NAVISTAR TMS 6611-2006 Insulation Heat Shrinkable Tubing (Revision A).pdf

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1、INTERNATIONAL TRUCK AND ENGINE CORPORATION TMS (TRUCK MATERIAL SPECIFICATION) NUMBER: TMS-6611 TITLE: Insulation, Heat Shrinkable Tubing REVISION: A WRITTEN/EDITED BY: Materials Engineering APPROVED BY: Materials Engineering DATE ISSUED: February 2006 PRINTED COPIES OF THIS DOCUMENT MUST BE VERIFIED

2、 FOR CURRENT REVISION This specification may involve hazardous materials, equipment, and procedures. This specification does not purport to address all of the safety issues associated with its use. The user is responsible to consult appropriate safety and health practices and to determine the applic

3、ability of regulatory limits prior to use. Change Notice: Revised Section 9.0; added Section 2.1. Reference: File: 30-1 Keywords: Insulation, electrical insulation, plastic tube, heat shrinkable tube. 1.0 APPLICATIONThis material specification covers the sealing requirements of co-extruded, cross-li

4、nked polyolefin heat shrinkable tubing the diameter of which will reduce to a predetermined size upon heating. This tubing is used for insulating electrical splices. 2.0 SCOPE This specification covers the material properties, performance requirements, production quality control, suppliers responsib

5、ility, source approval and quality control, general information, and sources for approved systems. 2.1 Restricted Chemical SubstancesEffective January 1, 2007, all product supplied to the requirements of this specification must comply with the requirements of the CEMS B-50 specification. 3.0 REFEREN

6、CE DOCUMENTS Unless otherwise specified the latest issue of all referenced standards shall apply. The following Specifications, Standards, and Regulations are referenced in this specification. International Quality System Standard QS-9000 (ISO 9000 or TS-16949) INTERNATIONAL TMS-6810 ASTM D471 INTER

7、NATIONAL IQR Quality Standard INTERNATIONAL TMS-6811 ASTM D570 INTERNATIONAL Manufacturing Std. D-13 INTERNATIONAL TMS-6812 ASTM D792 INTERNATIONAL Eng. Design Std. A-16 INTERNATIONAL TMS-9543 ASTM D2671 INTERNATIONAL CEMS B-1 CFR 29, Part 1910 SAE J1128 INTERNATIONAL CEMS B-38 ASTM D257 SAE J1703 I

8、NTERNATIONAL CEMS B-50 4.0 GENERAL REQUIREMENTS Material supplied to this specification shall insulate the intended substrates, where continuous operating temperatures can reach up to 135C (275F), when applied with due care. The Property and Performance requirements of these materials are listed in

9、Table I. Each new substrate for any system shall be qualified and listed in Table III. 4.1 Construction Materials supplied to this specification shall be uniform in color, texture, finish, physical, mechanical, and electrical properties. Materials shall be free from seams, cracks, porosity, blisters

10、, pinholes, surface This document is restricted and may not be sent outside International Truck and Engine Corporation or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2006 by International Truck and Engine Corp. February 200

11、6 Page 1 of 8 NUMBER: TITLE: REVISION: TMS-6611 Insulation, Heat Shrinkable Tubing A This document is restricted and may not be sent outside International Truck and Engine Corporation or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent lia

12、bility. 2006 International Truck and Engine Corp. lubricants, and defects caused by processing, handling, or contamination. Approval of materials for compatibility to these materials is the responsibility of the heat shrinkable tubing supplier, the process manager and the process suppliers. Length a

13、nd minimum wall thickness shall be determined by part drawing or supplier data. 4.2 Property and Performance Requirements 4.2.1 Extruded Tubing Requirements Unless otherwise specified, a minimum of five samples shall be prepared for each condition tested. Extruded tubing samples shall be preshrunk b

14、y conditioning for 10 minutes in a 135C 2C (275F 4F) air circulating oven or at the proper conditions based on manufacturers guidelines for sealing material and splice configuration. The samples are then allowed to stabilize for 3 hours at 23C 2C (73F 4F) and 50 5% relative humidity. The conditionin

15、g shall be as representative of production conditions as possible and will be fully described in the test report. These conditions will be listed in Table III and shall be reproducible for future testing. Note: Oven temperatures should represent actual sample splice temperatures rather than the repo

16、rted temperatures of the heating elements or the oven air temperature. 4.2.1.1 Specific Gravity4.2.1.1.1 Method: ASTM D792 4.2.1.1.2 Required: See Table 1 4.2.1.2 Flammability4.2.1.2.1 Method: ASTM D2671, Procedure B 4.2.1.1.2 Required: Self-extinguishing within 60 seconds, using mandrel size of 50%

17、 of expanded I.D. 4.2.1.3 Dimensional Recovery, Longitudinal Change4.2.1.3.1 Method: Measure five samples of tubing, 152mm (6 in.), for length and I.D. per ASTM D2671. Condition samples for 10 minutes at 135C 2C (275F 3.6F). Immediately after conditioning, quench samples in a water bath maintained l

18、ess than 35C 2C (95F 4F) for 3 seconds. Wipe dry with a clean cloth and re-measure. 4.2.1.3.2 Required: Dimensions shall meet those specified in supplier specifications. Longitudinal change shall be measured as the difference in lengths expressed as a percentage of the original length. See Table I.

19、4.2.1.4 Heat Aging4.2.1.4.1 Method: Condition samples in a mechanical convection oven at 135C 2C (275F 3.6F) with an air velocity of 30.5-61 M (100-200ft.) per minute. After conditioning, the samples are allowed to stabilize for 3 hours at 23C 2C (73F 3.6F) and 50 5% relative humidity. The samples a

20、re then bent through 180 over a mandrel selected in accordance with Table II. 4.2.1.4.2 Required: Samples shall not exhibit any cracking. 4.2.1.5 Heat Shock4.2.1.5.1 Method: Test per ASTM D2671 at 225C 2C (437F 3.6F) for 4 hours. 4.2.1.5.2 Required: Samples shall not crack, flow or drip. February 20

21、06 Page 2 of 8 NUMBER: TITLE: REVISION: TMS-6611 Insulation, Heat Shrinkable Tubing A This document is restricted and may not be sent outside International Truck and Engine Corporation or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent li

22、ability. 2006 International Truck and Engine Corp. 4.2.1.6 Tensile Strength, Ultimate Elongation4.2.1.6.1 Method: Test per ASTM D2671. Jaw separation rate shall be 50mm (2 in.) per minute. Original cross section shall be that of the outer wall only. 4.2.1.6.2 Required: See Table I. 4.2.1.7 Dielectri

23、c Strength4.2.1.7.1 Method: Test per ASTM D2671. Test outer wall only. 4.2.1.7.2 Required: See Table I. 4.2.1.8 Volume Resistivity4.2.1.8.1 Method: Prepare per ASTM D2671. Test per ASTM D257 4.2.1.8.2 Required: See Table I. 4.2.1.9 Water Absorption4.2.1.9.1 Method: Test per ASTM D570, procedure A. 4

24、.2.1.9.2 Required: See Table I. 4.2.2 Splice Sealing Requirements: Table III 4.2.2.1 Sample Preparation A minimum of twenty-five samples of each configuration shall be prepared for each condition tested unless otherwise specified. Splices shall be conditioned for 10 minutes in a 135C 2C (275F 4F) ai

25、r circulating oven or at the proper conditions based on manufacturers guidelines for sealing material and splice configuration. The samples are then allowed to stabilize for 3 hours at 23C 2C (73F 4F) and 50% 5% relative humidity. The conditioning shall be as representative of production conditions

26、as possible and fully described in the test report. These conditions will be listed in Table III and shall be reproducible for future testing. 4.2.2.2 Initial Current Leakage4.2.2.2.1 Method: Immerse the center of each splice in a water bath maintained at 23C 2C (73F 3.6F) containing 5% by weight so

27、dium chloride (NaCl) for 24 hours. Leave the ends of the samples a minimum of 50 mm (2 in.) above the water line. Measure the current leakage between the conductors in the sample and the water bath using an applied voltage of 50 volts DC. 4.2.2.2.2 Required: Current leakage shall be less than 0.25 m

28、icroamps. 4.2.2.3 Heat Aging4.2.2.3.1 Method: Place samples vertically in a mechanical convection oven at 135C 2C (275F 3.6F) with an air velocity of 30.5 - 61 M (100-200ft.) per minute. After conditioning, the samples are allowed to stabilize for 3 hours at 23C 2C (73F 3.6F) and 50 5% relative humi

29、dity. The samples are then subjected to the current leakage test. 4.2.2.3.2 Required: Samples shall not crack, flow, or drip and current leakage shall be less than 0.25 microamps. February 2006 Page 3 of 8 NUMBER: TITLE: REVISION: TMS-6611 Insulation, Heat Shrinkable Tubing A This document is restri

30、cted and may not be sent outside International Truck and Engine Corporation or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2006 International Truck and Engine Corp. 4.2.2.4 Thermal Humidity Cycling4.2.2.4.1 Method: Test sam

31、ple splices at the conditioning periods listed below. In each condition, the sample splice shall be positioned horizontally and time between conditioning periods shall be less than 5 minutes. The 5 day conditioning cycle is as indicated below. 4.2.2.4.1.1 16 hours relative humidity of 100% at 135C 2

32、C (275F 3.6F). 4,2.2.4.1.2 3 hours at -40C 2C (-40F 3.6F). 4,2.2.4.1.3 3 hours at 105C 2C (221F 3.6F). 4,2.2.4.1.4 2 hours stabilization at ambient temperature and humidity. 4,2.2.4.1.5 Repeat 24 hour cycle 5 times 4,2.2.4.1.6 Within 15 minutes of finishing the last cycle, perform current leakage te

33、st. 4.2.2.4.2 Required: Current leakage shall be less than 0.25 microamps. 4.2.2.5 Thermal Cycling4.2.2.5.1 Method: Test sample-splices at the conditioning periods listed below. In each condition, the samples will be positioned horizontally and time between cycles will be less than 2 minutes. 4.2.2.

34、5.1.1 30 minutes at 135C 2C (275F 3.6F) 4.2.2.5.1.2 Immerse in 5% by weight NaCl water bath at 5C 2C (41F 3.6F) for 30 minutes. 4.2.2.5.1.3 Repeat above cycle 5 times 4.2.2.5.1.4 Within 15 minutes of finishing the last cycle, perform current leakage test. 4.2.2.5.2 Required: Current leakage shall be

35、 less than 0.25 microamps. 4.2.2.6 Low Temperature Flexibility4.2.2.6.1 Method: Ten samples of each configuration and their mandrel of corresponding size indicated in Table II shall be conditioned for 4 hours at -40C 2C (-40F 3.6F). Immediately after this time, the samples shall be wrapped for not l

36、ess than 360 around the mandrel in approximately 2 seconds. Repeat for 5 cycles. Within 15 minutes of the last cycle, perform current leakage test. 4.2.2.6.2 Required: Samples shall not crack and current leakage shall be less than 0.25 microamps. 4.2.2.7 Tensile Strength4.2.2.7.1 Method: Five unweld

37、ed 1:1 splice samples shall be assembled using concentric wound, stranded, uncoated, soft-temper, copper 18 ga. Wire, type GXL as per SAE J1128. Test per ASTM D2671. Jaw separation rate shall be 50 mm (2 in.) per minute. Both attachment points shall be 50 10 mm (2 0.4 in.) from the edges of the spli

38、ce covering. Original cross section shall be that of the outer wall only. 4.2.2.7.2 Required: Minimum strength of splice shall be 9 Mpa (1305 psi). 4.2.2.8 Dielectric Strength4.2.2.8.1 Method: Immerse samples in a water bath containing 5% by weight NaCl at 23C 2C (73F 3.6F) for 2 hours. Ends of each

39、 sample shall be 50 mm (2 in.) above the water line. After conditioning, raise the voltage over a 15 second period, between the conductors and the salt water to1000 volts (RMS) at 60 Hz. Hold the voltage at 1000 volts for 60 seconds. 4.2.2.8.2 Required: Sealing material shall not rupture. February 2

40、006 Page 4 of 8 NUMBER: TITLE: REVISION: TMS-6611 Insulation, Heat Shrinkable Tubing A This document is restricted and may not be sent outside International Truck and Engine Corporation or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent l

41、iability. 2006 International Truck and Engine Corp. 4.2.2.9 Fluid Compatibility4.2.2.9.1 Method: Prepare 35 samples, each configuration, and measure and record the circumference at the center of the splice. 4.2.2.9.2 Immerse 5 samples, each configuration, in the fluids indicated, for 1 hour 100C 2C.

42、 4.2.2.9.2.1 IRM 903 oil (ASTM D471) 4.2.2.9.2.2 Power steering fluid (TMS 6810, TMS-6811) 4.2.2.9.2.3 Automatic transmission fluid (TMS-6812) 4.2.2.9.2.4 Engine coolant (CEMSB-1) 4.2.2.9.3 Immerse 5 samples of each configuration in the following fluids for 1 hour at 232C. . 4.2.2.9.3.1 Diesel fuel

43、(ASTM reference F fuel, ASTM D471) 4.2.2.9.3.2 SAE J1703 brake fluid 4.2.2.9.3.3 Windshield washer fluid (CEMS B-38) 4.2.2.9.4 Following immersion, blot off excess fluid and inspect integrity. Re-measure and record the circumference at the center of the splice. Within 15 minutes perform the current

44、leakage test. 4.2.2.9.5 Required: Swelling shall be less than 25% of the original circumference and current leakage shall be less than 0.25 microamps. 5.0 QUALITY 5.1 QualificationMaterials and processes submitted for approval to this specification will include the indicated below. 5.1.1 A detailed

45、and signed test report documenting testing to this specification prepared to TMS-9543. 5.1.2 Test specimens or photographs showing failures for each applicable test. 5.1.3 The complete process for preparing and curing materials for test, with cure temperatures and times. 5.1.4 Samples of tubing and

46、wires representative to production splice configurations. 5.1.5 Questions regarding qualification requirements, reports and test materials shall be addressed to: Manager of Non-Metallic Materials Materials Engineering and Technology International Truck Development and Technology Center P.O. Box 1109

47、 Fort Wayne, In. 46801-1109 5.2 Quality Control Plan A Quality Control Plan for this product will be established by mutual agreement between INTERNATIONAL and the supplier. Unless specific exception is noted, the following characteristics, where applicable*, shall be included in the plan as features

48、 for management by statistical process control.* KCCLength * Other characteristics for inclusion in the control plan may be specified on the engineering drawing and/or purchase order. * See INTERNATIONAL Engineering Design Standard A-16. 6.0 SOURCE APPROVAL AND QUALITY CONTROL6.1 Supplier RequirementsFebruary 2006