Tyco Electronics Corporation 300 Constitutional Drive Menlo Park, CA 94025 USA SPECIFICATION: THIS ISSUE: DATE: REPLACES: RT-1113 Issue 2 May 15, 2003 Issue 1 THERMOFIT(R) ES1000 TUBING Polyolefin, Semi-Rigid, 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 135 C (275 F). 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) D 2671 Standard Methods of Testing Heat-Shrinkable Tubing for Electrical Use (Copies of ASTM publications may be obtained from the American Society for Testing and Materials, 1916 Race Street, Philadelphia, Pennsylvania 19103.) 3. REQUIREMENTS 3.1 DIMENSIONS The dimensions shall be in accordance with Table 2. 3.2 MATERIALS The tubing shall consist of two components. a) The jacket shall be fabricated from a thermally stabilized, modified semi-rigid polyolefin, and shall be crosslinked by irradiation. b) The liner shall be a thermoplastic adhesive sealant 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. If this document is printed it becomes uncontrolled. Check for the latest revision. Page 2 3.3 SPECIFICATION RT-1113 REVISION Issue 2 COLOR Unless otherwise specified, the jacket shall be clear; 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 Acceptance tests shall be performed on each lot of tubing or an a skip-lot basis per a statistically justified control plan determined by Thermofit. 4.2 SAMPLING INSTRUCTIONS 4.2.1 Qualification Test Samples Qualification test samples shall consist of 50 feet (15 m) of tubing of each size. Qualification of ES1000-1 qualifies ES1000-1 and ES1000-2 Qualification of ES1000-3 qualifies ES1000-3 and ES1000-4 4.2.2 Acceptance Test Samples Acceptance test samples shall consist of not less than 16 feet (5 m) 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 4.3.1.1 Unless otherwise specified, perform tests on specimens which have been recovered by conditioning for 3 minutes in a 175 3 C (347 5 F) oven. Condition the test specimens (and measurement gauges, when applicable) for 3 hours at 23 3 C (73 5 F) and 50 5 percent relative humidity for 3 hours prior to all testing. Use mechanical convection type ovens in which air passes the specimens at a velocity of 100 to 200 feet (30 to 60 m) per minute. Dimensions and Longitudinal Change If this document is printed it becomes uncontrolled. Check for the latest revision. SPECIFICATION RT-1113 REVISION Issue 2 Page 3 Measure three 6-inch (150 mm) specimens of tubing as supplied, for length 1/32 inch ( 1 mm), 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), and then remeasure. 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: L - L C = 1 L 0 x 100 0 Where: 4.3.1.2 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 1-inch (25-mm) bench marks, 1-inch (25-mm) initial jaw separation and jaw separation speed of 2 0.2 inches (50 5 mm) per minute. Calculate the tensile strength based on the wall thickness of the jacket only. 4.3.1.3 Heat Aging Three samples shall be conditioned for 168 hours in an air circulating oven at 1753C. After conditioning, the specimens shall be cooled to room temperature and bent through 180 over a mandrel selected in accordance to Table 1. Any side cracking caused by flattening of the specimen on the mandrel shall be disregarded. Table 1: Mandrel Sizes Tube Size "I.D", inches .047 ID .250 .250 ID .500 .500 ID 2.0 4.4 Mandrel, O.D. inches .313 .375 .437 REJECTION AND RETEST 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 lengths in accordance with the applicable drawings. 5.2 PACKAGING Packaging shall be in accordance with good commercial practice. If this document is printed it becomes uncontrolled. Check for the latest revision. Page 4 5.3 SPECIFICATION RT-1113 REVISION Issue 2 MARKING Each container of tubing shall be permanently and legibly marked with the size, quantity, manufacturer's identification, part number, and lot number. TABLE 2 Tubing Dimensions Part Number ES1000-1 ES1000-2 ES1000-3 ES1000-4 As Supplied Minimum Expanded I.D. Including Core mm. in. 5.72 0.225 7.44 0.293 0.427 10.85 0.700 17.78 Maximum Recovered I.D. Including Core mm. in. 1.27 0.050 1.65 0.065 2.41 0.095 4.45 0.175 As Recovered Minimum Minimum Recovered Recovered Jacket Wall Adhesive Wall mm. mm. in. in. 0.64 0.56 0.025 0.022 0.76 0.76 0.030 0.030 0.89 1.02 0.035 0.040 1.04 1.37 0.041 0.054 Minimum Recovered Total Wall mm. in. 1.20 0.047 1.52 0.060 1.91 0.075 2.41 0.095 TABLE 3 Requirements PROPERTY Material Properties Dimensions UNIT REQUIREMENT TEST METHOD inches (mm) ASTM D 2671 Section 4.3.1.1 Longitudinal Change Tensile Strength Ultimate Elongation Low Temperature Flexibility -40 C Heat Shock 4 hours at 225 C (437 F) Heat Aging 168 hrs at 175 C Dielectric Strength, (jacket only)* Volume Resistivity Water Absorption percent psi (MPa) percent -- In accordance with Table 2 0 to -10 1500 (10.3) minimum 200 minimum No Cracking No cracking of outer jacket -- No Cracking Volts/mil ohm-cm % 350 minimum 1.0 x 1012 minimum 1.0 maximum ASTM D 3032 Section 4.3.1.3 ASTM D 149 ASTM D 2671 ASTM D 570 Procedure A *Calculate based on wall thickness of jacket only. 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