ES2000-NO.2-B9-0-65MM (063725P012) - Tyco Electronics

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Tyco Electronics Corporation

305 Constitution Drive

Menlo Park, CA 94025 USA

Raychem

Tubing SPECIFICATION:

THIS ISSUE:

DATE:

REPLACES:

RT-1112

Issue 5

April 22, 2008

Issue 4

ES2000 TUBING

Environmental Sealing,

Polyolefin, Semirigid, Adhesive-Lined

1. SCOPE

This specification covers the requirements for a dual wall, electrically insulating, extruded tubing, whose

diameter will reduce to a predetermined size upon application of heat in excess of 135ºC (275ºF).

2. APPLICABLE DOCUMENTS

This specification takes precedence over documents referenced herein. Unless otherwise specified, the

latest issue of the referenced documents applies. The following documents form a part of this specification

to the extent specified herein.

2.1 AMERICAN SOCIETY FOR TESTING AND MATERIAL (ASTM)

ASTM D 471 Oil, IRM 903

ASTM D 471 Fuel C

ASTM D 975 Diesel Fuel No. 2

ASTM D 2671 Standard Methods of Testing Heat-Shrinkable Tubing for Electrical Use

ASTM D 3032 Method of Testing Hookup Wire Insulation

ASTM D 3306 Engine Coolant, Type III

(Copies of ASTM publications may be obtained from the American Society for Testing and Materials, 1916

Race Street, Philadelphia, Pennsylvania 19103).

2.2 SOCIETY OF AUTOMOTIVE ENGINEERS (SAE)

SAE J 1128 Low Tension Primary Cable, Standard

SAE J 1703 Brake Fluid

(Copies of SAE publications may be obtained from the Society of Automotive Engineers, Inc.,

400 Commonwealth Drive, Warrendale, Pennsylvania 15096).

3. REQUIREMENTS

3.1 DIMENSIONS

The dimensions shall be in accordance with Table 1.

3.2 MATERIALS

The tubing shall consist of two components.

a) The jacket shall be fabricated from a thermally stabilized, modified semirigid polyolefin and shall be

crosslinked by irradiation.

b) The liner shall be a thermoplastic adhesive which melts and flows at the shrink temperature of

the jacket.

The tubing shall be essentially free from flaws, defects, pinholes, bubbles, seams, cracks and inclusions.

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3.3 COLOR

Unless otherwise specified, the jacket shall be black and the adhesive liner shall be amber.

3.4 PROPERTIES

The tubing shall meet the requirements of Table 3.

4. QUALITY ASSURANCE PROVISIONS

4.1 CLASSIFICATION OF TESTS

4.1.1 Qualification Tests

Qualification tests are those performed on tubing submitted for qualification as a satisfactory product and

shall consist of all tests listed in this specification.

4.1.2 Acceptance Tests

Acceptance tests are those performed on tubing submitted for acceptance under contract. Acceptance tests

shall consist of:

Dimensions

Tensile Strength

Ultimate Elongation

Heat Shock

Longitudinal Change

4.2 SAMPLING INSTRUCTIONS

4.2.1 Qualification Test Samples

Qualification test samples shall consist of 15 m (50 feet) of tubing of each size.

Qualification of ES2000-No.1 qualifies ES2000-No.1 and ES2000-No.2

Qualification of ES2000-No.3 qualifies ES2000-No.3 and ES2000-No.4

4.2.2 Acceptance Test Samples

Acceptance test samples shall consist of not less than 5 m (16 feet) of tubing selected at random from each

lot. A lot shall consist of all tubing of the same size from the same production run and offered for inspection

at the same time.

4.3 TEST PROCEDURES

4.3.1 Material Properties

Unless otherwise specified, perform tests on specimens which have been recovered by heating for 3 minutes

in a 200 ± 5ºC (392 ± 9ºF) oven. Condition the test specimens (and measurement gauges when applicable)

for 3 hours at 23 ± 3ºC (73 ± 5ºF). For referee purposes, condition the test specimens at 50 ± 5 percent

relative humidity for 3 hours prior to testing. Use mechanical convection type ovens in which air passes the

specimens at a velocity of 30 to 60 m (100 to 200 feet) per minute.

SPECIFICATION RT-1112 REVISION 5 Page 3

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4.3.1.1 Dimensions and Longitudinal Change

Measure three 150 mm (6 inch) specimens of tubing, as supplied, for length ± 1 mm (± 1/32 inch) and

inside diameter in accordance with ASTM D 2671. Condition the specimens for 3 minutes in a 200 ± 5°C

(392 ± 9°F) oven, cool to 23 ± 3°C (73 ± 5°F), then re-measure. Prior to and after conditioning, the

dimensions of the tubing shall be in accordance with Table 1 and the longitudinal change shall be in

accordance with Table 3. Calculate the longitudinal change as follows:

C = L1 - L0

L0 x 100

Where: C = Longitudinal Change [percent]

L

0 = Length Before Conditioning [inches (mm)]

L

1 = Length After Conditioning [inches (mm)]

4.3.1.2 Tensile Strength and Ultimate Elongation

Perform the tests in accordance with ASTM D 2671 using 25 mm (1 inch) bench marks, 25 mm (1 inch)

initial jaw separation and jaw separatio n speed of 50 ± 5 mm (2.0 ± 0.2 inches) per minute.

Calculate the tensile strength based on the wall thickness of the jacket only.

4.3.1.3 Dynamic Cut-Through

Perform the test in accordance with ASTM D 3032. Recover the specimens on a 4.7 mm (0.187 inch)

diameter steel rod and cool to room temperature. Use the optional cutting edge with a flat configuration of

0.127 mm (0.005 inch). The speed shall be 0.2 inches (5.0 mm) per minute.

4.3.1.4 Flammability

Recover five 500 mm (20 inch) lengths of tubing over mandrels with a diameter 75 ± 5 percent of the

specified minimum expanded (as supplied) inside diameter of the tubing.

Using a Bunsen burner with a 100 mm (4 inch) tube, adjust the burner to achieve a flame with an inner blue

cone of approximately 50 mm (2 inches).

Suspend each specimen in a draft free environment in the configuration shown in Figure 1. The time of

exposure of the test flame to each specimen is one 30 second application.

Record the time for each specimen to self extinguish after removal of the flame. The result is the average

burning time for all five specimens.

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45º

tip of blue cone

burner tube

4 inches (100 mm)

ES2000

specimen

Figure 1. Flammability Test Configuration

V

e

r

t

i

c

a

l

a

x

i

s

4.3.2.1 Specimen Preparation

Where crosslinked polyolefin wire is specified for specimen preparation, use wire conforming to SAE J 1128

SXL. Where polyvinyl chloride wire is specified, use wire conforming to SAE J 1128 GPT. Test three

specimens for each property.

4.3.2.1.1 ES2000-No.1

Construct a 2 wire to 2 wire inline splice in any suitable manner (crimped, soldered or welded). Splice two

(2) AWG 20 wires to two (2) AWG 20 wires, using wires approximately 30 cm (12 inches) long. The splice

area shall have a length of approximately 12.5 mm (0.5 inch) of exposed conductor. Install a 50 mm (2 inch)

length of ES2000-No.1 centrally over the splice in an air circulating oven at 150 ± 3ºC (302 ± 5ºF) for 5

minutes, then cool to room temperature.

4.3.2.1.2 ES2000-No.3

Construct a 2 wire to 7 wire inline splice in any suitable manner (crimped, soldered or welded). Splice two

(2) AWG 14 wires to seven (7) AWG 20 wires, using wires approximately 30 cm (12 inches) long. The

splice area shall have a length of approximately 12.5 mm (0.5 inch) of exposed conductor. Install a 65 mm

(2.5 inch) length of ES2000-No.3 centrally over the splice in an air circulating oven at 150 ± 3ºC (302 ± 5ºF)

for 5 minutes, then cool to room temperature.

SPECIFICATION RT-1112 REVISION 5 Page 5

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4.3.2.2 Current Leakage

Test three specimens each with SXL wire and GPT wire.

Immerse the center section of all specimens in a 23 ± 3ºC (73 ± 5ºF) water bath containing 5 percent

sodium chloride by weight. The ends of the specimens should be a minimum of 50.8 mm (2 inches) above

the water line.

Measure the leakage current between the conductors in the specimens and the water bath after 24 hours of

immersion. The applied voltage for the measurement shall be 50 volts dc. After environmental exposure

(sections 4.3.2.3 through 4.3.2.7) the immersion period shall be 4 hours.

4.3.2.3 Flex Test

While at room temperature, wrap 3 specimens made with SXL wire and 3 specimens made with GPT wire

around 50.8 mm (2 inch) mandrels, using the following procedure. Attach one end of the specimen to the

mandrel and the other end to a weight (see Table 2). Rotate the mandrel sufficiently to cause the splice area

to wrap around the mandrel, and the wires on the opposite side of the splice to contact the mandrel. Rotate

the mandrel in the opposite direction until the splice is again wrapped around the mandrel. This shall be one

cycle. Test each sample for five cycles. Measure the current leakage in accordance with section 4.3.2.2.

4.3.2.4 Thermal Shock

Suspend vertically 3 specimens made with SXL wire in a circulating air oven for 30 minutes at 130 ± 5ºC

(266 ± 9ºF) and 3 specimens made with GPT wire for 30 minutes at 105 ± 5ºC (221 ± 9ºF). Remove the

specimens from the oven and within 2 minutes immerse them in a 5 percent sodium chloride solution by

weight at 5 ± 5ºC (41 ± 9ºF). Remove them from the bath within 30 minutes. This shall be one cycle. Test

the samples for 5 cycles and measure the current leakage in accordance with section 4.3.2.2.

4.3.2.5 Low Temperature Flexibility

4.3.2.5.1 SXL Wire

Condition 3 specimens in a cold chamber for 4 hours at -30 ± 3°C (-22 ± 5ºF). While at this temperature,

wrap the specimens around a 10 cm (4 inch) mandrel. Attach one end of the specimen to the mandrel and

the other end to a weight (see Table 2). Rotate the mandrel sufficiently to cause the splice area to wrap

around the mandrel, and the wires on the opposite side of the splice to contact the mandrel. Then rotate the

mandrel in the opposite direction until the splice is again wrapped around the mandrel. This shall be one

cycle. Test each specimen for five cycles. Upon completion of the fifth cycle, test the specimens for

dielectric withstand.

Dielectric Withstand

Immerse the center section of all specimens in a 23 ± 3ºC (73 ± 5ºF) water bath containing 5 percent sodium

chloride by weight. The ends of the specimens should be a minimum of 50.8 mm (2 inches) above the water

line. The specimens shall remain immersed in the bath for two hours prior to testing. Raise the voltage on

the immersed specimens to 1,000 volts ac and hold for 1 minute, then inspect for insulation rupture.

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4.3.2.5.2 GPT Wire

Fix one end of each of 3 specimens to a 10 cm (4 inch) diameter mandrel at 23 ± 3ºC (73 ± 5ºF). Attach the

weight specified in Table 2 to the free end of each specimen, then wrap around the mandrel. Remove the

weight, fix the free end of the specimens to the mandrels and place in a -30 ± 3ºC (-22 ± 5ºF) cold chamber

for 4 hours. Remove the mandrels with the wrapped specimens from the cold chamber and condition at

23 ± 3ºC (73 ± 5ºF) for 4 hours. Remove the specimens from the mandrels and test for dielectric withstand

in accordance with section 4.3.2.5.1.

4.3.2.6 Heat Aging

Suspend the specimens vertically for 168 hours in a circulating air oven.

SXL wire Heat age at 130 ± 5ºC (266 ± 9ºF)

GPT wire Heat age at 105 ± 5ºC (221 ± 9ºF)

Remove the specimens from the oven and within 2 minutes, immerse in a 5 percent sodium chloride solution

by weight at room temperature. Measure current leakage in accordance with section 4.3.2.2.

4.3.2.7 Fluid Immersion

4.3.2.7.1 Immerse 3 specimens of each wire type for 1 hour at 100 ± 3ºC (212 ± 5ºF) in each of the following fluids:

Oil, IRM 903 (ASTM D 471)

Automatic Transmission Fluid (Dextron III/Mercon)

Engine Coolant, Type III (ASTM D 3306)

4.3.2.7.2 Immerse 3 specimens of each wire type for 24 hours at 23 ± 3ºC (73 ± 5ºF) in each of the following fluids:

Diesel Fuel, Grade No. 2 (ASTM D 975)

Windshield Washer Fluid, PRESTONE

Fuel C, ASTM D 471 (SXL wire only)

4.3.2.7.3 Immerse 3 specimens of each wire type for 10 seconds in each of the following fluids at intervals of 30

minutes for 16 hours at 23 ± 3ºC (73 ± 5ºF) to simulate a splash environment:

Engine Cleaner, GUNK*

Brake Fluid, SAE J 1703

Allow the specimens to drain between immersions.

*Trademark of the Radiator Specialty Co., Charlotte, NC

4.3.2.7. 4 Visually inspect all fluid immersion specimens for splice insulation integrity. Calculate the percent swell of

the minimum outside dimension of the specimen. Immediately measure current leakage in accordance with

section 4.3.2.2.

4.4 REJECTION AND RETEST

SPECIFICATION RT-1112 REVISION 5 Page 7

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Failure of any sample of tubing to conform to any one of the requirements of this specification shall be

cause for rejection of the lot represented. Tubing which has been rejected may be replaced or reworked to

correct the defect and then resubmitted for acceptance. Before resubmitting, full particulars concerning

previous rejection and action taken to correct the defects shall be furnished to the inspector.

5. PREPARATION FOR DELIVERY

5.1 FORM

The tubing shall be supplied in cut pieces, unless otherwise specified.

5.2 PACKAGING

Packaging shall be in accordance with good commercial practice.

5.3 MARKING

Each container of tub ing shall be permanently and legibly marked with the size, quantity, manufacturer's

identification, part number and lot number.

TABLE 1

ES2000 Tubing Dimensions

As Supplied As Recovered

Size Minimum

Expanded I.D.

Including Core

Maximum

Recovered I.D.

Including Core

Minimum

Recovered

Jacket Wall

Minimum

Recovered

Adhesive Wall

Minimum

Recovered Total

Wall

inch mm inch mm inch mm inch mm inch mm

-No.1 0.225 5.72 0.050 1.27 0.025 0.64 0.022 0.56 0.047 1.20

-No.2 0.293 7.44 0.065 1.65 0.030 0.76 0.030 0.76 0.060 1.52

-No.3 0.427 10.85 0.095 2.41 0.035 0.89 0.040 1.02 0.075 1.91

-No.4 0.700 17.78 0.175 4.45 0.041 1.04 0.054 1.37 0.095 2.41

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TABLE 2

Weights for Flex Test Procedure

(Section 4.3.2.3)

Size Weight

-No.1 5 pounds (2.27 kg)

-No.3 10 pounds (4.54 kg)

TABLE 3

Requirements

PROPERTY UNIT REQUIREMENT TEST METHOD

Material Properties

Dimensions

inch (mm)

In accordance with Table 1

ASTM D 2671

Section 4.3.1.1

Longitudinal Change percent +0, -10

Tensile Strength psi (MPa) 1,500 (10.3) minimum ASTM D 2671

Ultimate Elongation percent 250 minimum Section 4.3.1.2

2% Secant Modulus* (expanded) psi (MPa) 20,000 (137) minimum ASTM D 2671

Heat Shock

4 hours at 225 ± 3ºC (437 ± 5ºF) -- No dripping, flowing or cracking

of outer jacket ASTM D 2671

Dynamic Cut Through pounds (kg) 30 (13.6) minimum ASTM D 3032

Section 4.3.1.3

Volume Resistivity ohm-cm 1.0 x 1012 minimum ASTM D 2671

Flammability Self-extinguishing within

30 seconds Section 4.3.1.4

Splice Performance Properties

Current Leakage (original sample)

microamps

0.25 maximum

Section 4.3.2.2

Room Temperature Flex Test -- -- Section 4.3.2.3

Current Leakage microamps 0.25 maximum Section 4.3.2.2

Thermal Shock -- -- Section 4.3.2.4

Current Leakage microamps 0.25 maximum Section 4.3.2.2

Low Temperature Flexibility -- -- Section 4.3.2.5

Dielectric Withstand

1 minute at 1,000 volts -- No breakdown Section 4.3.2.5.1

Heat Aging -- -- Section 4.3.2.6

Current Leakage microamps 0.25 maximum Section 4.3.2.2

Fluid Immersion -- -- Section 4.3.2.7

Current Leakage microamps 0.25 maximum Section 4.3.2.2

Swell percent 50 maximum Section 4.3.2.7.4

*Calculate based on wall thickness of jacket only.