CMC-0553-8-9CS2351 (204193-000) - Tyco Electronics

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SPECIFICATION:

THIS ISSUE: Amendment 1, Issue 1

Wire and Cable Division

DATE: 10 December 1998

Raychem Corporation, 300 Constitution Drive, Menlo Park, CA 94025

REPLACES: None

FLEXLINE WIRE AND CABLE, ELECTRIC, GENERAL PURPOSE,

RADIATION-CROSSLINKED, MODIFIED, FLEXIBLE FLUOROPOLYMER-

INSULATED

This amendment forms a part of Raychem Corporation Specification 80,

Issue 1 dated July 16, 1996.

PAGE 3

Para. 3.3.1, Conductor:

Add the following sentence to the end of the paragraph:

“For the 82 series conductors, the minimum allowable number of strands may be 98 percent of the

number specified in the applicable specification sheet, as long as the dimensional and resistance

requirements are met.”

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SPECIFICATION:

THIS ISSUE: Issue 1

Wire and Cable Division

DATE:

16 July 1996

Raychem Corporation, 300 Constitution Drive, Menlo Park, CA 94025-1164

REPLACES: Draft W1

FLEXLINE WIRE AND CABLE, ELECTRIC,

GENERAL PURPOSE, RADIATION-CROSSLINKED,

MODIFIED, FLEXIBLE FLUOROPOLYMER-INSULATED

1. SCOPE

1.1 SCOPE

This specification covers radiation-crosslinked, extruded, modified, flexible fluoropolymer-

insulated wire, and single- and multiple-conductor cables which may be shielded and jacketed.

This flexible insulation is highly flame retarded and is intended for use as a high-temperature,

thin-wall insulation system in military, aerospace, and general wire hook-up applications.

1.2 CLASSIFICATION

Products in accordance with this specification shall be of the following types, as specified in

the applicable specification sheet.

Finished Wire A single conductor, insulated as specified in the applicable

specification sheet.

Finished Cable Any construction other than finished wire, utilizing a wire or wires

with or without shielding, or with or without an outer jacket.

1.3 TEMPERATURE RATING

The maximum conductor temperature of the finished wire and cable for continuous use shall

be as specified in the applicable specification sheet.

2. APPLICABLE DOCUMENTS

2.1 GOVERNMENT-FURNISHED DOCUMENTS

The following documents, of the issue in effect on date of invitation for bids or request for

proposal, form a part of this specification to the extent specified herein.

FlexLine is a trademark of Raychem Corporation.

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Page 2 SPECIFICATION 80, ISSUE 1

2.1.1 Department of Defense

SPECIFICATIONS

Federal

TT-I-735 Isopropyl Alcohol

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-7808 Lubricating Oil, Aircraft Turbine Engine, Synthetic Base

MIL-W-22759 Wire, Electric, Fluoropolymer-Insulated, Copper or Copper Alloy

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

MIL-C-27500 Cable, Power, Electrical and Cable Special Purpose, Electrical Shielded

and Unshielded, General Specification for

MIL-W-29606 Wire, Electrical, Uninsulated Copper, Copper Alloy, or Aluminum, or

Thermocouple Extension, General Specification for

STANDARDS

Federal

FED-STD-191 Textile Test Methods

FED-STD-228 Cable and Wire, Insulated; Methods of Testing

Military

MIL-STD-104 Limits for Electrical Insulation Color

MIL-STD-105 Sampling Procedures and Tables for Inspection by Attributes

MIL-STD-109 Quality Assurance Terms and Definitions

MIL-STD-129 Marking for Shipment and Storage

MIL-STD-681 Identification Coding and Application of Hook Up and Lead Wire

(Copies of Department of Defense documents may be obtained from the Naval Publications

and Forms Center, 5801 Tabor Avenue, Philadelphia, Pennsylvania 19120.)

2.2 OTHER PUBLICATIONS

The following documents form a part of this specification to the extent specified herein. Unless

otherwise indicated, the issue in effect on date of invitation for bids or request for proposal

shall apply:

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SPECIFICATION 80, ISSUE 1 Page 3

2.2.1 American Society for Testing and Materials (ASTM)

D 882 Tensile Properties of Thin Plastic Sheeting

F 777 Standard Test Method for Resistance of Electrical Wire Insulation Materials to

Flame at 60°

(Copies of ASTM publications may be obtained from the American Society for Testing and

Materials, 1916 Race Street, Philadelphia, Pennsylvania 19103.)

2.2.2 Society of Automotive Engineers, Inc. (SAE)

Aerospace Standard

AS 1241 Fire Resistant Phosphate Ester Hydraulic Fluid for Aircraft

(Copies of SAE aerospace standards may be obtained from the Society of Automotive

Engineers, Inc., 400 Commonwealth Drive, Warrendale, Pennsylvania 15096.)

3. REQUIREMENTS

3.1 SPECIFICATION SHEETS

The requirements for the individual wires and cables furnished under this specification shall be

as specified herein and in accordance with the applicable specification sheet. In case of

conflict, the requirements of the specification sheet shall govern.

3.2 QUALIFICATION

The qualification requirements specified herein characterize particular properties that are

applicable to all products covered by this specification. Specific wire and cable constructions,

as described in 4.2.1, are representative of the types of products furnished under this

specification, and are used to demonstrate the ability to meet the qualification tests specified

herein (see 4.2).

3.3 MATERIALS AND CONSTRUCTION

Materials not specifically designated herein shall be of the quality and form best suited for the

purpose intended. Unless otherwise specified, materials and construction shall meet the

following requirements:

3.3.1 Conductor

Copper and copper alloy conductor materials and standard MIL-W-29606 conductor (81 series

part numbers) constructions shall be in accordance with MIL-W-29606. All other conductor

materials and constructions (e.g., 82 series part numbers with high-strand-count conductors)

shall be as specified in the applicable specification sheet.

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Page 4 SPECIFICATION 80, ISSUE 1

3.3.2 Shield

Shield strands shall conform to the requirements for conductor materials (3.3.1), and shall be

constructed in accordance with MIL-C-27500 and the applicable specification sheet.

3.3.2.1 Flat Wire Shield

Flat wire shields shall be constructed from strands which have been formed by flattening round

wire strands. After flattening, the strands shall meet the coating thickness and continuity

requirements of the appropriate round wire strand material.

3.3.3 Insulation and Jacket

All insulations and jackets shall be extruded, low-outgassing, radiation-crosslinked modified,

flexible fluoropolymer, and shall be constructed as specified in the applicable specification

sheet.

3.3.3.1 Insulation Material Under Conductor Strands

When stranded conductors are used in the construction of the finished wire, there shall be no

insulation under any of the strands of the conductor.

3.4 IN-PROCESS REQUIREMENTS

3.4.1 Conductor Elongation (High Strand Count)

When high-strand-count conductors are tested in accordance with 4.6.3, the elongation shall be

5 percent, minimum average, for the whole stranded conductor of regular bunch constructions,

or for one whole member from rope bunch constructions, as applicable.

3.4.2 Conductor Splices

Splices shall be in accordance with MIL-W-29606.

3.4.3 Insulation Flaws

One hundred percent of the wire shall pass the impulse dielectric test or the spark test of

MIL-W-22759 at any designated point or points in the manufacturing process prior to com-

pletion of the finished wire, using the voltage specified in the applicable specification sheet.

3.5 FINISHED WIRE AND CABLE

Finished wire and cable shall conform to the applicable requirements of 3.5.1 to 3.5.14, Table

1 and the applicable specification sheet.

3.5.1 Blocking

Adjacent turns and layers of wire insulation or cable jacket shall not block after specimens are

subjected to 200 ± 3°C. Blocking shall be defined as a transfer of material between adjacent

surfaces when they are separated.

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SPECIFICATION 80, ISSUE 1 Page 5

TABLE 1

REQUIREMENTS FOR FINISHED WIRE AND CABLE

EXAMINATION OR TEST

REQUIREMENT TEST

METHOD TEST

TYPE 1/

Finished Wire

Blocking

3.5.1 and MIL-W-22759

MIL-W-22759

Color 3.5.2 4.6.6 1

Concentricity Specification Sheet MIL-W-22759 2

Conductor Diameter Specification Sheet 4.6.2 1

Conductor Elongation and Breaking Strength:

– Standard MIL-W-29606 Conductor

(81 series part numbers)

– High-Strand-Count Conductor

(82 series part numbers)

MIL-W-29606

3.4.1

MIL-W-29606

4.6.3

Conductor Material 3.3.1 4.6.6 1

Conductor Resistance Specification Sheet MIL-W-29606 1

Conductor Stranding Specification Sheet 4.6.6 1

Crosslinking Proof Test Specification Sheet and 3.5.4 4.6.4 2

Finished Wire Diameter Specification Sheet 4.6.2 1

Flammability 3.5.5 4.6.7 Q

Identification and Color Striping Durability Specification Sheet MIL-W-22759 1

Identification of Product 3.5.6 4.6.6 1

Immersion 3.5.7 4.6.8 Q

Insulation Elongation and Tensile Strength Specification Sheet 4.6.9 1

Insulation Flaws Specification Sheet and 3.5.8 MIL-W-22759 3

Insulation Material and Construction 3.3.3 4.6.6 1

Insulation Resistance 3.5.9 MIL-W-22759 Q

Insulation Thickness Specification Sheet 4.6.6 2

Life Cycle 3.5.12 4.6.12 Q

Low Temperature-Cold Bend 3.5.13 and MIL-W-22759 MIL-W-22759 Q

Removability of Insulation MIL-W-22759 MIL-W-22759 1

Secant Modulus 3.5.14 4.6.13 Q

Shrinkage Specification Sheet MIL-W-22759 2

Weight Specification Sheet MIL-W-22759 1

Workmanship MIL-W-22759 MIL-W-22759 1

(continued)

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Page 6 SPECIFICATION 80, ISSUE 1

TABLE 1 (CONTINUED)

REQUIREMENTS FOR FINISHED WIRE AND CABLE

EXAMINATION OR TEST

REQUIREMENT TEST

METHOD TEST

TYPE 1/

Finished Cable

Blocking

3.5.1 and MIL-C-27500

MIL-C-27500

Cabling MIL-C-27500 MIL-C-27500 1

Conductor and Shield Continuity 3.5.3 and MIL-C-27500 MIL-C-27500 3

Crosslinking Proof Test Specification Sheet and 3.5.4 4.6.4 2

Dielectric Withstand Specification Sheet MIL-C-27500 3

Dimensions Specification Sheet 4.6.6 1

Flammability 3.5.5 4.6.7.1 Q

Identification of Product 3.5.6 4.6.6 1

Immersion 3.5.7 4.6.8 Q

Jacket Color 3.5.2 4.6.6 1

Jacket Concentricity 3.5.10 4.6.10 2

Jacket Elongation and Tensile Strength Specification Sheet 4.6.9 1

Jacket Flaws Specification Sheet and 3.5.11 4.6.11 3

Jacket Material and Construction 3.3.3 4.6.6 1

Jacket Thickness Specification Sheet 4.6.6 2

Life Cycle 3.5.12 4.6.12 Q

Low Temperature-Cold Bend 3.5.13 and MIL-C-27500 MIL-C-27500 Q

Secant Modulus 3.5.14 4.6.13 Q

Shield Material and Construction 3.3.2 MIL-C-27500 1

Shield Coverage Specification Sheet MIL-C-27500 1

Weight Specification Sheet 4.6.15 1

Workmanship MIL-C-27500 MIL-C-27500 1

1/ TEST TYPE:

Q - Qualification Test (4.2)

1 - Quality Conformance Test, Group 1 (4.3)

2 - Quality Conformance Test, Group 2 (4.3)

3 - Quality Conformance Test, Group 3 (4.3)

P - Process Control Inspection (4.4)

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SPECIFICATION 80, ISSUE 1 Page 7

3.5.2 Color

Color shall be in accordance with MIL-STD-104, Class 1. White is preferred for both

insulation and jacket. Color code designators, and colored stripes and bands, if used, shall

be in accordance with MIL-STD-681.

3.5.3 Conductor and Shield Continuity

When finished cable is tested in accordance with MIL-C-27500, there shall be no loss of

continuity in the conductors or shield.

3.5.4 Crosslinking Proof Test

When finished wire and cable is tested in accordance with 4.6.4, there shall be no cracking of

the insulation or jacket and no dielectric breakdown.

3.5.5 Flammability

3.5.5.1 Procedure 1

When qualification samples are tested in accordance with 4.6.7.1, the burn length shall not

exceed 3 inches (76 mm) and the afterburn time shall not exceed 3 seconds.

3.5.5.2 Procedure 2

When AWG 22 and 20 wire specimens are tested in accordance with 4.6.7.2, the burn length

shall not exceed 3 inches (76 mm) and the afterburn time shall not exceed 3 seconds.

3.5.6 Identification of Product

When specified, the finished wire and cable shall be identified by a marking applied to the

outer surface. The identification shall consist of the appropriate mark as specified by contract

or the applicable specification sheet. The mark shall be in a contrasting color to that of the

finished wire or cable. Identification shall be applied with the vertical axis of the characters

parallel to the longitudinal axis of the wire when the nominal diameter of the wire is 0.050

inch (1.27 mm) or smaller. The vertical axis of the characters may be either perpendicular or

parallel to the longitudinal axis of the wire when the nominal diameter of the wire exceeds

0.050 inch (1.27 mm). Wires with diameters of 0.035 inch (0.89 mm) and smaller shall not be

marked.

3.5.7 Immersion

When qualification samples are tested in accordance with 4.6.8, the diameter change shall be

no more than 5 percent, and there shall be no cracking of the insulation or jacket and no

dielectric breakdown.

3.5.8 Insulation Flaws

One hundred percent of finished wire shall pass the impulse dielectric test or the spark test of

MIL-W-22759 using the voltage specified in the applicable specification sheet. The test shall

be performed during the final winding of the wire on shipment spools or reels.

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Page 8 SPECIFICATION 80, ISSUE 1

3.5.9 Insulation Resistance

The minimum insulation resistance for 1000 feet of the wire specimens shall be 500 megohms

(152.4 M

Ω

-1 km) for AWG 22 and 20, and 100 megohms (30.5 M

Ω

-1 km) for AWG 8.

3.5.10 Jacket Concentricity

When finished cable is tested in accordance with 4.6.10, the jacket concentricity shall be 70

percent, minimum.

3.5.11 Jacket Flaws

One hundred percent of finished shielded and jacketed cable shall pass the jacket flaws test of

4.6.11 using the voltage specified in the applicable specification sheet.

3.5.12 Life Cycle

When tested in accordance with 4.6.12, using a test temperature of 230 ± 3°C for the AWG 8

specimen, and 200 ± 3°C for the other specimens, qualification samples shall exhibit no

cracking of the insulation or jacket and no dielectric breakdown.

3.5.13 Low Temperature-Cold Bend

When qualification samples are tested at -65 ± 3°C, there shall be no cracking of the insulation

or jacket and no dielectric breakdown.

3.5.14 Secant Modulus

When tested in accordance with 4.6.13, the secant modulus shall not exceed 5.0 x 104 lbf/in2

(345 N/mm2) for AWG 22 and 20 wire specimens, or 4.0 x 104 lbf/in2 (276 N/mm2) for cable

and AWG 8 wire specimens.

4. QUALITY ASSURANCE PROVISIONS

4.1 RESPONSIBILITY FOR INSPECTION

The supplier is responsible for the performance of all the inspection tests specified herein. The

supplier may utilize his own or any other inspection facility and services acceptable to the

buyer. Inspection records of the examination and tests shall be kept complete and available to

the buyer as required.

4.2 QUALIFICATION INSPECTION

Qualification inspection shall consist of all tests in Table 1, as applicable to finished wire or to

finished cable.

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SPECIFICATION 80, ISSUE 1 Page 9

4.2.1 Qualification Samples

Qualification samples shall consist of the following part numbers (insulation/jacket colors

shall be optional):

81A081X-22

(will qualify all dual-wall primary wire, AWG 10 and smaller)

81A081X-8

(will qualify all dual-wall primary, AWG 8 and larger)

82A011X-20

(will qualify all single-wall primary wire)

82A112X-20

(will qualify all cable constructions)

The “X” in the part numbers above shall be replaced by a conductor material designator,

which, for qualification samples, may be either “1” or “3” (tin- or nickel-coated copper,

respectively).

4.2.2 Qualification Test Reports

When requested by the procuring activity, qualification test reports shall be supplied plainly

identified with the following information:

Qualification test report for

FLEXLINE WIRE AND CABLE,

ELECTRIC, GENERAL PURPOSE,

RADIATION-CROSSLINKED MODIFIED,

FLEXIBLE FLUOROPOLYMER-INSULATED

Raychem Corporation

Part number of qualification sample

Part numbers qualified

Specification 80

4.3 QUALITY CONFORMANCE INSPECTION

Quality conformance inspection shall consist only of those examinations and tests listed in

Table 1 and identified by a group number, as applicable to finished wire or to finished cable.

Quality conformance inspection shall be performed on every lot of wire or cable procured

under this specification.

4.3.1 Sampling for Quality Conformance Inspection

MIL-STD-109 shall apply for definitions of inspection terms used herein. For purposes of this

specification, the following shall apply:

4.3.1.1 Lot

The inspection lot shall include all wire and cable of one part number subjected to inspection

at one time.

4.3.1.2 Unit of Product

The unit of product for determining lot size for sampling shall be one continuous length of

wire or cable as offered for inspection.

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Page 10 SPECIFICATION 80, ISSUE 1

4.3.1.3 Sample Unit (Groups 1 and 2 tests)

The sample unit for Groups 1 and 2 tests shall consist of a single length of finished wire or

cable chosen at random from the inspection lot and of sufficient length to permit all applicable

examinations and tests. Unless otherwise specified, the length of the sample unit for Group 1

tests of Table 1 shall be 20 feet (6.1 m) and the length of the sample unit for Group 2 tests

shall be 25 feet (7.6 m). Not more than one sample unit for each group of tests shall be taken

from a single unit of product.

4.3.1.4 Inspection Levels and Acceptable Quality Levels (AQL) (Groups 1 and 2 tests)

For Group 1, the inspection level shall be S-2 and the AQL shall be 6.5 percent in accordance

with MIL-STD-105; for Group 2, the inspection level shall be S-3 and the AQL shall be 1.5

percent.

4.3.1.5 Sampling and Acceptance Level for Group 3 Tests

Unless otherwise specified in the applicable specification sheet, the finished wire or cable

sample for the Group 3 tests shall be 100 percent of the finished wire or cable, and every

length of the wire or cable shall be fully tested. Portions showing breakdown in these dielectric

tests and ends or portions not subjected to these tests shall be marked or removed and the

remaining lengths tested until no failure occurs.

4.3.2 Nonconforming Inspection Lots

Disposition of inspection lots found unacceptable under initial quality conformance inspection

shall be in accordance with MIL-STD-105.

4.4 PROCESS CONTROL INSPECTION

This inspection comprises tests and examinations (Table 2) of such a nature that they cannot

be performed on the finished wire or cable and therefore must be performed at an appropriate

stage of manufacture. Process control inspection shall be performed on every lot of wire or

cable procured under this specification.

TABLE 2

PROCESS CONTROL INSPECTION

Examination or Test Requirement Test Method

Conductor material 3.3.1 4.6.6

Shield material 3.3.2 4.6.6

Insulating and jacketing material 3.3.3 4.6.6

Conductor elongation (high strand count) 3.4.1 4.6.3

Conductor splices 3.4.2 4.6.6

Insulation flaws 3.4.3 MIL-W-22759

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SPECIFICATION 80, ISSUE 1 Page 11

4.4.1 Sampling for Process Control Inspection

4.4.1.1 Conductor Material

Process control sample selection and inspection of uninsulated conductor shall be performed at

receiving inspection. The conductor lot size, for purposes of sampling, shall consist of the

num-ber of reels of a given type and size of conductor received at one time from one supplier

against a single purchase order. For lot sizes of 3 reels or less, one 15-foot (4.6-m) length of

conductor shall be selected from each reel. For lot sizes of not less than 4 and not more than 25

reels, a minimum of three 15-foot (4.6-m) lengths of conductor shall be selected at random, in

such a manner as to be representative of the material. For lot sizes in excess of 25 reels, the

inspection level shall be Level 1 and the AQL shall be 4.0 percent in accordance with MIL-

STD-105.

4.4.1.2 Insulation Flaws (Impulse Dielectric Test or Spark Test)

One hundred percent of the wire, after the application of the primary insulation, shall be tested

in accordance with the applicable specification sheet and MIL-W-22759.

4.4.2 Rejection and Retest in Process Control Inspection

When a sample selected from an inspection lot fails to meet the specified test (Table 2), except

the insulation flaws test (see 4.4.1.2), no items still on hand or later produced from that lot

shall be accepted until the extent and cause of the failure has been determined.

4.4.2.1 Effect of Process Control Failure on Quality Conformance Testing

Quality conformance testing may be continued during the investigation of a failure of a process

control sample, but final acceptance of the material shall not be made until it is determined that

the lot meets all the process control and quality conformance requirements of the specification.

4.5 PERIODIC QUALIFICATION RE-EVALUATION

Qualification re-evaluation shall be performed, at the manufacturer's discretion, whenever any

significant change is made to the materials or manufacturing process.

4.6 TEST METHODS

4.6.1 Bend Test (Post-Environmental)

At a temperature maintained between 20 and 25°C, one end of a finished wire specimen shall

be secured to the mandrel and the other end to the weight specified in the applicable

specification sheet. For finished cable specimens, the mandrel shall be as specified in Table 3

and sufficient weight shall be used to maintain contact with the mandrel. The mandrel shall be

rotated until the full length of the specimen is wrapped around the mandrel and is under the

specified tension with adjoining turns in contact. The mandrel shall then be rotated in the

reverse direction until the full length of the specimen which was outside during the first

wrapping is now next to the mandrel. This procedure shall be repeated until two bends in each

direction have been formed in the same section of the specimen. The specimen shall then be

examined for cracking of the insulation or jacket, as applicable.

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Page 12 SPECIFICATION 80, ISSUE 1

TABLE 3

MANDREL DIAMETERS FOR CABLES FOR BEND TEST

(POST-ENVIRONMENTAL)

Finished Cable Diameter Mandrel Diameter

inch mm inch mm

≤ 0.083

≤

2.11 .750 19

> 0.083 and ≤ 0.111 >2.11 and

≤

2.82 1.00 25

> 0.111 and ≤ 0.139 >2.82 and

≤

3.53 1.25 32

> 0.139 and ≤ 0.194 >3.53 and

≤

4.93 1.75 44

> 0.194 and ≤ 0.250 >4.93 and

≤

6.35 2.25 57

> 0.250 and ≤ 0.334 >6.35 and

≤

8.48 3.00 76

> 0.334 and ≤ 0.444 >8.48 and

≤

11.3 4.00 102

> 0.444 and ≤ 0.556 >11.3 and

≤

14.1 5.00 127

> 0.556 and ≤ 0.667 >14.1 and

≤

16.9 6.00 152

> 0.667 and ≤ 0.889 >16.9 and

≤

22.6 8.00 203

> 0.889 and ≤ 1.111 >22.6 and

≤

28.2 10.0 254

> 1.111 and ≤ 1.556 >28.2 and

≤

39.5 14.0 356

> 1.556 and ≤ 2.000 >39.5 and

≤

50.8 18.0 457

4.6.2 Conductor and Finished Wire Diameter

Diameter measurements shall be made on a 24-inch (610-mm), minimum, length of finished

wire taken from the end of the sample unit. The conductor shall be made accessible by

stripping and removing the insulation carefully so as not to nick, cut, cold-work, or otherwise

damage the conductor. Three points for measurement shall be located 8 inches (203 mm) apart

along the conductor or finished wire specimen length, as applicable. For AWG 10 and smaller,

measure-ments shall be made at each point at two approximately perpendicular planes or as

required to assure that the minimum and maximum reading is attained at each point. A total of

six measure-ments shall be performed on each specimen. Measurements shall be made with a

micrometer caliper or equivalent device capable of resolving a measurement to 0.0001 inch

(0.0025 mm). For AWG 8 and larger, a circumferential measuring tape may be used in lieu of a

micrometer, and a total of three measurements, taken 8 inches (203 mm) apart, shall be

performed on each specimen. The circumferential measuring tape shall be capable of resolving

a measurement to 0.001 inch (0.025 mm) over a diameter range of 0.200 inch (5.08 mm) and

larger. The average diameter of all applicable measurements shall be calculated and recorded.

4.6.3 Conductor Elongation (High Strand Count)

High-strand-count conductors shall be tested for elongation in accordance with Method 3211

of FED-STD-228, except that the test shall be performed upon the whole conductor for regular

bunch-stranded constructions, and upon one whole member removed from rope bunch-

stranded constructions. In either case, elongation shall be measured upon breakage of the first

strand of the whole conductor or member, as applicable.

4.6.4 Crosslinking Proof Test

Crosslinking proof tests of finished wire and cable shall be conducted in accordance with the

life cycle test method of 4.6.12. The time and temperature specified for the crosslinking proof

test on the applicable specification sheet shall be used.

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SPECIFICATION 80, ISSUE 1 Page 13

4.6.5 Examination of Preparation for Delivery

Preparation for delivery of materials ready for shipment shall be examined to determine

compliance with the requirements of Section 5.

4.6.6 Examination of Product

All samples of wire and cable shall be examined to determine conformance with this specifica-

tion and the applicable specification sheet with regard to requirements not covered by specific

test methods.

4.6.7 Flammability

4.6.7.1 Procedure 1

Procedure 1 flammability testing shall be in accordance with ASTM F 777, with a flame

application period of 30 seconds. The procedure of ASTM F 777 conforms with FAR,

Part 25, Appendix F (g).

4.6.7.2 Procedure 2

(N/A for cable and AWG 8 wire samples)

The test shall be performed in a sheet metal cabinet conforming to FED-STD-191, Method

5903. Two inches (51 mm) of insulation shall be removed from one end of an 18-inch (457-

mm) specimen of finished wire and the specimen shall be mounted as shown in Figure 1. A

1.5-inch (38-mm) high yellow flame from a Bunsen burner conforming to FED-STD-191,

Method 5903, shall be applied to the specimen at the junction of the insulation and the bare

conductor in such a manner that the lower end of the insulation is located 0.75 inch (19 mm)

into the flame. After 12 seconds of flame application, the burner shall be removed from below

the specimen and immediately turned off. The burn length and the time of burning after

removal of the flame shall be recorded. The burn length shall be the distance from the original

bend made in the conductor to the farthest point of damage. Damage shall consist of bare

conductor and charred insulation. Light discoloration of the insulation shall not constitute

failure.

FIGURE 1 - Flammability Test Apparatus, Procedure 2

(shown without metal cabinet)

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Page 14 SPECIFICATION 80, ISSUE 1

4.6.8 Immersion

Specimens of sufficient length to perform the subsequent tests shall be measured at their

midpoints to determine their initial diameters, and shall then be immersed to within 6 inches

(152 mm) of their ends in each of the fluids (using a separate specimen for each fluid) for the

time and temperature specified in Table 4. During immersion, the radius of bend of the

specimens shall be not less than 14, nor more than 35, times the specified maximum diameter

of the wire or cable under test. Upon removal from the fluids, the specimens shall remain for 1

hour in free air at room temperature. The diameters shall then be remeasured at the original

point of measurement and compared to the initial diameters. The percent change in diameter

shall then be calculated. For finished wire, 1 inch (25 mm) of insulation shall be removed from

each end of a 24-inch (610-mm) length of each specimen. For finished cable, 2 inches (51 mm)

of the jacket shall be removed from each end of a 24-inch (610-mm) length of each specimen,

and the shield shall be pushed back and formed into a pigtail at each end of the specimen. One

inch (25 mm) of insulation of each of the primary wires shall then be removed from each end

of the specimen. The specimens shall then be subjected to the bend test (4.6.1 - use the

mandrels and test weights specified on the applicable specification sheet for the Crosslinking

Proof Test), followed by the voltage withstand test (4.6.14).

TABLE 4

IMMERSION TEST FLUIDS

TEST FLUID

TEST TEMPERATURE IMMERSION

TIME

(a) MIL-L-23699, Lubricating Oil, Aircraft Turbine

Engine,Synthetic Base 48 to 50°C (118 to 122°F) 20 hours

(b) MIL-H-5606, Hydraulic Fluid, Petroleum Base,

Aircraft, Missile and Ordnance 48 to 50°C (118 to 122°F) 20 hours

(d) MIL-T-5624, Turbine Fuel, Aviation, Grade JP-4

or JP-8 20 to 25°C (68 to 77°F) 168 hours

(e) SAE-AS-1241, Fire Resistant Phosphate Ester

Hydraulic Fluid for Aircraft 48 to 50°C (118 to 122°F) 20 hours

(f) MIL-L-7808, Lubricating Oil, Aircraft Turbine

Engine, Synthetic Base; or NATO 148 118 to 121°C (244 to 250°F)

30 minutes

4.6.9 Insulation Elongation and Tensile Strength

Specimens of the entire insulation shall be carefully removed from the conductor and tested for

tensile strength and elongation in accordance with FED-STD-228, Methods 3021 and 3031,

respectively, using 1-inch (25-mm) bench marks, a 1-inch (25-mm) initial jaw separation, and a

jaw separation speed of 2 inches (51 mm) per minute. For cables, the method shall be the same,

but only the cable jacket shall be tested.

4.6.10 Jacket Concentricity

The concentricity of the cable jacket shall be determined by first locating and recording the

minimum wall thickness measured on a cross-section of the jacket. The maximum wall thick-

ness of this same cross-section of the jacket shall also be measured and recorded. The ratio of

the minimum wall thickness to the maximum wall thickness shall define the concentricity. All

wall-thickness measurements shall be made under suitable magnification. The wall thickness

shall be the radial distance between the inner and outer rim of the jacket.

NOTE: ANY COPY OF THIS DOCUMENT THAT DOES NOT HAVE A

RED “CONTROL” STAMP IS AN UNCONTROLLED COPY.

SPECIFICATION 80, ISSUE 1 Page 15

4.6.11 Jacket Flaws

Finished cable shall be tested in accordance with the jacket flaws test of MIL-C-27500, or

the impulse dielectric test procedure of MIL-W-22759, with the shield grounded at one or

both ends.

4.6.12 Life Cycle

Finished wire and cable specimens, prepared in accordance with 4.6.12.1 or 4.6.12.2, as

applicable, shall be conditioned in an air-circulating oven for 500 hours at the temperature

specified. The velocity of air past the specimens (measured at room temperature) shall be

between 100 and 200 feet (30 and 61 m) per minute. After conditioning, the oven shall be shut

off, the door opened, and the specimens allowed to cool in the oven for at least 1 hour. When

cool, the finished wire specimens shall be freed from tension, removed from the mandrel, and

straightened. The finished wire and cable specimens shall then be subjected to the bend test

(4.6.1) followed by the voltage withstand test (4.6.14).

4.6.12.1 Finished Wire Preparation

One inch (25 mm) of insulation shall be removed from each end of a 24-inch (610-mm) speci-

men of finished wire. The central portion of the specimen shall then be bent at least halfway

around a horizontally positioned smooth stainless steel mandrel of the diameter specified in the

applicable specification sheet for the Crosslinking Proof Test. To prevent sticking of the speci-

men to the mandrel, the mandrel shall be covered with polytetrafluoroethylene in the form of

either a dispersion coating (preferred) or wrapped tape, provided that the diameter of the

mandrel still conforms to the applicable specification sheet. Each end of the conductor shall be

loaded with the weight specified in the applicable specification sheet for the Crosslinking

Proof Test, so that the portion of the insulation between the conductor and mandrel is under

compres-sion while the conductor is under tension. This specimen, so prepared on the mandrel,

shall be conditioned and tested as specified above.

4.6.12.2 Finished Cable Preparation

Two inches (51 mm) of the jacket shall be removed from each end of a 15-inch (380-mm)

specimen of finished cable, and the shield, if any, shall be pushed back and formed into a

pigtail at each end of the specimen. One inch (25 mm) of insulation of each of the primary

wires shall then be removed from each end of the specimen. The cable specimen shall then be

loaded with sufficient weight to hang straight, and shall be conditioned and tested as specified

above.

4.6.13 Secant Modulus

Specimens of the wire insulation, or cable jacket, shall be carefully removed and tested for

secant modulus in accordance with ASTM D 882, using a 2-inch (50-mm) initial jaw separa-

tion, a jaw speed of 0.2 inch (5 mm) per minute, and a chart speed of 20 inches (508 mm) per

minute. The pounds-force (N) shall be read from the chart 4 inches (102 mm) from where the

trace begins to rise for 0 pounds-force (N).

Secant Modulus (lbsf/in2 @ 2%) =

Where: CSA = cross sectional area

lbsf

CSA x 0.2

NOTE: ANY COPY OF THIS DOCUMENT THAT DOES NOT HAVE A

RED “CONTROL” STAMP IS AN UNCONTROLLED COPY.

Page 16 SPECIFICATION 80, ISSUE 1

4.6.14 Voltage Withstand

The uninsulated ends of the specimen shall be attached to an electric lead. The specimen shall

be immersed in a 5-percent, by weight, solution of sodium chloride in water at 20 to 25°C,

except that the uninsulated ends and 1.5 inches (38 mm) of insulated wire or cable at each end

of the specimen shall protrude above the surface of the solution. After immersion for 5 hours,

the voltage specified in the applicable specification sheet shall be applied at 60 Hz between the

conductor or the shield, as applicable, and an electrode in contact with the liquid. The voltage

shall be gradually increased at a uniform rate from zero to the specified voltage in 0.5 minute,

maintained at that voltage for a period of 5 minutes for finished wire specimens and 1 minute

for finished cable specimens, and then gradually reduced to zero in 0.5 minute.

4.6.15 Weight

The weight of each lot of finished cable shall be determined in accordance with the procedure

specified for finished wire in MIL-W-22759.

5. PREPARATION FOR DELIVERY

5.1 PACKAGING AND PACKING

Wire and cable shall be delivered wound on reels or spools in accordance with 5.1.3.

5.1.1 Winding Requirements

All layers of wire or cable shall be wound on the reel or spool with sufficient tension to prevent

shifting of layers and creation of crossovers within layers.

5.1.1.1 Finished Wire

All finished wire lengths wound on one reel or spool shall be spliced into one mechanically

and electrically continuous length.

5.1.1.2 Finished Cable

Finished cable shall be wound with no more than 5 lengths per reel or spool, and in such a

manner that all ends are accessible.

5.1.2 Lengths

Unless otherwise specified, minimum continuous length (between splices) for finished wire

shall be in accordance with Table 5. For finished cable, the minimum acceptable length for

shipment shall be 50 feet (15.2 m).

NOTE: ANY COPY OF THIS DOCUMENT THAT DOES NOT HAVE A

RED “CONTROL” STAMP IS AN UNCONTROLLED COPY.

SPECIFICATION 80, ISSUE 1 Page 17

TABLE 5

FINISHED WIRE LENGTHS

Wire Size Range Minimum Percentage of Total Length in

Shipment With Lengths Greater Than:

AWG

500 ft (152 m)

100 ft (30.5 m)

50 ft (15.2 m)

30 through 10

0.057 through 4.74

100

---

8 through 0000 8.60 through 106.9 --- --- 100

5.1.3 Reels and Spools

Reels and spools shall be of a nonreturnable type. Each reel and spool shall have an

appropriate diameter for the respective wire size. In no case shall the barrel of the reel or spool

have a diameter less than 3.5 inches (89 mm). Reels and spools shall be suitably finished to

prevent corrosion under typical storage and handling conditions.

5.1.4 Containers

Unless otherwise specified (see 6.1), wire and cable shall be delivered in standard commercial

containers so constructed as to ensure acceptance by common or other carrier for safe trans-

portation at the lowest rate to the point of delivery.

5.1.5 Marking of Shipments

All spools or reels and shipping containers shall be identified with the following information:

Specification Sheet Part Number

Lot Number

Quantity in feet (or meters)

Raychem Corporation (or Raychem Ltd.)

6. NOTES

6.1 ORDERING DATA

Procurement documents should specify the following:

(a) Title, number, and date of this specification

(b) Applicable specification sheet part number

(d) Special preparation for delivery requirements, if applicable

6.2 METRIC UNITS

Metric units are for information only.

6.3 MIL-W-22759

Wherever MIL-W-22759 refers to "applicable specification sheet", use the applicable

specification sheet of this Raychem specification.