ZHTM-8/4-0-SP (6649664003) - Tyco Electronics

If this document is printed it becomes uncontrolled. Check f

or the latest revision.

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® ZEROHAL™ 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 121°C

(250°F).

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 Hydraulic Fluid, Petroleum Base, Aircraft, Missile, and Ordnance

MIL-T-5624 Turbine Fuel, Aviation, Grades JP-4 and JP-5

MIL-L-23699 Lubricating Oil, Aircraft Turbine Engines, Synthetic Base

MIL-C-24643 Cable and Cord, Electrical, Low Smoke, for Shipboard Use, General Specification for

2.2 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 Candle-

like 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).

Page 2 SPECIFICATION RT-1157 ISSUE 2

If this document is printed it becomes uncontrolled. Check f

or the latest revision.

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.

SPECIFICATION RT-1157 ISSUE 2 Page 3

If this document is printed it becomes uncontrolled. Check f

or the latest revision.

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 ± 2°C (302 ± 4°F) oven. Prior to all testing, the test specimens (and

measurement gauges, when applicable) shall be conditioned for 3 hours at

23 ± 3°C (73 ± 5°F) 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 ± 2°C (392 ±

4°F) oven, cooled to 23 ± 3°C (73 ± 5°F) 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 = L1 - L0

L0 x 100

Where: C = Longitudinal Change (percent)

L0 = Length Before Conditioning [inches (mm)]

L1 = Length After Conditioning [inches (mm)]

4.3.2 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 1-

inch (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 ± 3°C (-13 ± 5°F) 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.

Page 4 SPECIFICATION RT-1157 ISSUE 2

If this document is printed it becomes uncontrolled. Check f

or the latest revision.

4.3.4 Heat Shock

Three 6-inch (150-mm) specimens of tubing shall be conditioned for 4 hours in a 225 ± 3°C

(437 ± 5°F) 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 ± 2°C (302 ± 4°F) 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 ± 2°C (± 4°F).

With the gas supply regulated to 21% oxygen content, determine the temperature, within 10°C (18°F), 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.

SPECIFICATION RT-1157 ISSUE 2 Page 5

If this document is printed it becomes uncontrolled. Check f

or the latest revision.

5. PREPARATION FOR DELIVERY

5.1 FORM

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.

Page 6 SPECIFICATION RT-1157 ISSUE 2

If this document is printed it becomes uncontrolled. Check f

or the latest revision.

TABLE 1

Tubing Dimensions

As Supplied As Recovered

Inside Diameter Inside Diameter Wall Thickness

Size Minimum Maximum Minimum Maximum Nominal

in. mm. in. mm. in. mm. in. mm. in. mm.

3/1.5 .118 3.0 .059 1.5 .024 0.60 .032 0.80 .028 0.70

5/2.5 .197 5.0 .098 2.5 .025 0.63 .035 0.87 .030 0.75

8/4 .315 8.0 .157 4.0 .025 0.65 .037 0.95 .031 0.80

12/6 .472 12.0 .236 6.0 .029 0.75 .041 1.05 .035 0.90

18/9 .709 18.0 .354 9.0 .032 0.82 .046 1.18 .039 1.00

24/12 .945 24.0 .472 12.0 .035 0.90 .051 1.30 .043 1.10

40/20 1.575 40.0 .787 20.0 .042 1.07 .060 1.53 .051 1.30

60/30 2.362 60.0 1.181 30.0 .048 1.22 .070 1.78 .059 1.50

SPECIFICATION RT-1157 ISSUE 2 Page 7

If this document is printed it becomes uncontrolled. Check f

or the latest revision.

TABLE 2

Requirements

PROPERTY UNIT REQUIREMENT TEST METHOD

PHYSICAL

Dimensions

Inches(mm)

In accordance with Table 1

Section 4.3.1

Longitudinal Change Percent 0 to -10 ASTM D 2671

Tensile Strength psi (MPa) 1150 (8) minimum Section 4.3.2

Ultimate Elongation Percent 200 min. ASTM D 2671

Secant Modulus at 2% Strain psi (MPa) 19,000 (130) maximum ASTM D 2671

Specific Gravity --- 1.5 maximum ASTM D 2671

Low Temperature Flexibility

4 hours at -25°C (-13°F) --- No cracking Section 4.3.3

Heat Shock

4 hours at 225°C (437°F) --- No dripping, flowing or cracking Section 4.3.4

Heat Resistance

168 hours at 150°C (302°F)

Followed by tests for:

--- --- Section 4.3.5

Tensile Strength psi (MPa) 1150 (8) minimum

Ultimate Elongation Percent 100 minimum

ELECTRICAL

Dielectric Strength

V/mil (kV/m)

375 (15) minimum

ASTM D 2671

Volume Resistivity ohm-cm 1012 minimum ASTM D 2671

CHEMICAL

Water Absorption

24 hours at 23°C (73°F)

Percent

0.75 maximum

ASTM D 2671

24 hours at 70°C (158°F) Percent 3.5 maximum

Limiting Oxygen Index Percent 29 minimum Section 4.3.6

ASTM D 2863

Oxygen Index

at Elevated Temperature °C 250 minimum Section 4.3.7

Flammability --- No burning of indicator ASTM D 2671

Average time of burning

Sizes No. 3/1.5 through No. 12/6

seconds

60 maximum

Procedure B

Sizes No. 18/9 through No. 60/30 seconds 30 maximum Procedure A

Smoke Density, Ds

4 minutes, flaming mode --- 70 maximum ASTM E 662

Acid Gas Generation

HCl Equivalent Percent 1.5 maximum MIL-C-24643

Page 8 SPECIFICATION RT-1157 ISSUE 2

If this document is printed it becomes uncontrolled. Check f

or the latest revision.

TABLE 2

Requirements

(continued)

PROPERTY UNIT REQUIREMENT TEST METHOD

CHEMICAL (continued)

Fluid Resistance

24 hours at 23°C (73°F) in:

Hydraulic Fluid (MIL-H-5606)

JP-4 Fuel (MIL-T-5624)

*Skydrol 500

Diesel Fuel (VV-F-800)

Water

---

Section 4.3.8

24 hours at 50°C (122°F) in:

Lube Oil (MIL-L-23699)

Insulating Oil (ASTM D 3487)

24 hr. at 100°C (212°F) in:

ASTM #2 Oil

Followed by tests for:

Tensile Strength psi (MPa) 725 (5) minimum

Ultimate Elongation Percent 150 minimum

*TM Monsanto Co.