsuggestions. SAE values your input. To provide feedbackon this Technical Report, please visit http:/www.sae.org/technical/standards/AS5419/5 RATIONALE AS5419/5 HAS BEEN REAFFIRMED TO COMPLY WITH THE SAE FIVE-YEAR REVIEW

6、POLICY. Type “K” thermocouple conductors are typically used as extension leads for aerospace application. These wires are only to be used in a matched pair and procured under AS5419. Thermocouple extension wires are calibrated for use together in fabricating thermocouples. If each leg of the thermoc

7、ouple extension wire is from a different lot, recalibration of the thermocouple pair will be required.FIGURE 1 - Wire, Thermocouple, Crosslinked Modified ETFEComponent wire insulation system must conform to the similar wire type designatedin Table 1 of AS5419. Manufacturers must be qualified to AS22

8、759/43 to produce this product.TABLE 1 - KP Construction DetailsTABLE 1A - KP Construction Details, inch-pound UnitsAEROSPACE STANDARD AS5419/5 SHEET 2 OF 8 WIRE, THERMOCOUPLE, FLUOROPOLYMER INSULATED, CROSSLINKED MODIFIED ETFE, NORMAL WEIGHT, NICKEL/ CHROMIUM (KP); NICKEL/ALUMINUM/MANGANESE (KN), T

9、HERMOCOUPLE EXTENSION, 200 CTABLE 1B - KP Construction Details, SI UnitsNotesElectromotive Force (EMF) designator = Type KPS conductor from ANSI/MC96.1 with standard limits= Type KPH conductor from ANSI/MC96.1 with special limitsExample: Size 20 standard EMF limits - SW-20KPS-9; Size 20 special EMF

10、limits - SW-20KPH-9These wires comply with the sealing range requirement for firewall connectors as specified in MIL-DTL-5015, MIL-DTL-38999, and MIL-C-83723 (superseded by MIL-C-26482 and MS3470 which are inactive for new design) except that 20 awg wire is not compatible with minimum sealing range

11、of MIL-DTL-38999 16 awg contacts and 14 awg wire is not compatible with minimum sealing range of MIL-C-83723 (superseded by MIL-C-26482 and MS3470 which are inactive for new design) and MIL-DTL-38999 12 awg contacts.TABLE 2 - KN CONSTRUCTION DETAILSTABLE 2A - KN CONSTRUCTION DETAILS, INCH-POUND UNIT

12、SAEROSPACE STANDARD AS5419/5 SHEET 3 OF 8 WIRE, THERMOCOUPLE, FLUOROPOLYMER INSULATED, CROSSLINKED MODIFIED ETFE, NORMAL WEIGHT, NICKEL/ CHROMIUM (KP); NICKEL/ALUMINUM/MANGANESE (KN), THERMOCOUPLE EXTENSION, 200 CTABLE 2B - KN Construction Details, SI UnitsNotesElectromotive Force (EMF) designator =

13、 Type KNS conductor from ANSI/MC96.1 with standard limits= Type KNH conductor from ANSI/MC96.1 with special limitsExample: Size 20 standard EMF limits - SW-20KNS-5; Size 20 special EMF limits - SW-20KNH-5These wires comply with the sealing range requirement for firewall connectors as specified in MI

14、L-DTL-5015, MIL-DTL-38999, and MIL-C-83723 (superseded by MIL-C-26482 and MS3470 which are inactive for new design) except that 20 awg wire is not compatible with minimum sealing range of MIL-DTL-38999 16 awg contacts and 14 awg wire is not compatible with minimum sealing range of MIL-C-83723 (super

15、seded by MIL-C-26482 and MS3470 which are inactive for new design) and MIL-DTL-38999 12 awg contacts.AEROSPACE STANDARD AS5419/5 SHEET 4 OF 8 WIRE, THERMOCOUPLE, FLUOROPOLYMER INSULATED, CROSSLINKED MODIFIED ETFE, NORMAL WEIGHT, NICKEL/ CHROMIUM (KP); NICKEL/ALUMINUM/MANGANESE (KN), THERMOCOUPLE EXT

16、ENSION, 200 CTABLE 3 - Performance DetailsTABLE 3A - Performance Details, inch-pound UnitsTABLE 3B - Performance Details, SI UnitsAEROSPACE STANDARD AS5419/5 SHEET 5 OF 8 WIRE, THERMOCOUPLE, FLUOROPOLYMER INSULATED, CROSSLINKED MODIFIED ETFE, NORMAL WEIGHT, NICKEL/ CHROMIUM (KP); NICKEL/ALUMINUM/MAN

17、GANESE (KN), THERMOCOUPLE EXTENSION, 200 CWIRE RATINGS AND ADDITIONAL REQUIREMENTSTEMPERATURE RATING: 200 C (392 F) max continuous conductor temperatureVOLTAGE RATING: Not applicableACCELERATED AGING: Oven temperature, 300 C 2 C (572 F 3.6 F) for 6 hours; for identification legibility 225 C 2 C (437

18、 F 3.6 F) for 6 hoursBLOCKING: 230 C 3 C (392 F 5.4 F)FLAMMABILITY: For requirements and procedures see belowHUMIDITY RESISTANCE: After humidity exposure, wire shall meet the requirement for initial insulation resistanceIDENTIFICATION: The finished wire shall be identified by a printed marking appli

19、ed to the outer surface of the wire. The printed marking shall be legible, black in color, and withstand a durability test of 125 cycles (250 strokes) (min), 500 grams weight. The size of the printed characters shall be consistent with the magnitude of the surface upon which it is printed. The dista

20、nce between the end of one mark and the beginning of the next shall be a maximum of 12 in. The printed marking shall be applied with the vertical axes of the print characters lengthwise on wire whose nominal diameter is 0.050 in (1.27 mm) or smaller. The vertical axes of the printed characters may b

21、e crosswise or lengthwise on wire whose nominal diameter is 0.051 in (1.30 mm) or larger.IMPULSE DIELECTRIC TEST: 8.0 kilovolts (peak), 100% testINSULATION RESISTANCE (min): 5,000 megohms for 1,000 ft (1,524 megohms for 1.0 km)LIFE CYCYLE: 500 hours at 230 C 3 C (446 F 5.4 F) Dielectric test, 2,500

22、volts (rms), 60 HzCROSSLINKING PROOF TEST: 7 hours at 300 C 3 C (572 F 5.4 F). Quality conformance test, Group II. Requirements and procedures as for life cycle except for time and temperature.DIELECTRIC TEST AFTER IMMERSION: 2,500 volts (rms), 60 HzINSULATION THICKNESS:0.003 in (min) for primary in

23、sulation0.004 in (min) for outer jacket0.008 in (min) for total insulationLOW TEMPERATURE (Cold Bend): Bend temperature, -65 C 3 C (-85 F 5.4 F) Dielectric test, 2,500 volts (rms), 60 HzIMMERSION: For procedure see belowPHYSICAL PROPERTIES OF INSULATION: Pulled at 2 in per minute. Primary insulation

24、 shall be separated from the outer jacket for determination of primary insulation tensile strength and elongationTensile strength, 5,000 lbf/in2(min) for primary insulation, 5,000 lbf/in2(min) for total insulation (primary insulation and jacket)Elongation, 125% (min) for primary insulation (AWG 22-1

25、4), 75% (min) for total insulation (primary insulation and jacket)PROPELLANT RESISTANCE: No dielectric breakdown. For procedure see below.SHRINKAGE: 0.125 in (max) at 200 C 3 C (392 F 5.4 F)SMOKE: 230 C 2 C (446 F 3.6 F); no visible smokeSPARK TEST OF PRIMARY INSULATION: 1,500 volts (rms), 60 HzSURF

26、ACE RESISTANCE: 500 megohms-in (min), initial and final readingsAEROSPACE STANDARD AS5419/5 SHEET 6 OF 8 WIRE, THERMOCOUPLE, FLUOROPOLYMER INSULATED, CROSSLINKED MODIFIED ETFE, NORMAL WEIGHT, NICKEL/ CHROMIUM (KP); NICKEL/ALUMINUM/MANGANESE (KN), THERMOCOUPLE EXTENSION, 200 CWIRE RATINGS AND ADDITIO

27、NAL REQUIREMENTS (Continued)THERMAL SHOCK RESISTANCE: Oven temperature, 200 C 3 C (392 F 5.4 F); max change in measurement 0.060 inWICKING: Procedure II; weight increase, no requirement. Dye travel between layers of insulation, 2.25 in (max) from end of specimenWRAP TEST: “Wrap back” test. Oven temp

28、erature, 313 C 3 C (595 F 5.4 F)FLAMMABILITY REQUIREMENTS AND PROCEDURETest in accordance with AS4373, Method 801IMMERSION PROCEDURETest in accordance with AS4373, Method 601, using the fluids of Table 4 of this supplement. Use mandrels and weights listed in Table 3 of this supplement for bend testi

29、ng. Dielectric test using 2,500 volts (rms) 60 Hz.PROPELLANT RESISTANCE PROCEDURE(Initial qualification test only) Test in accordance with AS4373, Method 605. Dielectric test using 2,500 volts (rms) 60 Hz.AEROSPACE STANDARD AS5419/5 SHEET 7 OF 8 WIRE, THERMOCOUPLE, FLUOROPOLYMER INSULATED, CROSSLINK

30、ED MODIFIED ETFE, NORMAL WEIGHT, NICKEL/ CHROMIUM (KP); NICKEL/ALUMINUM/MANGANESE (KN), THERMOCOUPLE EXTENSION, 200 CTABLE 4 - Immersion Test FluidsAEROSPACE STANDARD AS5419/5 SHEET 8 OF 8 WIRE, THERMOCOUPLE, FLUOROPOLYMER INSULATED, CROSSLINKED MODIFIED ETFE, NORMAL WEIGHT, NICKEL/ CHROMIUM (KP); N

31、ICKEL/ALUMINUM/MANGANESE (KN), THERMOCOUPLE EXTENSION, 200 CADDITIONAL CONDUCTOR REQUIREMENTSSTRAND MATERIAL: Type KPH and KPS strands shall be made from an alloy of 90% nickel - 10% chromium and Type KNH and KNS strands shall be made from an alloy of 95% nickel - 2% aluminum - 2% manganese - 1% sil

32、icon and minor traces of other materials and shall conform to ANSI-MC96.1.SPLICES: Splices in individual strands or groups of individual strands shall be butt brazed with silver solder. Splices shall be so constructed and disposed throughout the conductor that the diameter, configuration, conductor

33、resistance, flexibility, and mechanical strength of the completed conductor are not adversely affected.SOLDERABILITY: Not applicableELONGATION: Not applicableTENSILE STRENGTH: Not applicableELECTROMOTIVE FORCE: EMF shall conform to ANSI/MC96.1 whereas Type KPS and KNS are used for standard EMF limits, Type KPH and KNH for special limitsCOATING: Not applicableNOTEThe wires form a thermocouple and are intended for use as the extension portion of the thermocouple system.