SAE-AS-22759-83B-2006.pdf

AEROSPACE STANDARD (R) WIRE, ELECTRICAL, POLYTETRAFLUOROETHYLENE/ POLYIMIDE INSULATED, NORMAL WEIGHT, SILVER COATED, COPPER CONDUCTOR, 200 °C, 600-VOLT AS22759/83 Copyright 2006 SAE International All rights reserved. No part of this publication may be reproduced, 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: 724-776-4970 (outside USA) Fax: 724-776-0790 Email: CustomerServicesae.org SAE WEB ADDRESS: http:/www.sae.org ISSUED 2000-06 REVISED 2006-12 THIRD ANGLE PROJECTION CUSTODIAN: SAE AE-8/AE-8D REV. B FEDERAL SUPPLY CLASS 6145 AS22759/83 SHEET 1 OF 5 REV. B SAE Technical Standards Board Rules provide that: “This report is published by SAE to advance the state of technical and engineering sciences. The use of this report is entirely voluntary, and its applicability and suitability for any particular use, including any patent infringement arising therefrom, is the sole responsibility of the user.” SAE reviews each technical report at least every five years at which time it may be reaffirmed, revised, or cancelled. SAE invites your written comments and suggestions. RATIONALE TOTAL REVISION AND UPDATE WORD-FOR-WORD MIL SPECIFICATIONS CONVERTED TO SAE STANDARDS. THE REQUIREMENTS FOR ACQUIRING THE PRODUCT DESCRIBED HEREIN SHALL CONSIST OF THIS SPECIFICATION SHEET AND THE ISSUE OF THE FOLLOWING SPECIFICATION LISTED IN THAT ISSUE OF THE DEPARTMENT OF DEFENSE INDEX OF SPECIFICATIONS AND STANDARDS (DODISS) SPECIFIED IN THE SOLICITATION: AS22759. THIS SPECIFICATION IS NOT INTENDED FOR USE IN NAVAL AIRCRAFT OR NAVAL AIR SYSTEMS APPLICATIONS. 1/ BRAID: BRIGHT AROMATIC POLYAMIDE YARN, 200 DENIER, 100 FILAMENTS, TIGHTLY FORMED, UNIFORM 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. FIGURE 1 - GENERAL CONFIGURATION CONDUCTOR, STRANDED, SILVER COATED COPPER FP/ POLYIMIDE/ FP TAPE FP TAPE FP TAPE META-ARAMID FIBER BRAID TREATED TO PREVENT FRAYING 1/ FP FLUOROCARBON POLYMER, MODIFIED POLYTETRAFLUOROETHYLENE (PTFE) -,-,- AEROSPACE STANDARD (R) WIRE, ELECTRICAL, POLYTETRAFLUOROETHYLENE/ POLYIMIDE INSULATED, NORMAL WEIGHT, SILVER COATED, COPPER CONDUCTOR, 200 °C, 600-VOLT AS22759/83 REV. B AS22759/83 SHEET 2 OF 5 REV. B TABLE 1 - CONSTRUCTION DETAILS CONDUCTOR FINISHED WIRE DIAMETER (IN) DIAMETER (IN) WEIGHT (LB/1000 FT) PART NO. 1/ WIRE SIZE STRANDING (NUMBER OF STRANDS X AWG GAUGE OF STRANDS) MIN MAX RESISTANCE AT 20 °C (68 °F) (OHMS/1000 FT MAX) MIN MAX MIN TARGET MAX M22759/83-8 M22759/83-6 M22759/83-4 M22759/83-2-* M22759/83-1-* M22759/83-01-* M22759/83-02-* M22759/83-03-* M22759/83-04-* 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 0.158 0.198 0.250 0.320 0.366 0.395 0.440 0.500 0.565 0.166 0.208 0.263 0.340 0.380 0.425 0.475 0.540 0.605 0.658 0.418 0.264 0.170 0.139 0.108 0.085 0.068 0.054 0.192 0.231 0.288 0.356 0.400 0.432 0.487 0.542 0.602 0.213 0.254 0.313 0.389 0.433 0.475 0.530 0.585 0.655 58.4 88.2 142 213 280 331 414 524 654 60.5 90.6 146 222 289 344 434 537 675 62.6 93.0 150 231 298 357 454 550 696 1/ PART NUMBER: THE PREFERRED COLOR IS DARK GREEN WITH THE COLOR DESIGNATOR 5D. EXAMPLE: SIZE 2 DARK GREEN - AS22759/83-2-5D. WHITE IS AN ACCEPTABLE ALTERNATE WITH A COLOR DESIGNATOR 9. TABLE 2 - WIRE INSULATION MATERIALS 1/ TAPE CODE THICKNESS NOMINAL MATERIAL 1 2 3 4 0.0020 0.0020 0.0030 0.0010 0.0005 (FP)/0.0010 (POLYIMIDE)/0.0005 (FP) FP (SKIVED) FP (UNSINTERED OR PRESINTERED BONDABLE) FP (SKIVED) 1/ PHYSICAL PROPERTIES OF FP TAPES (SKIVED AND UNSINTERED) SHALL BE IN ACCORDANCE WITH AS22759 REQUIREMENTS. TABLE 3 - PHYSICAL PROPERTIES OF FP/POLYIMIDE/FP TAPES TENSILE STRENGTH 19,000 LB/IN SQ (AVERAGE MINIMUM) TENSILE MODULUS 350,000 LB/IN SQ (AVERAGE MINIMUM) ELONGATION 40 PERCENT (AVERAGE MINIMUM) DIELECTRIC STRENGTH 4,000 VOLTS/MIL (AVERAGE MINIMUM) 0.0005 FP LAYER (BOTTOM) DISTINGUISHABLE COLOR (NEXT TO CONDUCTOR) MAY BE USED AT MANUFACTURER'S OPTION -,-,- AEROSPACE STANDARD (R) WIRE, ELECTRICAL, POLYTETRAFLUOROETHYLENE/ POLYIMIDE INSULATED, NORMAL WEIGHT, SILVER COATED, COPPER CONDUCTOR, 200 °C, 600-VOLT AS22759/83 REV. B AS22759/83 SHEET 3 OF 5 REV. B TABLE 4 - TAPE OVERLAP REQUIREMENTS WRAP 1 WRAP 2 WRAP 3 WRAP 4 PERCENT OVERLAP PERCENT OVERLAP PERCENT OVERLAP PERCENT OVERLAP WIRE SIZE TAPE CODE MIN MAX TAPE CODE MIN MAX TAPE CODE MIN MAX TAPE CODE MIN MAX NOMINAL WALL THICKNESS (MILS) 2/ 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 50.5 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 54.0 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. RATINGS: TEMPERATURE RATING: 200 °C (392 °F) MAXIMUM CONTINUOUS CONDUCTOR TEMPERATURE. VOLTAGE RATING: 600 VOLTS (RMS) AT SEA LEVEL. ADDITIONAL REQUIREMENTS: WET ARC PROPAGATION RESISTANCE (TEST REQUIRED FOR INITIAL QUALIFICATION ONLY): QUALIFICATION BY SIMILARITY TO AS22759/86-20. DRY ARC PROPAGATION RESISTANCE (TEST REQUIRED FOR INITIAL QUALIFICATION ONLY): QUALIFICATION BY SIMILARITY TO AS22759/86-20. BLOCKING: 200 °C ± 2 °C (392 °F ± 3.6 °F). COLOR: FOR BRAIDED CONSTRUCTIONS, PREFERRED COLOR SHALL BE DARK GREEN WITH THE MUNSELL COLOR LIMITS OF 5Y 3/2 AND 5B 2/0.5. WHITE IS AN ACCEPTABLE ALTERNATIVE. CONFORMITY OF COLOR TO THE LIMITS OF MIL-STD-104 SHALL NOT BE REQUIRED AFTER OVEN EXPOSURE. COLOR STRIPING OR BANDING DURABILITY: NOT REQUIRED. CONDUCTOR STRAND ADHESION: REQUIRED. CONTINUOUS LENGTHS: SCHEDULE B. FLAMMABILITY: TEST IN ACCORDANCE WITH AS4373, METHOD 801. REQUIREMENTS: DURATION OF AFTER-FLAME 3 SECONDS (MAX) FLAME TRAVEL 3 INCHES (MAX) NO FLAMING OF TISSUE HIGH FREQUENCY SPARK TEST: (WHEN USED IN LIEU OF IMPULSE DIELECTRIC TEST) TEST IN ACCORDANCE WITH AS4373, METHOD 505, 5.7 KILOVOLTS (RMS) TEST 100% OF THE WIRE. HUMIDITY RESISTANCE: AFTER HUMIDITY EXPOSURE WIRE SHALL MEET THE REQUIREMENTS FOR INITIAL INSULATION RESISTANCE. IDENTIFICATION OF PRODUCT: COLOR CODE DESIGNATOR NOT REQUIRED. IDENTIFICATION DURABILITY: NOT REQUIRED. -,-,- AEROSPACE STANDARD (R) WIRE, ELECTRICAL, POLYTETRAFLUOROETHYLENE/ POLYIMIDE INSULATED, NORMAL WEIGHT, SILVER COATED, COPPER CONDUCTOR, 200 °C, 600-VOLT AS22759/83 REV. B AS22759/83 SHEET 4 OF 5 REV. B IMMERSION (TEST REQUIRED FOR INITIAL QUALIFICATION ONLY): TEST IN ACCORDANCE WITH AS4373, METHOD 601 INCLUDING THE ADDITIONAL FLUIDS LISTED IN TABLE 5 OF THIS SPECIFICATION. USE MANDRELS AND WEIGHTS LISTED IN TABLE 6 FOR BEND TESTING. DIELECTRIC TEST, 2500 VOLTS (RMS), 60 HZ FOR TURBINE FUEL IMMERSION TEST OF AS4373, EITHER JP4 OR MIL-DTL-83133 TYPE JP-8 (NATO TYPE F-34) MAY BE USED. TABLE 5 - FLUID TABLE TEST FLUID TEST TEMPERATURE (°C (°F) IMMERSION TIME (HOURS) A. SAE AMS1424, ANTI-ICING AND DEICING DEFROSTING FLUID, UNDILUTED 48-50 (118-122) 20 B. SAE AMS1424, ANTI-ICING AND DEICING DEFROSTING FLUID, DILUTED 60/40 (FLUID/WATER) RATIO 48-50 (118-122) 20 C. MIL-C-43616, CLEANING COMPOUND, AIRCRAFT SURFACE, TYPE I 48-50 (118-122) 20 D. ASTM D 1153, METHYL ISOBUTYL KETONE (FOR USE IN ORGANIC COATINGS) 20-25 (68-77) 168 E. SAE AS1241, FIRE RESISTANT HYDRAULIC FLUID FOR AIRCRAFT 48-50 (118-122) 20 F. MIL-PRF-7808, LUBRICATING OIL, AIRCRAFT TURBINE ENGINE, SYNTHETIC BASE 118-121 (244-250) 30 G. MIL-PRF-87937, CLEANING COMPOUND, AEROSPACE EQUIPMENT, TYPE II OR TYPE IV, UNDILUTED 63-68 (145-154) 20 H. MIL-PRF-87937, CLEANING COMPOUND, AEROSPACE EQUIPMENT, TYPE II OR TYPE IV, DILUTED 25/75 (FLUID/WATER) RATIO 63-68 (145-154) 20 I. TT-S-735, STANDARD TEST FLUIDS: HYDROCARBON, TYPE I 20-25 (68-77) 168 J. TT-S-735, STANDARD TEST FLUIDS: HYDROCARBON, TYPE II 20-25 (68-77) 168 K. TT-S-735, STANDARD TEST FLUIDS: HYDROCARBON, TYPE IV 20-25 (68-77) 168 L. DIELECTRIC-COOLANT FLUID SYNTHETIC SILICATE ESTER BASE, MONSANTO COOLANOL 25 OR APPROVED EQUIVALENT 20-25 (68-77) 168 M. ASTM D4814, GASOLINE, AUTOMOTIVE, COMBAT 20-25 (68-77) 168 IMPULSE DIELECTRIC TEST: 8.0 KILOVOLTS (PEAK). TEST 100% OF THE WIRE. INSULATION RESISTANCE: 3000 MEGOHMS FOR 1000 FEET (MIN). LAMINATION SEALING: (GROUP II QUALITY CONFORMANCE TEST) WHEN TESTED IN ACCORDANCE WITH AS4373, METHOD 809 AT 260 °C FOR 6 HOURS, THERE SHALL BE NO EVIDENCE OF TAPE SEPARATION OR LIFTING. THREE SAMPLES PER LOT SHALL BE TESTED. LIFE CYCLE: 500 HOURS AT 230 °C ± 2 °C (446 °F ± 3.6 °F). DIELECTRIC TEST, 2500 VOLTS (RMS), 60 HZ USE MANDRELS COATED WITH POLYTETRAFLUOROETHYLENE SUCH THAT THE DIAMETER OF THE MANDRELS, AFTER COATING, STILL CONFORM TO THE REQUIRED TEST MANDRELS DIAMETERS OF TABLE 6. AFTER OVEN EXPOSURE, LAYERS SHALL NOT SEPARATE AND OR TAPES SHALL NOT LIFT ALONG THE INSULATION OR AT THE ENDS. LOW TEMPERATURE (COLD BEND): USE MANDRELS AND WEIGHTS SPECIFIED IN TABLE 6. CHAMBER TEMPERATURE, -65 °C ± 2 °C (-85 °F ± 3.6 °F). DIELECTRIC TEST, 2500 VOLTS (RMS), 60 HZ. SHRINKAGE: .125 INCH (MAX) AT 230 °C ± 2 °C (446 °F ± 3.6 °F). SMOKE: 200 °C ± 5 °C (392 °F ± 9 °F); NO VISIBLE SMOKE, SOLDERABILITY: REQUIRED. STRIPPABILITY: NOT REQUIRED. TAPE OVERLAP: IN ACCORDANCE WITH MIL-STD-2223, METHOD 6005. TENSILE MODULUS: TEST COMPOSITE FILM IN ACCORDANCE WITH ASTM D 882, METHOD A. THERMAL INDEX: (TEST REQUIRED FOR INITIAL QUALIFICATION ONLY). QUALIFICATION BY SIMILARITY TO AS22759/86. THERMAL SHOCK RESISTANCE: OVEN TEMPERATURE, 200 °C ± 2 °C (392 °F ± 3.6 °F), MAXIMUM CHANGE IN MEASUREMENT, .125 INCHES. -,-,- AEROSPACE STANDARD (R) WIRE, ELECTRICAL, POLYTETRAFLUOROETHYLENE/ POLYIMIDE INSULATED, NORMAL WEIGHT, SILVER COATED, COPPER CONDUCTOR, 200 °C, 600-VOLT AS22759/83 REV. B AS22759/83 SHEET 5 OF 5 REV. B WRAP (MANDREL WRAP): NO CRACKING, NO DIELECTRIC BREAKDOWN. USE MANDRELS SPECIFIED IN TABLE 6. DIELECTRIC TEST, 2500 VOLTS (RMS), 60 HZ. TABLE 6 - TEST MANDREL AND TEST LOAD REQUIREMENTS TEST MANDREL DIAMETER 1/ (INCHES) TEST LOAD 1/ (LB) WIRE SIZE (AWG) COLD BEND LIFE CYCLE/ BEND TEST WRAP COLD BEND LIFE CYCLE/ BEND TEST 8 6 4 2 1 0 00 000 0000 4.00 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 0.750 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. QUALIFICATION OF WIRE: FOR QUALIFICATION, A SOURCE IS REQUIRED TO SUBMIT DATA ON QUALITY CONFORMANCE TESTS AND ANY FINISHED WIRE TESTS AS REQUIRED BY THE QUALIFICATION AUTHORIZATION LETTER. ALL OTHER TESTING WILL BE PERFORMED BY THE QUALIFYING ACTIVITY AT THE SOURCES EXPENSE. DUE TO THE EXTENDED TIME PERIOD OVER WHICH THE THERMAL INDEX TEST IS PERFORMED, A SOURCE MAY BECOME QUALIFIED UNDER THIS SPECIFICATION SHEET WHILE THIS TEST IS STILL IN PROGRESS. THE 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. -,-,-