SAE AS 81824 12A-2016 SPLICE ELECTRIC PERMANENT CRIMP STYLE TIN-COATED COPPER INSULATED ENVIRONMENT RESISTANT CLASS 1 150 C HEATLESS SEALING.pdf

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1、 AEROSPACE STANDARD SPLICE, ELECTRIC, PERMANENT, CRIMP STYLE, TIN- COATED COPPER, INSULATED, ENVIRONMENT RESISTANT, CLASS 1, 150 C, HEATLESS SEALING AS81824/12Copyright 2016 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 ISSUED2011-04 REVISED2016-04THIRD ANGLE PROJECTION CUSTODIAN: AE-8/AE-8C2 REV.A FEDERAL SUPPLY CLASS 5940 AS81824/12 SHEET 1 OF 4 REV. A PROCUREMENT SPECIFICATION: AS81824 SAE Technical Standards BoardRules providethat:“This reportis published bySAEto advance the state o

4、ftechnicaland engineering sciences. The use of this report isentirely voluntary, andits applicability andsuitability for any particularuse, includingany patentinfringement arising therefrom,is the soleresponsibility of theuser.”SAE reviews eachtechnical reportatleast every fiveyears atwhichtimeitmay

5、 berevised,reaffirmed, stabilized,orcancelled. SAE invites yourwrittencomments andsuggestions.SAE values your input. To provide feedback on this Technical Report, please visit http:/www.sae.org/technical/standards/AS81824/12A RATIONALE REMOVE INSTALLATION TOOLING DETAILS WITH THE PUBLICATION OF AS22

6、520/44. HEAT AGING TEMPERATURE REVISED TO BE COMPATIBLE WITH THE NOT TO EXCEED HEATING STATEMENT IN THE APPLICATION NOTE. NOTICE THE COMPLETE REQUIREMENTS FOR PROCURING THE PRODUCT DESCRIBED HEREIN SHALL CONSIST OF THIS DOCUMENT AND THE LATEST ISSUE OF AS81824. FIGURE 1 - HEATLESS SEALED SPLICE TABL

7、E 1 - CONSTRUCTION DETAILS INCHES (MM) PART NUMBER WIRE SIZE RANGE WIRE O.D. RANGE A MAX B r.005 (0.1) C r.008 (0.2) D r.020 (0.5) E r.010 (0.3) F r.020 (0.5) (L) END CAP COLOR CODE (2 PL) M81824/12-1 26-24-22-20 .04-.07 (1.0-1.8) .170 (4.3) .048 (1.2) .097 (2.5) .475 (12.1) .140 (3.6) .500 (12.7) 1

8、.475 (37.5) RED M81824/12-2 18-16 .06-.10 (1.5-2.5) .205 (5.2) .070 (1.8) .133 (3.4) .575 (14.6) .120 (3.0) .465 (11.8) 1.505 (38.1) BLUE M81824/12-3 14-12 .08-.14 (2.0-3.6) .240 (6.1) .095 (2.4) .157 (4.0) .575 (14.6) .120 (3.0) .465 (11.8) 1.505 (38.1) YELLOW NOTES: 1. CONDUCTOR VIEWING WINDOW AND

9、 WIRE STOP CONFIGURATION MAY VARY FROM THAT SHOWN. 2. CONTOURS MAY VARY FROM THAT SHOWN. 3. UNLESS OTHERWISE INDICATED, DIMENSIONS ARE IN INCHES (MM). 4. METRIC EQUIVALENTS TO THE NEAREST 0.1 MM ARE GIVEN FOR GENERAL INFORMATION AND REFERENCE ONLY. VALUES ARE CALCULATED AND ROUNDED ON 1 INCH = 25.4

10、MM INSULATION SLEEVE COLOR CODED END CAP IN ACCORDANCE WITH TABLE I (2PL) D EB A C WIRE STOP VIEWING WINDOW SEE TABLE 1. F (2 PL) L (REF) SEALANT (2 PL) METAL CRIMP BARREL AEROSPACE STANDARD AS81824/12 SHEET 2 OF 4 REV. A SPLICE, ELECTRIC, PERMANENT, CRIMP STYLE, TIN- COATED COPPER, INSULATED, ENVIR

11、ONMENT RESISTANT, CLASS 1, 150 C, HEATLESS SEALING MATERIALS: 1. CRIMP BARREL: COPPER PER ASTM B280, ASTM B75, ASTM F68, OR ASTM B187. 2. METAL FINISH: TIN PLATED. 3. INSULATION SLEEVE: TRANSPARENT POLYVINYLIDENE FLUORIDE PER AMS-DTL-23053/8. 4. SEALANT MATERIAL: TRANSPARENT CROSSLINKED GEL. 5. END

12、CAPS: THERMOPLASTIC. COLOR CODED PER TABLE 1. REQUIREMENTS: 1. CONSTRUCTION: THE SPLICE ASSEMBLY SHALL CONSIST OF A ONE-PIECE-ASSEMBLY WHICH INCLUDES THE SEALING SLEEVE WITH SELF-CONTAINED GEL SEALANT, METAL CRIMP BARREL, AND COLOR CODED END CAPS. 2. SPLICE ASSEMBLY (TRANSPARENT - SLEEVE AND GEL) SH

13、ALL PERMIT VISUAL EXAMINATION OF THE WIRE AS IT IS INSTALLED IN THE SPLICE ASSEMBLY. THE WIRE CONDUCTOR ENDS SHALL BE VISIBLE AGAINST THE WIRE STOP PRE AND POST CRIMPING OPERATION. 3. CONTINUOUS OPERATING TEMPERATURE SHALL BE -55 TO +150 C. 4. QUALIFICATION TESTS SHALL BE IN ACCORDANCE WITH AS81824

14、QUALIFICATION INSPECTION TABLE EXCEPT AS FOLLOWS: a. TWENTY-FOUR SAMPLES SHALL BE TESTED FOR EACH DASH NUMBER AND DISTRIBUTED IN ACCORDANCE WITH AS81824 QUALIFICATION INSPECTION TABLE EXCEPT GROUP VIII SHALL BE 8 SAMPLES. b. SPLICE ASSEMBLIES SHALL BE MADE IN ACCORDANCE WITH THE SUPPLIER ASSEMBLY IN

15、STRUCTIONS WITH AS22752/82 WIRE FOR AS81824/12-1, AND AS22759/92 WIRE FOR AS81824/12-2 AND -3. NO ETCHING OR SOLVENT TREATING OF THE ASSOCIATED WIRE INSULATION SHALL BE PERMITTED. THE SAMPLES SHALL BE CRIMPED USING THE CRIMP TOOL SPECIFIED IN TABLE 2. GROUPS II AND III ARE NOT APPLICABLE. c. UNRESTR

16、ICTED RECOVERY AND LONGITUDINAL CHANGE: TESTS ARE NOT APPLICABLE. d. GROUP V. MODIFIED TEMPERATURE CYCLING AND HEAT AGING TEST: THE HEAT AGING TEST SHALL BE PERFORMED AT THE MAXIMUM RATED TEMPERATURE (SEE REQUIREMENT PARAGRAPH 3) FOR THE DURATION OF 2250 HOURS. THE SPLICE ASSEMBLY SHALL BE MOUNTED V

17、ERTICALLY WITH A FILTER PAPER POSITIONED BELOW THE SPLICE ASSEMBLY (SEE FIGURE 2). ANY LEAKAGE OF THE SEALANT MIGRATED ONTO THE FILTER PAPER AROUND THE WIRE SHALL BE CONSIDERED AS A FAILURE OF THE SPLICE ASSEMBLY. IN THE TEST SET UP, WIRE SHALL PENETRATE THE FILTER PAPER BY THE OPENING MADE BY A CRO

18、SS CUT. LEGS OF THE CROSS SHALL BE APPROXIMATELY EQUAL TO THE OUTER DIAMETER OF THE WIRE SUCH THAT THE PAPER IS IN CONTACT WITH THE WIRE JACKET DURING THE TEST. THE FILTER PAPER SHALL BE LOCATED AT A DISTANCE EQUAL TO THE OUTER DIAMETER OF THE SPLICE (SEE “A” IN TABLE 1). 5. GROUP VI. VIBRATION: VIB

19、RATIONS SHALL INCLUDE AN 18 HOUR THIRD AXIS (VERTICAL). ANY LEAKAGE OF THE SEALING GEL DURING VIBRATION IN ANY OF THE THREE AXES OF VIBRATION SHALL BE CONSIDERED AS A FAILURE OF THE SPLICE ASSEMBLY. SAMPLES SHALL PASS ALL REMAINING TESTS IN GROUP V. AEROSPACE STANDARD AS81824/12 SHEET 3 OF 4 REV. A

20、SPLICE, ELECTRIC, PERMANENT, CRIMP STYLE, TIN- COATED COPPER, INSULATED, ENVIRONMENT RESISTANT, CLASS 1, 150 C, HEATLESS SEALING FIGURE 2 - FIXTURE FOR TEMPERATURE CYCLING AND HEAT AGING TEST TOOLING: 1. THE CRIMPING TOOL NUMBER M22520/44-01 IS RECOMMENDED. TABLE 2 - CRIMP TOOL TABLE 3 - M22520/39-0

21、3 IN-SERVICE INSPECTION GAGE GAGING LIMITS WIRE SIZE GO TIP POSITION (STEP) NO-GO TIP POSITION (STEP) 20-26 A (1STSTEP) F (1STSTEP) 16-18 B (2NDSTEP) E (2NDSTEP) 12-14 C (3RDSTEP) D (3RDSTEP) SPLICE PART NO. CRIMP TOOL NO. M81824/12-1 M22520/44-01 M81824/12-2 M22520/44-01 M81824/12-3 M22520/44-01 CR

22、IMP SPLICE FILTER PAPER DIAMETER 3.54 IN (90MM) SPLICE DIAMETER AS22759/11 WIRE (SEE REQUIREMENT) AEROSPACE STANDARD AS81824/12 SHEET 4 OF 4 REV. A SPLICE, ELECTRIC, PERMANENT, CRIMP STYLE, TIN- COATED COPPER, INSULATED, ENVIRONMENT RESISTANT, CLASS 1, 150 C, HEATLESS SEALING APPLICATION NOTES: 1. T

23、HE SPLICE IS NOT RECOMMENDED FOR APPLICATION OF CONTINUOUS OPERATING TEMPERATURE ABOVE 150 C. SEE AS81824 FOR LISTING OF HIGHER TEMPERATURE SPLICES. WARNING: DO NOT USE A HEATING TOOL TO SHRINK THE OUTER SLEEVE DURING THE INSTALLATION OR TO SEAL THIS SPLICE. IF A HEATING TOOL IS USED TO HEAT THE OUT

24、ER SLEEVE DURING INSTALLATION, THE SPLICE WILL BE PERMANENTLY DAMAGED AND MUST BE REPLACED. 2. THIS SPLICE MAY BE USED IN APPLICATIONS WHERE AS81824/1 SPLICES ARE USED IF DIMENSIONAL DIFFERENCES DO NOT IMPACT THE FIT. 3. INTENDED USE: a. THIS SPLICE IS INTENDED FOR USE IN MAKING ENVIRONMENTALLY PROT

25、ECTED PERMANENT JOINTS CONNECTING ONE TO ONE WIRES FOR WIRES FALLING WITHIN THE DIAMETER RANGE SPECIFIED IN THIS SPECIFICATION WITHOUT THE APPLICATION OF HEAT (HEATLESS INSTALLATION). b. THE CRIMPING OF THIS DEVICE IS INTENDED TO BE PERFORMED OVER THE INSULATION TUBING. CRIMPING WIRES INTO THE SPLIC

26、E IS PERFORMED WITHOUT REMOVING THE INSULATION SLEEVE. THE SPLICE IS LOADED INTO THE DESIGNATED CRIMP TOOL AND CRIMPED ON THE INSULATION SLEEVE. 4. THIS SPLICE MAY BE USED WITH TIN, NICKEL, AND SILVER COATED CONDUCTORS, WHICH FALL WITHIN THE WIRE RANGE AS INDICATED IN THIS SPECIFICATION. THE APPLICA

27、TION SHALL NOT EXCEED THE 150 C RATING OF THE SPLICE. 5. REFER TO MANUFACTURERS INSTALLATION INSTRUCTIONS FOR INSTALLING DETAILS. 6. COLOR CODED WIRE STRIP LENGTH REFERENCE SLOT IS INCLUDED ON DESIGNATED CRIMP TOOLS MEETING AS22520/44. SPECIFICATION NOTES: 1. REVISION INDICATOR: A CHANGE BAR (I) LOC

28、ATED 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.