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(R) 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 90C (194F). 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 125C, 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.) If this document is printed it becomes uncontrolled. Check for the latest revision. Page 2 3. 3.1 SPECIFICATION RW-3009 ISSUE 3 REQUIREMENTS 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. If this document is printed it becomes uncontrolled. Check for the latest revision. SPECIFICATION RW-3009 ISSUE 3 4.3 Page 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 3C (73 5F) 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 3C (392 5F) oven, removed from the oven, cooled to 23 3C (73 5F), re-measured for length, inside diameter, and wall thickness in accordance with ASTM D 2671. The longitudinal change shall be calculated as follows: C = Where: 4.3.2 L1 - L0 x 100 L0 C = Longitudinal Change (percent) L0 = Length Before Conditioning [mm (inches)] L1 = Length After Conditioning [mm (inches)] 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 3C (73 5F). Three specimens shall be conditioned for 7 days in 158.0 1.0C (316.4 1.8F) oven. After conditioning, the specimens shall be removed from the oven and cooled to 23 3C (73 5F). 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. If this document is printed it becomes uncontrolled. Check for the latest revision. Page 4 4.3.5 SPECIFICATION RW-3009 ISSUE 3 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 3C (392 5F) 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 (1inch) 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 1.0C (316.4 1.8F) 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. If this document is printed it becomes uncontrolled. Check for the latest revision. SPECIFICATION RW-3009 ISSUE 3 Page 5 TABLE 1 Versafit TUBING DIMENSIONS, IMPERIAL (USA CUSTOMARY) AS SUPPLIED Inside Diameter Size 3/64 1/16 3/32 1/8 3/16 1/4 3/8 1/2 5/8 3/4 1 1-1/4 1-1/2 2 3 4 Mm 1.63.2 1.85 .2 2.79 .2 3.43 .2 5.21 .3 7.11 .3 10.16 .4 13.72 .4 16.90 .4 20.45 .4 26.80 .4 33.40 .7 39.88 .8 52.83.1.0 78.49.1.0 104.14.1.3 in .064.008 .073.007 .110.007 .135.007 .205.010 .280.010 .400.015 .540.015 .665.015 .805.015 1.055.015 1.315.025 1.570.030 2.080.040 3.090.040 4.100 Inside Diameter Maximum mm in 0.58 .023 0.79 .031 1.17 .046 1.57 .062 2.36 .093 3.17 .125 4.74 .187 6.35 .250 8.0 .315 9.52 .375 12.70 .500 15.88 .625 19.05 .750 25.40 1.000 38.10 1.500 50.80 2.000 RECOVERED Wall Thickness Minimum Maximum mm in mm in 0.32 .013 0.48 .019 0.35 .014 0.51 .020 0.43 .017 0.59 .023 0.43 .017 0.59 .023 0.43 .017 0.59 .023 0.56 .022 0.72 .028 0.56 .022 0.72 .028 0.56 .022 0.72 .028 0.68 .027 0.84 .033 0.68 .027 0.84 .033 0.76 .030 1.01 .040 0.86 .034 1.17 .046 0.86 .034 1.17 .046 0.96 .038 1.32 .052 1.06 .042 1.47 .058 1.17 .046 1.63 .064 Nominal mm in 0.40 .016 0.43 .017 0.51 .020 0.51 .020 0.51 .020 0.64 .025 0.64 .025 0.64 .025 0.76 .030 0.76 .030 0.88 .035 1.01 .040 1.01 .040 1.14 .045 1.27 .050 1.39 .055 Versafit 3X Size 1/8 1/4 3/8 1/2 3/4 1 AS SUPPLIED Inside Diameter Minimum in. mm. .125 3.2 .250 6.4 .375 9.5 .500 12.7 .750 19.1 1.000 25.4 Inside Diameter Maximum in. mm. .042 1.1 .083 2.2 .125 3.2 .166 4.3 .250 6.4 .333 8.5 RECOVERED Wall Thickness Minimum Maximum in. mm. in. mm. .020 0.50 .026 0.66 .020 0.50 .026 0.66 .021 0.53 .027 0.69 .021 0.53 .027 0.69 .021 0.53 .027 0.69 .022 0.56 .028 0.72 If this document is printed it becomes uncontrolled. Check for the latest revision. Nominal in. mm. .023 0.58 .023 0.58 .024 0.61 .024 0.61 .024 0.61 .025 0.64 Page 6 SPECIFICATION RW-3009 ISSUE 3 TABLE 2 Requirements PROPERTY PHYSICAL Dimensions Dimensional Recovery Longitudinal Change ASTM D 2671 ASTMD 2671 (Over-expanded sizes) UL 224 Eccentricity (Recovered) Tensile Strength Ultimate Elongation Secant Modulus (expanded) Low Temperature Flexibility 1 hour at -30C (-22F) Heat Shock 4 hours at 250C (482F) Heat Aging 7 days at 158C (316F) Followed by tests for: Tensile Strength UNIT In accordance with Table 1 Percent Percent Percent Percent MPa (psi) Percent MPa (psi) 172 maximum(2.5 x 104) -- No cracking Section 4.3.1 ASTM D 2671 Section 4.3.1 ASTM D 2671 ASTMD 2671 UL 224 ASTM D 2671 Section 4.3.2 ASTM D 2671 Section 4.3.3 ASTM D 2671 UL 224 -- No cracking UL 224 -- -- UL 224 MPa (psi) 70% minimum of unaged specimens 100 minimum No cracking 60 minimum 50% minimum of unaged specimen Section 4.3.2 UL 224 Percent -Seconds Volts Dielectric Strength kV/mm (Volts/mil) Volume Resistivity TEST METHOD mm(inches) Ultimate Elongation Flexibility Dielectric Withstand at 2500 V Dielectric Breakdown Copper Stability 7 days at 158C (316F) Followed by test for Ultimate Elongation Restricted Shrinkage ELECTRICAL Dielectric Withstand at 2500 V Dielectric Strength REQUIREMENT Percent -Seconds kV/mm (Volts/mil) Ohm-cm +1, -5 +0, -15 +3, -3 30 maximum 10.3 minimum (1500) 200 minimum Section 4.3.5 ASTM D 2671 19.7 minimum (500) No brittleness, glazing, cracking or severe discoloration of tubing. No pitting or blackening of copper. 100 minimum Pass Section 4.3.4 ASTM D 2671 60 minimum 19.7 minimum (500) UL 224 Section 4.3.5 1014 minimum ASTM D 2671 If this document is printed it becomes uncontrolled. Check for the latest revision. Section 4.3.2 UL 224 SPECIFICATION RW-3009 ISSUE 3 Page 7 TABLE 2 Requirements (continued) PROPERTY CHEMICAL (continued) Corrosive Effect 7 days at 158C (316F) Flammability Water Absorption (Recovered) 24 hrs. at 23C (73F) Fungus Resistance Followed by tests for: Tensile Strength Ultimate Elongation Dielectric Strength UNIT REQUIREMENT -- No Corrosion -Percent Pass 0.5 maximum TEST METHOD Section 4.3.6 ASTM D 2671 UL 224, VW-1 ASTM D 2671 ISO 846 Method B psi (Mpa) percent Volts per mil (volts per mm) 1500 minimum (10.3) 200 minimum 500 minimum (19,700) If this document is printed it becomes uncontrolled. Check for the latest revision. Section 4.3.2 ASTM D 2671 ASTM D 2671