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 135C (275F). 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. (c) 2008 Tyco Electronics Corporation. All rights reserved If this document is printed it becomes uncontrolled. Check for the latest revision. Page 2 3.3 SPECIFICATION RT-1112 REVISION 5 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 5C (392 9F) oven. Condition the test specimens (and measurement gauges when applicable) for 3 hours at 23 3C (73 5F). 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. (c) 2008 Tyco Electronics Corporation. All rights reserved If this document is printed it becomes uncontrolled. Check for the latest revision. SPECIFICATION RT-1112 REVISION 5 4.3.1.1 Page 3 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 5C (392 9F) oven, cool to 23 3C (73 5F), 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 = Where: 4.3.1.2 L1 - L0 x 100 L0 C = Longitudinal Change [percent] L0 = Length Before Conditioning [inches (mm)] L1 = Length After Conditioning [inches (mm)] 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 separation 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. (c) 2008 Tyco Electronics Corporation. All rights reserved If this document is printed it becomes uncontrolled. Check for the latest revision. Page 4 SPECIFICATION RT-1112 REVISION 5 ES2000 specimen 45 V e r t i c a l 4 inches (100 mm) a x i s 45 tip of blue cone burner tube Figure 1. Flammability Test Configuration 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 3C (302 5F) 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 3C (302 5F) for 5 minutes, then cool to room temperature. (c) 2008 Tyco Electronics Corporation. All rights reserved If this document is printed it becomes uncontrolled. Check for the latest revision. SPECIFICATION RT-1112 REVISION 5 4.3.2.2 Page 5 Current Leakage Test three specimens each with SXL wire and GPT wire. Immerse the center section of all specimens in a 23 3C (73 5F) 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 5C (266 9F) and 3 specimens made with GPT wire for 30 minutes at 105 5C (221 9F). Remove the specimens from the oven and within 2 minutes immerse them in a 5 percent sodium chloride solution by weight at 5 5C (41 9F). 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 3C (-22 5F). 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 3C (73 5F) 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. (c) 2008 Tyco Electronics Corporation. All rights reserved If this document is printed it becomes uncontrolled. Check for the latest revision. Page 6 SPECIFICATION RT-1112 REVISION 5 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 3C (73 5F). 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 3C (-22 5F) cold chamber for 4 hours. Remove the mandrels with the wrapped specimens from the cold chamber and condition at 23 3C (73 5F) 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 GPT wire Heat age at 130 5C (266 9F) Heat age at 105 5C (221 9F) 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 3C (212 5F) 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 3C (73 5F) 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 3C (73 5F) 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 (c) 2008 Tyco Electronics Corporation. All rights reserved If this document is printed it becomes uncontrolled. Check for the latest revision. SPECIFICATION RT-1112 REVISION 5 Page 7 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 tubing shall be permanently and legibly marked with the size, quantity, manufacturer's identification, part number and lot number. TABLE 1 ES2000 Tubing Dimensions Size -No.1 -No.2 -No.3 -No.4 As Supplied Minimum Expanded I.D. Including Core inch mm 0.225 5.72 0.293 7.44 0.427 10.85 0.700 17.78 Maximum Recovered I.D. Including Core inch mm 0.050 1.27 0.065 1.65 0.095 2.41 0.175 4.45 As Recovered Minimum Minimum Recovered Recovered Jacket Wall Adhesive Wall inch mm inch mm 0.025 0.64 0.022 0.56 0.030 0.76 0.030 0.76 0.035 0.89 0.040 1.02 0.041 1.04 0.054 1.37 (c) 2008 Tyco Electronics Corporation. All rights reserved If this document is printed it becomes uncontrolled. Check for the latest revision. Minimum Recovered Total Wall inch mm 0.047 1.20 0.060 1.52 0.075 1.91 0.095 2.41 Page 8 SPECIFICATION RT-1112 REVISION 5 TABLE 2 Weights for Flex Test Procedure (Section 4.3.2.3) Size -No.1 -No.3 Weight 5 pounds (2.27 kg) 10 pounds (4.54 kg) TABLE 3 Requirements PROPERTY Material Properties Dimensions UNIT REQUIREMENT TEST METHOD inch (mm) In accordance with Table 1 ASTM D 2671 Section 4.3.1.1 Longitudinal Change Tensile Strength Ultimate Elongation 2% Secant Modulus* (expanded) Heat Shock 4 hours at 225 3C (437 5F) Dynamic Cut Through percent psi (MPa) percent psi (MPa) -- +0, -10 1,500 (10.3) minimum 250 minimum 20,000 (137) minimum No dripping, flowing or cracking of outer jacket 30 (13.6) minimum Volume Resistivity Flammability ohm-cm 1.0 x 1012 minimum Self-extinguishing within 30 seconds microamps -microamps -microamps --- 0.25 maximum -0.25 maximum -0.25 maximum -No breakdown Section 4.3.2.2 Section 4.3.2.3 Section 4.3.2.2 Section 4.3.2.4 Section 4.3.2.2 Section 4.3.2.5 Section 4.3.2.5.1 -microamps -microamps percent -0.25 maximum -0.25 maximum 50 maximum Section 4.3.2.6 Section 4.3.2.2 Section 4.3.2.7 Section 4.3.2.2 Section 4.3.2.7.4 Splice Performance Properties Current Leakage (original sample) Room Temperature Flex Test Current Leakage Thermal Shock Current Leakage Low Temperature Flexibility Dielectric Withstand 1 minute at 1,000 volts Heat Aging Current Leakage Fluid Immersion Current Leakage Swell pounds (kg) *Calculate based on wall thickness of jacket only. (c) 2008 Tyco Electronics Corporation. All rights reserved If this document is printed it becomes uncontrolled. Check for the latest revision. ASTM D 2671 Section 4.3.1.2 ASTM D 2671 ASTM D 2671 ASTM D 3032 Section 4.3.1.3 ASTM D 2671 Section 4.3.1.4