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Tyco Electronics Corporation
300 Constitutional Drive
Menlo Park, CA 94025 USA
Specification
This Issue:
Date:
Replaces:
RW-3009
Issue 3
July 18, 2003
Issue 2
VERSAFIT® TUBING
Polyolefin, Flexible, Heat-Shrinkable, Flame Retardant
1. SCOPE
This specification covers the requirements for one type of flexible electrical insulating, extruded tubing
whose diameter will reduce to a predetermined size upon the application of heat in excess of 90°C (194°F).
This tubing meets the requirements of SAE-AMS-DTL-23053/5 with a continuous operating temperature
range of -55° C to +135° C. Versafit is free of polybrominated biphenyls (PBB) and polybrominated
biphenyl oxides (PBBO). Versafit is also a 125°C, VW-1 rated, UL recognized tubing meeting the
requirements of UL 224 as well as meeting the requirements of Standard C22.2 No. 198.1 and is CSA
certified.
2. APPLICABLE DOCUMENTS
This specification takes precedence over documents referenced herein. Unless otherwise specified, the latest
issued of referenced documents applies. The following documents form a part of this specification to the
extent specified herein.
2.1 UNDERWRITERS LABORATORIES, INCORPORATED
UL Subject 224 Extruded Insulating Tubing
(Copies of UL publication may be obtained from Underwriters Laboratories, Inc., 1285 Walt Whitman Road,
Melville, Long Island, New York 11746.)
2.2 CANADIAN STANDARDS ASSOCIATION
C22.2 No. 198.1 Extruded Insulating Tubing
(Copies of CSA publications may be obtained from Canadian Standards Association, 1897 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3.)
2.3 OTHER PUBLICATIONS
ISO 846 Plastics-Evaluation of the action of microorganisms.
American Society for Testing and Materials (ASTM)
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.)
Page 2 SPECIFICATION RW-3009 ISSUE 3
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3. REQUIREMENTS
3.1 MATERIAL
The tubing shall be fabricated from thermally stabilized, flame-retardant, modified polyolefin and shall be
crosslinked by irradiation. It shall be homogeneous and essentially free from flaws, defects, pinholes,
bubbles, seams, cracks, and inclusions.
3.2 PROPERTIES
The tubing shall meet the requirements of Table 2.
3.3 COLOR
The tubing shall be available in black, white, red, yellow, blue, green, brown, orange, violet and gray.
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
Statistical process control data may be used to demonstrate conformance for dimensions.
4.2 SAMPLING INSTRUCTIONS
4.2.1 Qualification Test Samples
Qualification test samples shall consist of 15mm (50 feet) of tubing of the size and color specified.
Qualification of one size or color shall qualify all sizes and colors.
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.
SPECIFICATION RW-3009 ISSUE 3 Page 3
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4.3 TEST PROCEDURES
Unless otherwise specified, tests shall be performed on specimens which have been fully recovered by
conditioning in accordance with 4.3.1 Prior to all testing, the test specimen (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 the specimens at a velocity of 30 - 60 m
(100 to 200 feet) per minute.
4.3.1 Dimensions and Longitudinal Change
Three 150-mm (6-inch) specimens of tubing, as supplied, shall be measured for length, to an accuracy of ± 1
mm (±1/32 inch), and inside diameter in accordance with ASTM D 2671. The specimens then shall be
conditioned for 3 minutes in a 200 ± 3°C (392 ± 5°F) oven, removed from the oven, cooled to 23 ± 3°C (73 ±
5°F), re-measured for length, inside diameter, and wall thickness in accordance with ASTM D 2671. The
longitudinal change shall be calculated as follows:
C = L1 - L0
L0 x 100
Where: C = Longitudinal Change (percent)
L
0 = Length Before Conditioning [mm (inches)]
L
1 = Length After Conditioning [mm (inches)]
4.3.2 Tensile Strength and Ultimate Elongation
The tensile strength and ultimate elongation of the tubing shall be determined in accordance with ASTM D
2671 using 25-mm (1-inch) benchmarks and a 25-mm (1-inch) initial jaw separation. The speed of jaw
separation shall be 500 ± 50 mm (20 ± 2 inches) per minute.
4.3.3 Secant Modulus
The secant modulus of the tubing shall be tested using tubing as supplied in accordance with ASTM D 2671.
4.3.4 Copper Stability
Three 150-mm (6-inch) specimens of tubing shall be slipped over a snug filling, straight, clean, bare copper
conductor. For tubing sizes 1/4 and smaller a solid conductor shall be used; for tubing sizes 3/8 and larger a
solid or tubular conductor shall be used. The specimens on the conductors shall be conditioned for 24 hours
in a desiccator or similar humidity chamber at 90 to 95 percent relative humidity and 23 ± 3°C (73 ± 5°F).
Three specimens shall be conditioned for 7 days in 158.0 ± 1.0°C (316.4± 1.8°F) oven. After conditioning,
the specimens shall be removed from the oven and cooled to 23 ± 3°C (73 ± 5°F). The copper conductor
than shall be removed from the tubing, and the tubing and conductor shall then be examined. Darkening of
the copper due to normal air oxidation shall not be cause for rejection. The tubing then shall be conditioned
at room temperature for 16 to 96 hours and tested for ultimate elongation in accordance with 4.3.2.
Page 4 SPECIFICATION RW-3009 ISSUE 3
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4.3.5 Dielectric Withstand, Breakdown, and Strength
The dielectric strength of the tubing shall be measured under oil in accordance with ASTM D 2671. Five
150-mm (6-inch) specimens of tubing shall be recovered over a metal mandrel by conditioning for 3 minutes
in a 200 ± 3°C (392 ± 5°F) oven. The mandrel diameter shall be slightly larger than the fully recovered
inside diameter of the tubing being tested. The metal mandrel shall serve as one electrode and a 25mm (1-
inch) wide strip of lead foil wrapped around the outside of the tubing as the other electrode. The test voltage
shall be applied at a rate of rise of 500 volts per second. Thickness measurements for calculating dielectric
strength shall be made adjacent to the point of breakdown. Specimens for dielectric withstand shall be held
for 60 seconds at 2500 volts.
4.3.6 Corrosive Effect
Three specimens of tubing shall be tested for copper contact corrosion in accordance with ASTM D 2671,
Procedure B. Three specimens shall be conditioned for 7 days in a 158.0 ± 1.0°C (316.4 ± 1.8°F) oven.
After conditioning, the specimens shall be visually examined for evidence of corrosion.
4.4 REJECTION AND RETEST
Failure of any samples 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 the
rejection and the action taken to correct the defect shall be furnished to the inspector.
5. PREPARATION FOR DELIVERY
5.1 FORM
The tubing shall be supplied on spools, 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, specification number, product designation, and lot number.
SPECIFICATION RW-3009 ISSUE 3 Page 5
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TABLE 1
Versafit
TUBING DIMENSIONS,
IMPERIAL
(USA CUSTOMARY)
AS SUPPLIED RECOVERED
Inside Diameter Inside Diameter Wall Thickness
Size Maximum Minimum Maximum Nominal
Mm in mm in mm in mm in mm in
3/64 1.63±.2 .064±.008 0.58 .023 0.32 .013 0.48 .019 0.40 .016
1/16 1.85± .2 .073±.007 0.79 .031 0.35 .014 0.51 .020 0.43 .017
3/32 2.79± .2 .110±.007 1.17 .046 0.43 .017 0.59 .023 0.51 .020
1/8 3.43± .2 .135±.007 1.57 .062 0.43 .017 0.59 .023 0.51 .020
3/16 5.21± .3 .205±.010 2.36 .093 0.43 .017 0.59 .023 0.51 .020
1/4 7.11± .3 .280±.010 3.17 .125 0.56 .022 0.72 .028 0.64 .025
3/8 10.16± .4 .400±.015 4.74 .187 0.56 .022 0.72 .028 0.64 .025
1/2 13.72± .4 .540±.015 6.35 .250 0.56 .022 0.72 .028 0.64 .025
5/8 16.90± .4 .665±.015 8.0 .315 0.68 .027 0.84 .033 0.76 .030
3/4 20.45± .4 .805±.015 9.52 .375 0.68 .027 0.84 .033 0.76 .030
1 26.80± .4 1.055±.015 12.70 .500 0.76 .030 1.01 .040 0.88 .035
1-1/4 33.40± .7 1.315±.025 15.88 .625 0.86 .034 1.17 .046 1.01 .040
1-1/2 39.88± .8 1.570±.030 19.05 .750 0.86 .034 1.17 .046 1.01 .040
2 52.83±.1.0 2.080±.040 25.40 1.000 0.96 .038 1.32 .052 1.14 .045
3 78.49±.1.0 3.090±.040 38.10 1.500 1.06 .042 1.47 .058 1.27 .050
4 104.14±.1.3 4.100± 50.80 2.000 1.17 .046 1.63 .064 1.39 .055
Versafit 3X
AS SUPPLIED RECOVERED
Inside Diameter Inside Diameter Wall Thickness
Size Minimum Maximum Minimum Maximum Nominal
in. mm. in. mm. in. mm. in. mm. in. mm.
1/8 .125 3.2 .042 1.1 .020 0.50 .026 0.66 .023 0.58
1/4 .250 6.4 .083 2.2 .020 0.50 .026 0.66 .023 0.58
3/8 .375 9.5 .125 3.2 .021 0.53 .027 0.69 .024 0.61
1/2 .500 12.7 .166 4.3 .021 0.53 .027 0.69 .024 0.61
3/4 .750 19.1 .250 6.4 .021 0.53 .027 0.69 .024 0.61
1 1.000 25.4 .333 8.5 .022 0.56 .028 0.72 .025 0.64
Page 6 SPECIFICATION RW-3009 ISSUE 3
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TABLE 2
Requirements
PROPERTY UNIT REQUIREMENT TEST
METHOD
PHYSICAL
Dimensions
mm(inches)
In accordance with Table 1
Section 4.3.1
Dimensional Recovery ASTM D 2671
Longitudinal Change Section 4.3.1
ASTM D 2671 Percent +1, -5 ASTM D 2671
ASTMD 2671 (Over-expanded sizes) Percent +0, -15 ASTMD 2671
UL 224 Percent +3, -3 UL 224
Eccentricity (Recovered) Percent 30 maximum ASTM D 2671
Tensile Strength MPa (psi) 10.3 minimum (1500) Section 4.3.2
Ultimate Elongation Percent 200 minimum ASTM D 2671
Secant Modulus (expanded) MPa (psi) 172 maximum(2.5 x 104) Section 4.3.3
ASTM D 2671
Low Temperature Flexibility
1 hour at -30°C (-22°F)
-- No cracking UL 224
Heat Shock
4 hours at 250°C (482°F)
-- No cracking UL 224
Heat Aging
7 days at 158°C (316°F)
Followed by tests for:
-- -- UL 224
Tensile Strength MPa (psi) 70% minimum of unaged
specimens
Section 4.3.2
UL 224
Ultimate Elongation Percent 100 minimum
Flexibility -- No cracking
Dielectric Withstand at 2500 V Seconds 60 minimum
Dielectric Breakdown Volts 50% minimum of unaged specimen Section 4.3.5
ASTM D 2671
Dielectric Strength kV/mm
(Volts/mil)
19.7 minimum (500)
Copper Stability
7 days at 158°C (316°F)
Followed by test for
No brittleness, glazing, cracking or
severe discoloration of tubing. No
pitting or blackening of copper.
Section 4.3.4
ASTM D 2671
Ultimate Elongation Percent 100 minimum Section 4.3.2
Restricted Shrinkage -- Pass UL 224
ELECTRICAL
Dielectric Withstand at 2500 V
Seconds
60 minimum
UL 224
Dielectric Strength kV/mm
(Volts/mil)
19.7 minimum (500) Section 4.3.5
Volume Resistivity Ohm-cm 1014 minimum ASTM D 2671
SPECIFICATION RW-3009 ISSUE 3 Page 7
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TABLE 2
Requirements
(continued)
PROPERTY UNIT REQUIREMENT TEST
METHOD
CHEMICAL (continued)
Corrosive Effect
7 days at 158°C (316°F)
--
No Corrosion
Section 4.3.6
ASTM D 2671
Flammability -- Pass UL 224, VW-1
Water Absorption (Recovered)
24 hrs. at 23°C (73°F)
Percent 0.5 maximum ASTM D 2671
Fungus Resistance
Followed by tests for:
Tensile Strength
Ultimate Elongation
Dielectric Strength
psi (Mpa)
percent
Volts per mil
(volts per mm)
1500 minimum (10.3)
200 minimum
500 minimum (19,700)
ISO 846
Method B
Section 4.3.2
ASTM D 2671
ASTM D 2671
