DLA DSCC-DWG-04042 REV C-2010 WIRE ELECTRICAL COMPOSITE POLYTETRAFLUOROETHYLENE POLYIMIDE INSULATED NORMAL WEIGHT TIN COATED COPPER CONDUCTOR 150 DEGREES C 600 VOLT.pdf

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1、REVISIONS LTR DESCRIPTION DATE APPROVED A Modifications to agree with SAE-AS22759/88. Editorial changes throughout. Update format. 6/22/07 Lee Suroweic B Added approved supplier. Technical modifications to agree with SAE-AS22759/88. Editorial changes throughout. Added approved supplier. New paragrap

2、h 3.3.1.1; pure tin. 30 March 2009 Abdo Abdouni C Added approved supplier. 8 September 2010 Abdo Abdouni Prepared in accordance with ASME Y14.100 Selected item drawing REV PAGE REV STATUS OF PAGES REV C B B B B B B B B C C PAGE 1 2 3 4 5 6 7 8 9 10 11 PMIC PREPARED BY DEFENSE SUPPLY CENTER, COLUMBUS

3、 COLUMBUS, OHIO 43218-3990 William Carpenter Original date of drawing 12 July 2004 CHECKED BY TITLE Lee Surowiec WIRE, ELECTRICAL, COMPOSITE, POLYTETRAFLUOROETHYLENE/POLYIMIDE INSULATED, NORMAL WEIGHT, TIN COATED, COPPER CONDUCTOR, 150C, 600 VOLT APPROVED BY Richard L. Taylor SIZE CAGE CODE DWG. NO.

4、 04042 A 037Z3 REV C PAGE 1 OF 11 AMSC N/A 6145-E096-003 CURRENT DESIGN ACTIVITY CAGE CODE 037Z3 HAS CHANGED NAMES TO: DLA LAND AND MARITIME COLUMBUS, OHIO 43218-3990 Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-DEFENSE SUPPLY CENTER, COLUMBUS COL

5、UMBUS, OH 43218-3990 SIZE CAGE CODE DWG NO. A 037Z3 04042 REV B PAGE 2 FP Fluorocarbon Polymer, modified Polytetrafluoroethylene (PTFE) FIGURE 1. General configuration. FP / POLYIMIDE / FP TAPE CONDUCTOR, STRANDED, SMALL DIAMETER, TIN COATED COPPER FP / POLYIMIDE / FP TAPE FP TAPE CONDUCTOR, STRANDE

6、D, SMALL DIAMETER, TIN COATED COPPER FP TAPE CONDUCTOR, STRANDED, SMALL DIAMETER, TIN COATED COPPER FP / POLYIMIDE / FP TAPE FP TAPE SIZES 8 THROUGH 6 SIZES 4 THROUGH 4/0 SIZES 26 THROUGH 10 Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-DEFENSE SUP

7、PLY CENTER, COLUMBUS COLUMBUS, OH 43218-3990 SIZE CAGE CODE DWG NO. A 037Z3 04042 REV B PAGE 3 1 SCOPE 1.1 Scope. This drawing covers the performance characteristics for a composite wire using a seamless polytetrafluoroethylene/hydrolysis resistant polyimide tape wrap insulation system, with a norma

8、l weight stranded conductor. 1.2 Part or Identifying Number (PIN). The complete PIN should be as follows: 04042 - 20 - 9 TABLE I. Details of construction (AWG conductors). PIN Wire size (AWG) Conductor Finished wire Stranding (number of strands X gauge (AWG) of strands) Diameter (inches) Resistance

9、at 20C ohms/1000ft. (max) Diameter (inches) Weight lb/1000ft. (max) Min Max Min Max 04042-26-* 26 19 X 38 .0175 .0204 41.3 .033 .037 1.55 04042-24-* 24 19 X 36 .0225 .0244 26.2 .038 .042 2.20 04042-22-* 22 19 X 34 .0285 .0314 16.2 .043 .047 3.00 04042-20-* 20 19 X 32 .0365 .0394 9.88 .051 .055 4.55

10、04042-18-* 18 19 X 30 .0455 .0494 6.23 .061 .065 6.70 04042-16-* 16 19 X 29 .0515 .0554 4.81 .068 .073 8.60 04042-14-* 14 19 X 27 .0645 .0694 3.06 .081 .086 12.95 04042-12-* 12 37 X 28 .0835 .0894 2.02 .100 .105 20.1 04042-10-* 10 37 X 26 .106 .112 1.26 .122 .127 31.4 04042-8-* 8 133 X 29 .158 .169

11、.701 .180 .188 57.6 04042-6-* 6 133 X 27 .198 .212 .445 .219 .229 88.3 04042-4-* 4 133 X 25 .250 .268 .280 .276 .288 143 04042-2-* 2 665 X 30 .320 .340 .183 .344 .364 223 04042-1-* 1 817 X 30 .366 .380 .149 .388 .408 289 04042-01-* 0 1045 X 30 .395 .425 .116 .420 .450 345 04042-02-* 00 1330 X 30 .44

12、0 .475 .091 .475 .505 432 04042-03-* 000 1665 X 30 .500 .540 .071 .530 .560 542 04042-04-* 0000 2109 X 30 .565 .605 .056 .590 .630 681 * The asterisks in the PIN column of table I should be replaced by color code designators (see 1.2.2). Example: 04042-26-93 is white with an orange stripe. 1.2.2 Col

13、or. The wire insulation color should be indicated by the color designator (see 1.2) and as specified in the contract. The insulation color should be in accordance with MIL-STD-681, system 1, differentiation color coding chassis wiring (3 numbers maximum). For laser marked wires, color limits should

14、be in accordance with MIL-STD-104, class I, or in accordance with table V of this drawing. Wire size (see table I) DSCC drawing number Insulation color designator (see table I) Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-DEFENSE SUPPLY CENTER, CO

15、LUMBUS COLUMBUS, OH 43218-3990 SIZE CAGE CODE DWG NO. A 037Z3 04042 REV B PAGE 4 2. APPLICABLE DOCUMENTS 2.1 Government documents. 2.1.1 Specifications, standards, and handbooks. The following specifications, standards, and handbooks form a part of this document to the extent specified herein. Unles

16、s otherwise specified, the issues of these documents are those cited in the solicitation or contract. DEPARTMENT OF DEFENSE STANDARDS MIL-STD-104 - Limits for Electrical Insulation Color MIL-STD-681 - Identification Coding and Application of Hookup and Lead Wire MIL-STD-2223 - Test Methods for Insul

17、ated Electric Wire (Copies of these documents are available online at https:/assist.daps.dla.mil/quicksearch/ or from the Standardization Document Order 700 Robbins Avenue, Building 4D, Philadelphia, PA 19111-5094.) 2.2 Non-government publications. The following documents form a part of this documen

18、t to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract. ASTM INTERNATIONAL ASTM B33 - Standard Specification for Tinned Soft or Annealed Copper Wire for electrical Purposes ASTM D3032 - Standard Test Methods for Hoo

19、kup Wire Insulation ASTM D4591 - Standard Test Method for Determining Temperatures and Heats of Transitions of Fluoropolymers by Differential Scanning Calorimetry (Copies of these documents are available from http:/www.astm.org/ or ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshoh

20、ocken, Pennsylvania, USA 19428-2959.) NCSL INTERNATIONAL NCSL Z540.3 - Laboratories Calibration and Measuring and Test Equipment (Copies of these documents are available from http:/www.ncsli.org or to National Conference of Standards Laboratories (NCSL), 2995 Wilderness Place, Suite 107, Boulder, CO

21、 80301-5404.) SAE INTERNATIONAL SAE-AS4373 - Test Methods for Insulated Electric Wire SAE-AS22759 - Wire, Electrical, Fluoropolymer-Insulated, Copper or Copper Alloy SAE-AS22759/88 - Wire, Electrical, Polytetrafluoroethylene/polyimide Insulated, Normal Weight, Tin Coated, Copper Conductor, 150C, 600

22、 Volts (Copies of these documents are available from http:/www.sae.org/ or SAE International, 400 Commonwealth Drive, Warrendale, PA 15096-0001). Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-DEFENSE SUPPLY CENTER, COLUMBUS COLUMBUS, OH 43218-3990

23、SIZE CAGE CODE DWG NO. A 037Z3 04042 REV B PAGE 5 3. REQUIREMENTS 3.1 DSCC requirements. Items described in this drawing shall meet the requirements of SAE-AS22759 and SAE-AS22759/88 except as specified herein. Any requirements included in this drawing shall be in addition to, or supersede those req

24、uirements included in SAE-AS22759 and SAE-AS22759/88. In case of conflict between the requirements in this drawing, SAE-AS22759 and SAE-AS22759/88, the requirements of this drawing shall take precedence. 3.2 Design configuration. The design, construction, and physical dimensions shall be as specifie

25、d in this drawing. The polyimide tape shall be hydrolysis resistant. 3.2.1 Design documentation. Design documentation shall be retained by the manufacturer and shall be available upon request for review by the contracting activity, DSCC, or contractor. 3.3 Material. 3.3.1 Conductor. Conductors shall

26、 be made of soft annealed copper wire in accordance with ASTM B33 and table I of this drawing. All strands shall be free from lumps, kinks, splits, scarred or corroded surfaces and skin impurities. 3.3.1.1 Pure tin. The use of pure tin is prohibited both internally and externally. Tin content of wir

27、e components, braids, jackets and solder shall not exceed 97 percent. Tin shall be alloyed with a minimum of 3 percent lead (see 6.9). 3.3.2 Insulation. Insulation shall be polytetrafluoroethylene and polytetrafluoroethylene/polyimide tape specified in tables II and III. The polyimide tape shall be

28、hydrolysis resistant. TABLE II. Wire insulation materials. 1/ Tape code Thickness nominal (inches) Material 1 .0020 .0005 FP/.0010 polyimide/.0005 FP 2 .0010 FP (Skived) 3 .0020 FP (Skived) 4 .0020 FP (Unsintered) 5 .0025 FP (Unsintered) 6 .0030 FP (Unsintered) 1/ Physical properties of PTFE unsinte

29、red tape shall be in accordance with SAE-AS22759. TABLE III. Physical properties of FP/Polyimide/FP tapes. Tensile strength 19,000 lb/in2(average min) Tensile modulus 350,000 lb/in2(average min) Elongation 40 percent (average min) Dielectric strength 4,000 volts/mil (average min) .0005 FP Layer Dist

30、inguishable color (next to conductor) may be used at manufacturers option Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-DEFENSE SUPPLY CENTER, COLUMBUS COLUMBUS, OH 43218-3990 SIZE CAGE CODE DWG NO. A 037Z3 04042 REV B PAGE 6 3.4 Wire construction

31、and physical dimensions. See figure 1 and tables I and IV. TABLE IV. Tape overlap requirements. 1/ Wrap 1 Wrap 2 Wrap 3 Wrap 4 Nominal wall thickness (mils) Wire size Tape code Percent overlap Tape code Percent overlap Tape code Percent overlap Tape code Percent overlap Min Max Min Max Min Max Min M

32、ax 22 1 50.5 54.0 4 50.5 54.0 - - - - - - 7.4 20 1 50.5 54.0 4 50.5 54.0 - - - - - - 7.4 18 1 50.5 54.0 4 50.5 54.0 - - - - - - 7.4 16 1 50.5 54.0 5 50.5 54.0 - - - - - - 8.3 14 1 50.5 54.0 5 50.5 54.0 - - - - - - 8.3 12 1 50.5 54.0 6 50.5 54.0 - - - - - - 9.1 10 1 50.5 54.0 6 50.5 54.0 - - - - - -

33、9.1 8 2 20.5 35 1 50.5 55.0 6 67.0 71.0 - - - 13.2 6 2 20.5 35 1 50.5 55.0 6 67.0 71.0 - - - 13.2 4 3 20.5 35 1 50.5 55.0 6 50.5 54.0 6 50.5 54.0 16.2 2 3 20.5 35 1 50.5 55.0 6 50.5 54.0 6 50.5 54.0 16.2 1 3 20.5 35 1 50.5 55.0 6 50.5 54.0 6 50.5 54.0 16.2 1/0 3 20.5 35 1 50.5 55.0 6 50.5 54.0 6 50.

34、5 54.0 16.2 2/0 3 20.5 35 1 50.5 55.0 6 50.5 54.0 6 50.5 54.0 16.2 1/ Wrap 1 is innermost tape which is in contact with the conductor. 3.5 Performance testing. Wire supplied to this drawing shall be qualified in accordance with SAE-AS22759/88 and shall meet any additional requirements of this drawin

35、g. 3.5.1 Wet arc propagation resistance (test required for initial qualification only). When tested in accordance with MIL-STD-2223, method 3006, the following requirements shall apply: a. A minimum of 70 wires shall pass the impulse dielectric test of SAE-AS22759. b. Not more than two wires shall f

36、ail the impulse dielectric test in any one bundle. c. Actual damage to the wire shall be not more than 1.0 inch (25.4 mm) in length in any bundle when measured along the axis. 3.5.2 Solderability: Not applicable. This wire is intended for crimped connections. 3.5.3 Forced hydrolysis (test required f

37、or initial qualification only). When tested in accordance with SAE-AS4373, method 602, the minimum average performance shall be 5000 hours at 70C. The following details shall apply: a. Number of specimens: 5. b. Wire size to be tested: 20 AWG. c. A specimen is considered “failed” when it can no long

38、er pass the dielectric test method of SAE-AS4373 method 602. d. Average the time to failure for all of the specimens evaluated. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-DEFENSE SUPPLY CENTER, COLUMBUS COLUMBUS, OH 43218-3990 SIZE CAGE CODE DWG

39、 NO. A 037Z3 04042 REV B PAGE 7 3.5.4 Insulation state of sinter (conformance inspection test). FP layers shall be evaluated with a differential scanning calorimeter in accordance with ASTM D4591. The FP layers shall meet the following requirements: a. First heat: Less than 25 Joules/gram (J/g). b.

40、Second heat: Maximum 2 J/g change when compared to first heat. c. Bonding between FP layers shall be homogenous. No evidence of tape edges or seams shall be present on the outer FP layer when visually examined with the unaided eye. The outer surface will be smooth and free of tape edges at the overl

41、ap. 3.5.5 Lamination sealing (conformance inspection test). When tested in accordance with SAE-AS4373, method 809 at 200C, there shall be no evidence of tape separation or lifting. There shall be no visible tape ridges that can contribute to tearing of the tape. 3.5.6 Strippability (conformance insp

42、ection test). There shall be no evidence of separation or elongation of FP layers when stripped with standard hand held tools using proper stripping blades. No evidence of insulation shall be left on the conductor when viewed with the naked eye. The following details shall apply: a. Test size: 26 AW

43、G - 14 AWG wire only in accordance with ASTM D3032, section 27. b. Length of insulation slugs shall be .25 inches (6.35 mm). c. The strip force shall be as follows: Wire size (AWG) Minimum force Maximum force 26 - 20 0.25 lbs 6.0 lbs 18 - 14 0.50 lbs 7.0 lbs 3.5.7 Durability (PTFE outer layer) (Test

44、 required for initial qualification only). When tested as specified, the wire shall withstand an average of 100 cycles without failure due to tear or surface cut through of the outer layer. The following details shall apply: a. Wire size: 22 AWG. b. Temperature: 23C. c. Weight: 300 grams (10.6 oz).

45、d. Edged abrading rod diameter: .026 inch (0.66 mm) nominal. e. Test specimens shall be manufactured to emulate the wire construction specified herein, except the polyimide shall be replaced with an aluminum/Mylar film of similar thickness with the conductive (aluminum) side out. The conductive surf

46、ace is used in a circuit path to determine when the abrading rod has penetrated the PTFE layer. f. Test method: (1) Install a .026 inch (0.66 mm) edged abrading rod with the edged surface facing down (perpendicular with the test specimen). (2) Remove approximately 1 inch (25.4 mm) of insulation from

47、 the end of the specimen and connect the circuit detection clip to the exposed conductor. (3) Apply the appropriate weights to the fixture. (4) Place the abrading rod on the specimen, ensuring the rod is level and perpendicular to the specimen surface. (5) Zero the counter on the abrasion tester. (6

48、) Turn the tester on. The rod will begin to oscillate over the surface of the specimen with an approximate 1 inch (25.4 mm) stroke. (7) The test will continue until the tester detects continuity between the abrading rod and the conductor. (8) Record the number of cycles to failure. (9) Repeat the pr

49、ocedure a minimum of 10 times (100 times preferred) to generate a statistically significant sample. (10) Average the results. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-DEFENSE SUPPLY CENTER, COLUMBUS COLUMBUS, OH 43218-3990 SIZE CAGE CODE DWG NO. A 037Z3 04042 REV B PAGE 8 3.5.8 UV laser marking (test required for in