SAE AS22759/187:2010 download free.WiRE. ELECTRICAL POLYTETRAFLUOROEThYLENEIPOLY).DE INSULATED. SMOOTH SURFA, NORPML WEIGHT. NICKEL COATED COPPER CONDUCTOR. 260 C. 600 VOLTS.
THIS SPECIFICATION HAS BEEN DEVELOPED AT THE REOUEST OF NAVAL AIR SYSTEMS COMMAND
AND THE UNITED STATES MR FORCE. THIS PRODUCT IS BASED ON AS22759(87 WiTh ADDITIONAL
REQUIREMENTS INCLUDING A SMOOTH OUTER FLUOROPOIYMER SURFACE.
NOTICE
THE REQUIREMENTS FOR ACQUIRING ThE PRODUCT DESCRIBED HEREIN SHALL CONSIST OF THIS
SPECIFICATiON SHEET AND THE ISSUE OF THE FOLLOWING SPECIFICATION USTED IN THAT ISSUE
OF THE DEPARTMENT Of DEFENSE INDE)( OF SPECIFICATIONS AND STANDARDS (DODISS)
SPECIFIED IN THE SOLICITATiON: AS22759
TEMPERATURE RATiNG: 260 °C (500 F) MAXIMUM CONTINUOUS CONDUCTOR TEMPERATURE.
VOLT4GE RATiNG: 600 VOLTS (RMS) AT SEA LEVEL.
ADDIT)NAL REQU IREMENTS:
DRY PC PROPAGATION RESISTANCE (TEST REQUIRED FOR INITIAL OUAUFICATION ONLY): TEST IN ACCORDANCE WITH
AS4373 METHOD SOS. MEASURE THE DAMAGE OF THE BUNDLE ALONG THE AXIS. THE WIRE IS ACCEPTABLE IF THE FOLLOWING
ARE MET:
1. A MINIMUM OF 70 WiRES PASS THE DIELETRIC TEST.
2. TWO WIRES OR LESS FAIL THE DIELECTRIC TEST IN ANY ONE BUNDLE.
3. ACTUAL DAMAGE TO THE WiRE IS NOT MORE THAN 1.0 INCHES IN ANY TEST BUNDLE.
BLOCKING: 260°C±2°C(500F±3.6°F)
COLOR: WHITE IS THE PREFERRED COLOR AND SHALL BE IN ACCORDANCE WiTH MIL-STD-104. CLASS 2. COLORS SHALL BE
LASER MARKABLE AND MEET THE COLOR LIMITS BELOW. FOR WIRE TESTING ASSOCIATED WiTH QUALIFICATION. RETENTION
OF OUAIJF1CATION AND OUALITY CONFORMANCE. CONFORMITY OF COLOR SHALL NOT BE REOUIRED AFTER OVEN EXPOSURE.
HIGH FREQUENCY SPARK TEST: (WHEN USED IN LIEU OF THE IMPULSE DIELECTRIC TEST) 5.7 KILOVOLTS (RMS). TEST 100 PERCENT OF THE WIRE.
HUMIDITY RESISTANCE: REQUIRED. AFTER HUMIDITY EXPOSURE. THE WIRE SHALL MEET THE REQUIREMENTS FOR INITIAL INSULATiON RESISTANCE.
IDENTIFICATION OF PROOUCT NOT REQUIRED FOR SIZE 26. COLOR CODE DESIGNATOR NOT REQUIRED. IDENTIFICATION DURABILITY: 125 CYCLES (250 STROKES) 250 GRAM WEIGHT.
IMMERSION (TEST REQUIRED FOR INTITAL QUALIFICATION ONLY) TEST IN ACCORDANCE WITH AS4373. METHOD 601. USE
MANDRELS AND WEIGHTS LISTED IN TABLE 5 FOR BEND TESTING. DIELECTRiC TEST. 2500 VOLTS (RMS). 60 HZ. FOR TURBINE F
IMMERSION TEST OF AS4373, EITHER JP-4 OR MIL-DTL-83133 TYPE JP-8 (NATO TYPE F-34) MAY BE USED.
IMPUlSE DIELECTRIC TEST: 8.0 KILOVOLTS (PEAK). TEST 100 PERCENT OF THE WIRE
INSULATiON RESISTANCE:
SIZES 26 THROUGH 10. 5000 MEGOHMS PER 1000 FEET (MINIMUM)
SIZES 8 THROUGH 04.3000 MEGOHMS PER 1000 FEET (MINIMUM)
INSULATION STATE OF SINTER: (QUALIFICATION AND QUALITY CONFORMANCE INSPECTION PERFORMED ON ONE SAMPLE PER
LOT) EVALUATE FLUOROPOLYMER LAYERS ONLY. THIS TEST IS APPICABLE TO 10 AWG AND SMALLER WIRES. THE
DIFFERENCE IN ENERGY TO MELT BETWEEN FIRST AND SECOND HEATS SHALL BE LESS THAN OR EQUAL TO 3 JOUI..ES PER
GRAM.
INSULATION STRIP FORCE: (QUALIFICATION AND GROUP II QUALITY CONFORMANCE TEST) TEST WIRE SIZES 28 THROUGH 14
ONLY. THE LENGTH OF THE INSULATION SLUG SHALL BE 0.25 INCHES. STRIP FORCE (LB) SHALL BE AS FOLLOWS. NO
EVIDENCE OF INSULATiON SHALL BE LEFT ON THE CONDUCTOR WHEN VIEWED WITH THE UNAIDED EYE.
LAMINATION SEAUNG: (OUAUFICATION AND GROUP II OUAUTY COMFORMANCE TEST) WHEN TESTED IN ACCORDANCE WiTH
AS4373. METHOD 809 AT 260 °C ±2 eC (500 F ± 3.6 °F) 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 290 eC ±2 ‘C (554 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 DL4METERS OF TABLE 5. 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 TABLE 5. CHAMBER TEMPERATURE. -65 °C ±2°C (-85 F ± 3.6 °F). DIELECTRK TEST, 2500 VOLTS (RMS), 60 HZ.
OUTER INSULATION LAYER SURFACE SMOOTHNESS: (OUALIFICAT1ON AND GROUP II QUALITY CONFORMANCE TEST) WHEN
TESTED IN ACCORDANCE WITH AS4373. METHOD 110. THE DIFFERENCE IN WALL THICKNESS OF THE OUTER PTFE INSULATON
LAYER AT THE DISCERNABLE TAPE EDGE SHALL NOT EXCEED THE LIMITS BELOW:
WIRE SIZES 26 AWG THROUGH 10 AWG: 10.0 PERCENT
WIRE SIZES 8 AWG THROUGH 6 AWG 7.0 PERCENT
WIRE SIZES 4 AWG THROUGH 04 AWG: 50 PERCENT
SHRINKAGE TEST AT 290°C ±2 °C (554 F ± 3.6 F). MAXIMUM CHANGE IN MEASUREMENT, SIZES 26 THROUGH 10,0091 INCH AND
SIZES 8 THROUGH 04,0.125 INCH.
SMOKE: 260 °C ±5°C (500°F ±9°F); NO VISIBLE SMOKE.
SOLDERABILITY: NOT REQUIRED. THIS SLASH SHEET IS PRIMARILY INTENDED FOR CRIMP TERMINATIONS. FOR SOLDERABIUTY APPliCATIONS. USE THE SILVER COATED COPPER VERSION OF THIS SPECIFICATION.
STRIPPABILITY: (OUAIJFICATION AND GROUP II QUALITY CONFORMANCE TEST) AFTER STRIPPING, NO FRAGMENTS OF ANY
LAYER SHALl EXTEND MORE THAN 0.031 INCHES BEYOND THE END OF THE POLYIMIDE TAPE LAYER. THE TEST IS APPliCABLE
TO WIRE SIZES 10 AWG AND SMALLER.
TAPE OVERLAP; TEST IN ACCORDANCE WITH AS4373. METHOD 109.
TENSILE MODULUS; TEST COMPOSITE FILM IN ACCORDANCE WiTH ASTM D 882. METHOD A
THERMAL INDEX: (TEST REQUIRED FOR INITIAL QUAliFICATION ONLY). TEST WiRE SIZE 20 ONLY. 260 °C (500 °F) MINIMUM FOR
10 000 HOURS..
THERMAL SHOCK RESISTANCE: OVEN TEMPERATURE. 260 °C ±2°C (500°F ± 3.6 °F). MAXIMUM CHANGE IN MEASUREMENT, SIZES
26 THROUGH 10 AWG, 0.091 INCH AND SIZES 8 THROUGH 04.0.125 INCH. NO CRACKING.
IN LASER MARKING: (QUAliFICATION AND GROUP I QUALITY CONFORMANCE TEST) APPLICABLE TO WHITE INSULATION. SIZES
26 THROUGH 10 ONLY. TEST IN ACCORDANCE WITH AS4373. METHOD 1001. CONTRAST SHALL BE A 62 PERCENT MINIMUM
AVERAGE ON SIX READINGS.
UV LASER CONTRAST AFTER THERMAL AGING: (INITIAL QUALIFICATION AND RETENTION OF QUALIFICATION) WiRE SIZE 20 ONLY.
PREPARE SAMPLE IN ACCORDANCE WITH AS4373 METHOD 1001. PLACE SAMPLE IN AN AIR CIRCULATING OVEN AT 290 C ±2 °C
(554 F ± 3.8 F) FOR 168 HOURS. MINIMUM AVERAGE CONTRAST AFTER AGING SHALL NOT BE LESS THAN 40 PERCENT.
WET ARC PROPAGATION RESISTANCE (TEST REQUIRED FOR INITIAL QUALIFICATION ONLY): TEST IN ACCORDANCE WITH AS4373, METHOD 509. MEASURE THE DAMAGE OF THE BUNDLE ALONG THE AXIS. THE WIRE IS ACCEPTABLE IF THE FOLLOWING ARE MET:
1. A MINIMUM OF 70 WIRES PASS THE DIELETRIC TEST.
2. T\VO WIRES OR LESS FAIL THE DIELECTRIC TEST IN ANY ONE BUNDLE.
3. AQTUAL DAMAGE TO THE WIRE IS NOT MORE THAN 1.0 INCHES IN ANY TEST BUNDLE.
WRAP MANDREL WRAP): NO CRACKING, NO DIELECTRIC BREAKDOWN. USE MANDRELS SPECIFIED IN TABLE 5. DIELECTRIC TEST, 2500 VOLTS (RMS). 60 HZ.
FOROUAUFICATION, A SOURCE IS REQUIRED TO SUBMIT DATA ON OUALITY CONFORMANCE TESTS AND ANY FINISHED WiRE
TEStS AS REQUIRED BY THE QUALIFICATiON AUTHORIZATION LETTER. ALL OThER TESTING WILL BE PERFORMED BY THE
OU4LIFYlNG ACTIVITY AT THE SOURCE’S EXPENSE.
DUTO THE EXTENDED TiME PERIOD OVER WHICH THE THERMAL INDEX AND THE FORCED HYDROLYSIS TESTS ARE PERFORMED. A SOURCE MAY BECOME QUALIFIED UNDER THIS SPECIFICATION SHEET WHILE THESE TESTS ARE STILt. IN PROGRESS.
NOIZS:
A CIANGE BAR (I) 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 TITI..E 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.