Tyco Electronics Corporation 300 Constitutional Drive Menlo Park, CA 94025 USA Specification This Issue: Date: Replaces: RT-1157 Issue 2 November 7, 1988 Issue 1 THERMOFIT(R) ZEROHALTM ZHTM TUBING Elastomeric, Halogen-Free, Flame-Retarded, Flexible, Heat-Shrinkable 1. SCOPE This specification covers the requirements for one type of highly flexible, electrical insulating, extruded tubing whose diameter will reduce to a predetermined size upon the application of heat in excess of 121C (250F). 2. APPLICABLE DOCUMENTS This specification takes precedence over documents referenced herein. Unless otherwise specified, the latest issue of referenced documents applies. The following documents form a part of this specification to the extent specified herein. 2.1 GOVERNMENT-FURNISHED DOCUMENTS Military MIL-H-5606 MIL-T-5624 MIL-L-23699 MIL-C-24643 2.2 Hydraulic Fluid, Petroleum Base, Aircraft, Missile, and Ordnance Turbine Fuel, Aviation, Grades JP-4 and JP-5 Lubricating Oil, Aircraft Turbine Engines, Synthetic Base Cable and Cord, Electrical, Low Smoke, for Shipboard Use, General Specification for OTHER PUBLICATIONS American Society for Testing and Materials (ASTM) D 412 Standard Test Methods for Rubber Properties in Tension D 2671 Standard Methods of Testing Heat-Shrinkable Tubing for Electrical Use D 2863 Standard Method for Measuring the Minimum Oxygen Concentration to Support Candlelike Combustion of Plastics (Oxygen Index) D 3487 Specification for Mineral Insulating Oil Used in Electrical Apparatus E 662 Test Method for Specific Optical Density of Smoke Generated by Solid Materials (Copies of ASTM publications may be obtained from the American Society for Testing and Materials, 1916 Race Street, Philadelphia, Pennsylvania 19103). If this document is printed it becomes uncontrolled. Check for the latest revision. Page 2 SPECIFICATION RT-1157 ISSUE 2 3. REQUIREMENTS 3.1 MATERIAL The tubing shall be fabricated from a stabilized, flame retarded, halogen-free, modified polyolefin and shall be radiation crosslinked. It shall be homogeneous and essentially free from flaws, defects, pinholes, bubbles, seams, cracks, and inclusions. 3.2 COLOR The tubing shall be black, unless otherwise specified. 3.3 PROPERTIES The tubing shall meet all the requirements of Table 2. 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 the following: Dimensions Longitudinal Change Tensile Strength Ultimate Elongation Secant Modulus Dielectric Strength. 4.2 SAMPLING INSTRUCTIONS 4.2.1 Qualification Test Samples Qualification test samples shall consist of 50 feet (15 m) of tubing and a molded slab 6 x 6 x 0.118 0.02 inches (150 x 150 x 3 0.5 mm). The molded slab shall be fabricated from the same lot of material and subjected to the same degree of crosslinking as the tubing. Qualification of any size will qualify all sizes. If this document is printed it becomes uncontrolled. Check for the latest revision. SPECIFICATION RT-1157 ISSUE 2 Page 3 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 Unless otherwise specified, tests shall be performed on specimens which have been fully recovered by conditioning for 5 minutes in a 150 2C (302 4F) oven. Prior to all testing, the test specimens (and measurement gauges, when applicable) shall be conditioned for 3 hours at 23 3C (73 5F) and 50 5 percent relative humidity. All ovens shall be of the mechanical convection type in which air passes over the specimens at a velocity of 100 to 200 feet (30 to 60 m) per minute. 4.3.1 Dimensions and Longitudinal Change Three 6-inch (150-mm) specimens of tubing, as supplied, shall be measured for length 1/32 inch ( 1 mm) and inside diameter in accordance with ASTM D 2671, conditioned for 10 minutes in a 200 2C (392 4F) oven, cooled to 23 3C (73 5F) and then remeasured. 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 2. Longitudinal change shall be calculated as follows: C = Where: 4.3.2 C = L0 = L1 = L1 - L0 x 100 L0 Longitudinal Change (percent) Length Before Conditioning [inches (mm)] Length After Conditioning [inches (mm)] Tensile Strength and Ultimate Elongation Tubing shall be tested for tensile strength and ultimate elongation in accordance with ASTM D 2671. For tubing size No. 12/6 and smaller, the specimens shall be full sections of tubing. For size No. 18/9 and larger, the specimens shall be cut with Die D of ASTM D 412. The specimens shall have 1inch (25-mm) bench marks, centrally located. The testing machine shall have an initial jaw separation of 1 inch (25 mm) for full sections of tubing and 2 inches (50 mm) for die cut specimens. The rate of jaw separation shall be 5 .5 inches (125 12.5 mm) per minute. 4.3.3 Low Temperature Flexibility Three specimens, each 12 inches (300 mm) in length, shall be conditioned, with the appropriate mandrels at 25 3C (-13 5F) for 4 hours. For tubing sizes No. 5/2.5 or smaller, the specimens shall be whole sections of recovered tubing. For tubing sizes 8/4 and larger, the specimens shall be 1/4-inch (6.3-mm) wide strips cut from tubing which has been recovered in accordance with 4.3. The mandrel diameter shall be 40 times, 10% the specimen thickness. For tubular specimens, the specimen thickness shall be taken as the outside diameter. While at the specified temperature, and still in the cold chamber, the specimens shall be wrapped around the mandrel not less than 360 degrees in 10 2 seconds. The specimens then shall be visually examined for evidence of cracking. If this document is printed it becomes uncontrolled. Check for the latest revision. Page 4 4.3.4 SPECIFICATION RT-1157 ISSUE 2 Heat Shock Three 6-inch (150-mm) specimens of tubing shall be conditioned for 4 hours in a 225 3C (437 5F) oven. After conditioning, the specimens shall be removed from the oven, cooled to room temperature, and visually examined for evidence of dripping, flowing, or cracking. 4.3.5 Heat Resistance Three specimens of tubing prepared and measured in accordance with 4.3.2, shall be conditioned for 168 hours in a 150 2C (302 4F) oven. After conditioning, the specimens shall be removed from the oven, cooled to room temperature, and tested for tensile strength and ultimate elongation in accordance with 4.3.2. 4.3.6 Limiting Oxygen Index Test three specimens in accordance with ASTM D 2863, 0.26 0.02 inches (6.5 0.5 mm ) wide; 0.118 0.02 inches (3.0 + 0.5 mm ) thick; 2-3/4 to 6 inches (70 to 150 mm ) long cut from a molded slab 6 x 6 x 0.118 + 0.02 inches (150 x 150 x 3.0 + 0.5 mm ) . The molded slabs shall be made from the same lot of material and subjected to the same degree of crosslinking as the tubing. 4.3.7 Oxygen Index at Elevated Temperature Determine the oxygen index using the apparatus described in ASTM D 2863 with the exception of a special double wall glass chimney replacing the standard chimney. The specimens shall be in accordance with section 4.3.6. This chimney must be equipped with a heating element and temperature controller capable of maintaining the temperature of the gas atmosphere in the chimney to 2C ( 4F). With the gas supply regulated to 21% oxygen content, determine the temperature, within 10C (18F), at which the specimen will burn 3 minutes or 2 inches (50 mm), whichever occurs first, using the endpoint criteria of D 2863. Report this temperature as the oxygen index at elevated temperature. 4.3.8 Fluid Resistance Three specimens prepared in accordance with 4.3.2, shall be completely immersed in each of the fluids listed in the applicable section of Table 2 for 24 hours at the specified temperature. The volume of the fluid shall be not less than 20 times that of the specimens. After conditioning, the specimens shall be lightly wiped and then air dried for 30 to 60 minutes at room temperature. The specimens then shall be tested for tensile strength and ultimate elongation in accordance with 4.3.2. 4.4 REJECTION AND RETEST Failure of any sample of tubing to comply with 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 submitted for acceptance. Before resubmitting, full particulars concerning the rejection and the action taken to correct the defect shall be furnished to the inspector. If this document is printed it becomes uncontrolled. Check for the latest revision. SPECIFICATION RT-1157 ISSUE 2 5. PREPARATION FOR DELIVERY 5.1 FORM Page 5 Unless otherwise specified, the tubing shall be supplied on spools. 5.2 PACKAGING Packaging shall be in accordance with good commercial practice. The shipping container shall be not less than 125 pound-test fiberboard. 5.3 MARKING Each container of tubing shall be permanently and legibly marked with the size, quantity, manufacturer's identification, and lot number. If this document is printed it becomes uncontrolled. Check for the latest revision. Page 6 SPECIFICATION RT-1157 ISSUE 2 TABLE 1 Tubing Dimensions Size 3/1.5 5/2.5 8/4 12/6 18/9 24/12 40/20 60/30 As Supplied Inside Diameter Minimum in. mm. .118 3.0 .197 5.0 .315 8.0 .472 12.0 .709 18.0 .945 24.0 1.575 40.0 2.362 60.0 Inside Diameter Maximum in. mm. .059 1.5 .098 2.5 .157 4.0 .236 6.0 .354 9.0 .472 12.0 .787 20.0 1.181 30.0 As Recovered Wall Thickness Minimum Maximum in. mm. in. mm. .024 0.60 .032 0.80 .025 0.63 .035 0.87 .025 0.65 .037 0.95 .029 0.75 .041 1.05 .032 0.82 .046 1.18 .035 0.90 .051 1.30 .042 1.07 .060 1.53 .048 1.22 .070 1.78 If this document is printed it becomes uncontrolled. Check for the latest revision. Nominal in. mm. .028 0.70 .030 0.75 .031 0.80 .035 0.90 .039 1.00 .043 1.10 .051 1.30 .059 1.50 SPECIFICATION RT-1157 ISSUE 2 Page 7 TABLE 2 Requirements PROPERTY PHYSICAL Dimensions Longitudinal Change Tensile Strength Ultimate Elongation Secant Modulus at 2% Strain Specific Gravity Low Temperature Flexibility 4 hours at -25C (-13F) Heat Shock 4 hours at 225C (437F) Heat Resistance 168 hours at 150C (302F) Followed by tests for: Tensile Strength Ultimate Elongation ELECTRICAL Dielectric Strength Volume Resistivity CHEMICAL Water Absorption 24 hours at 23C (73F) 24 hours at 70C (158F) Limiting Oxygen Index Oxygen Index at Elevated Temperature Flammability Average time of burning Sizes No. 3/1.5 through No. 12/6 Sizes No. 18/9 through No. 60/30 Smoke Density, Ds 4 minutes, flaming mode Acid Gas Generation HCl Equivalent UNIT REQUIREMENT TEST METHOD Inches(mm) Percent psi (MPa) Percent psi (MPa) ----- In accordance with Table 1 0 to -10 1150 (8) minimum 200 min. 19,000 (130) maximum 1.5 maximum No cracking Section 4.3.1 ASTM D 2671 Section 4.3.2 ASTM D 2671 ASTM D 2671 ASTM D 2671 Section 4.3.3 --- No dripping, flowing or cracking Section 4.3.4 --- --- Section 4.3.5 psi (MPa) Percent 1150 (8) minimum 100 minimum V/mil (kV/m) ohm-cm 375 (15) minimum 1012 minimum Percent Percent Percent 0.75 maximum 3.5 maximum 29 minimum C 250 minimum Section 4.3.6 ASTM D 2863 Section 4.3.7 --- No burning of indicator ASTM D 2671 seconds seconds --- 60 maximum 30 maximum 70 maximum Procedure B Procedure A ASTM E 662 Percent 1.5 maximum MIL-C-24643 ASTM D 2671 ASTM D 2671 ASTM D 2671 If this document is printed it becomes uncontrolled. Check for the latest revision. Page 8 SPECIFICATION RT-1157 ISSUE 2 TABLE 2 Requirements (continued) PROPERTY CHEMICAL (continued) Fluid Resistance 24 hours at 23C (73F) in: Hydraulic Fluid (MIL-H-5606) JP-4 Fuel (MIL-T-5624) *Skydrol 500 Diesel Fuel (VV-F-800) Water 24 hours at 50C (122F) in: Lube Oil (MIL-L-23699) Insulating Oil (ASTM D 3487) 24 hr. at 100C (212F) in: ASTM #2 Oil Followed by tests for: Tensile Strength Ultimate Elongation UNIT REQUIREMENT TEST METHOD --- --- Section 4.3.8 psi (MPa) Percent 725 (5) minimum 150 minimum *TM Monsanto Co. If this document is printed it becomes uncontrolled. Check for the latest revision.