Tyco Electronics Corporation 300 Constitution Drive Menlo Park, CA 94025 USA Specification This Issue: Date: Replaces: RT-555 Issue 6 November 28, 2006 Issue 5 Raychem RT-555 TUBING Modified Fluoropolymer, Radiation Crosslinked, Flexible, Abrasion Resistant, Flame Retardant, Heat Shrinkable 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 220C (428F). The tubing is suitable for use in wire harness systems requiring high fluid resistance. 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-PRF-372 Cleaning Compound, Solvent SAE-AMS1424 Fluid, Deicing/Anti-Icing, Aircraft, SAE Type 1 MIL-PRF-2104 Lubricating Oil, Internal Combustion Engine, Combat/Tactical Service MIL-PRF-23699 Lubricating Oil, Aircraft Turbine Engine, Synthetic Base MIL-PRF-46167 Lubricating Oil, Internal Combustion Engine, Arctic MIL-PRF-46170 Hydraulic Fluid, Rust Inhibited, Fire-resistance, Synthetic Hydrocarbon Base MIL-PRF-5606 Hydraulic Fluid, Petroleum Base, Aircraft; Missile and Ordinance MIL-PRF-2104 Lubricating Oil, Internal Combustion Engine, Combat/Tactical Service MIL-PRF-7808 Lubricating Oil, Aircraft Turbine Engine, Synthetic Base MIL-DTL-83133 Turbine Fuels, Aviation Kerosene Types, Nato F-34(JP-8), Nato F-35, JP-8 + 100 Federal A-A-52557 A-A-59133 Fuel Oil, Diesel for Posts, Camps and Stations Cleaning Compound, High Pressure (Steam) Cleaner (formerly P-C-437) Ordnance Drawings 10873919 Electrolyte 2.2 OTHER PUBLICATIONS American Society for Testing and Materials (ASTM) ASTM D 412 Standard Test Methods for Vulcanized Rubber & Thermoplastic Elastomers ASTM D 792 Specific Gravity & Density of Plastics by Displacement, Tests for ASTM D 910 Standard Specification for Aviation Gasoline ASTM D 2671 Standard Methods of Testing Heat-Shrinkable Tubing for Electrical Use ASTM D 4814 Standard Specification for Automotive Spark-Ignition Fuel ASTM G 21 Standard Recommended Practice for Determining Resistance of Synthetic Polymeric Materials to Fungi (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. (c) 2006 Tyco Electronics Corporation. All rights reserved Page 2 SPECIFICATION RT-555 ISSUE 6 NASA SP-R-0022 General Specification, Vacuum Stability Requirements of Polymeric Material for Spacecraft Applications 3. REQUIREMENTS 3.1 MATERIAL The product shall consist of a heat shrinkable, crosslinked, thermally stabilized, flame-retardant modified fluoropolymer material. The product shall be homogeneous and essentially free from flaws, defects, pinholes, bubbles, cracks and inclusions. 3.2 COLOR The tubing shall be black unless otherwise specified. 3.3 PROPERTIES The tubing shall meet the requirements of Tables 1 and 3. 4. QUALITY ASSURANCE PROVISIONS 4.1 CLASSIFICATION OF TESTS 4.1.1 Qualification Tests Qualification tests are those performed on product 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 product submitted for acceptance under contract. Acceptance tests shall consist of the following: Visual Dimensions Longitudinal Change Tensile Strength Ultimate Elongation Heat Shock If this document is printed it becomes uncontrolled. Check for the latest revision. (c) 2006 Tyco Electronics Corporation. All rights reserved SPECIFICATION RT-555 ISSUE 6 Page 3 4.2 SAMPLING INSTRUCTIONS 4.2.1 Qualification Test Samples Qualification test samples shall consist of 50 feet (15 m) of tubing of the size specified. Qualification of any size within each size range specified below will qualify all sizes in the same range. Size Ranges 1/8 through 3/4 1" through 2" 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. 4.2 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 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 the specimens at a velocity of 100 to 200 feet (30 to 60 m) per minute. 4.3.1 Dimensions, Dimensional Recovery, Longitudinal Change and Concentricity Measure three 6-inch (150 mm) specimens of tubing, as supplied, for length 1/32 inch ( 1 mm) and inside diameter in accordance with ASTM D 2671. Recover these specimens fully by conditioning for 3 minutes in a 250 5C (482 9F) oven. Remove the specimens from the oven, allow to cool to 23 3C (73 5F) and re-measure. Calculate longitudinal change as follows: LC = Where: LC L0 L1 = = = L1 - L0 L0 X 100 Longitudinal Change [Percent] Length Before Conditioning [Inches (mm)] Length After Conditioning (Inches (mm)] Measure the wall thickness of three 6-inch (150-mm) long specimens, as supplied, in accordance with ASTM D 2671. Calculate concentricity as follows: M C = M1 X 100 2 Where: C = M1 = M2 = Concentricity [Percent] Minimum Thickness [Inches (mm)] Maximum Thickness [Inches (mm)] If this document is printed it becomes uncontrolled. Check for the latest revision. (c) 2006 Tyco Electronics Corporation. All rights reserved Page 4 4.3.2 SPECIFICATION RT-555 ISSUE 6 Tensile Strength and Ultimate Elongation Test three specimens of tubing for tensile strength and ultimate elongation in accordance with ASTM D 2671. For tubing sizes 3/8 and smaller, use full sections of tubing. For sizes 1/2 and larger, cut the specimens with Die D, ASTM D 412. Apply 1-inch (25-mm) centrally located benchmarks to the specimens. Use an initial machine jaw separation of 1 inch (25 mm) for full sections of tubing and 2 inches (51 mm) for die cut specimens. Test at a rate of jaw separation of 2.0 0.2 inches (50 5 mm) per minute. 4.3.3 Low Temperature Flexibility Condition three specimens, each 12 inches (300 mm) in length, and a mandrel selected in accordance with Table 2, at -65 3C (-85 5F) for 4 hours. For tubing sizes 3/4 or less, use whole sections of tubing recovered on a stranded wire (nearest AWG which is larger than the tubing maximum inside diameter after unrestricted shrinkage). For tubing sizes larger than 3/4, use 1/4-inch (6.3-mm) wide strips cut from tubing which has been recovered in accordance with 4.3.1. After 4 hours conditioning, and while still at the conditioning temperature, wrap the specimens consisting of whole sections of tubing around the mandrel for not less than 180 degrees in 10 2 seconds. Wrap strip specimens around the mandrel for not less than 360 degrees in 10 2 seconds. Examine the specimens visually for evidence of cracking. 4.3.4 Heat Shock Condition three 6-inch (150-mm) specimens of tubing for 4 hours in a 300 5C (572 9F) oven. Remove the specimens from the oven, cool to 23 3C (73 5F), wrap 360 degrees around a mandrel selected in accordance with Table 2 and then visually examine for evidence of dripping, flowing or cracking. Any side cracking caused by flattening of the specimen on the mandrel shall not constitute failure. 4.3.5 Heat Resistance Condition three 6-inch (150-mm) specimens prepared in accordance with 4.3.2 for 336 hours in a 250 3C (482 5F) oven. After conditioning, the specimens shall be removed from the oven, cooled to 23 3C (73 5F) and tested for tensile strength and ultimate elongation in accordance with 4.3.2. 4.3.6 Copper Stability Slide three 6-inch (150-mm) specimens of tubing over a snug-fitting, straight, clean, bare solid or tubular copper conductor. Condition the specimens on the conductors for 24 hours in an appropriate humidity chamber at 90 to 95 percent relative humidity and 23 3C (73 5F), followed by 16 hours in a 200 3C (392 5F) oven. After conditioning, remove the specimens from the oven and cool to 23 3C (73 5F). Remove the copper conductor from the tubing and examine the tubing and conductor. Darkening of the copper due to normal air oxidation shall not be cause for rejection. Test the tubing for ultimate elongation in accordance with 4.3.2. 4.3.7 Corrosive Effect Test the tubing for copper mirror corrosion in accordance with ASTM D 2671, Procedure A, for 16 hours at 200 3C (392 5F). Use specimens of 1/4 x 1 inch (6 x 25 mm) strips cut longitudinally from the tubing. Evidence of corrosion shall be the removal of copper from the mirror, leaving an area of transparency greater than 8 percent of its total area. If this document is printed it becomes uncontrolled. Check for the latest revision. (c) 2006 Tyco Electronics Corporation. All rights reserved SPECIFICATION RT-555 ISSUE 6 4.3.8 Page 5 Fluid Resistance Immerse three 6-inch (150-mm) specimens of tubing, prepared and measured in accordance with 4.3.2, completely in each listed fluid for the time and temperature specified in Table 3. Use a volume of fluid not less than 20 times that of the specimens. After immersion, lightly wipe the specimens and air-dry for 30 to 60 minutes at room temperature. Test the specimens from each fluid for tensile strength and ultimate elongation in accordance with 4.3.2. 4.3.9 Flammability After Fluid Exposure Flammability tests shall be performed in accordance with ASTM D 2671 Procedure C on a 22-inch (559-mm) length of the tubing that has been fully immersed for 24 hours with ends open in fluids specified in Table 3. The outside of the tubing shall be wiped to remove excess fluid and mounted in the apparatus. The inside of the tubing shall be allowed to drain for 5 minutes before flame is applied. 4.3.10 Radiation Resistance Three specimens prepared in accordance with Section 4.3.2 shall be subjected to gamma radiation for a total dosage of 10 Mrad at a rate of less than 0.5 Mrad per hour. The specimens shall be measured for tensile strength and ultimate elongation in accordance with Section 4.3.2. 4.4 REJECTION AND RETEST Failure of any sample to conform to any one of the requirements of the specification shall be cause for rejection of the lot represented. Product 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 PACKAGING Packaging shall be in accordance with good commercial practice. 5.2 MARKING Each container of product shall be permanently and legibly marked with the manufacturer's part number, size, quantity, manufacturer's identification, lot number and date of manufacture. If this document is printed it becomes uncontrolled. Check for the latest revision. (c) 2006 Tyco Electronics Corporation. All rights reserved Page 6 SPECIFICATION RT-555 ISSUE 6 TABLE 1 Inside Diameters and Wall Thicknesses of Tubing Size No. 1/8 3/16 1/4 3/8 1/2 5/8 3/4 1 1-1/4 1-1/2 2 As Supplied Inside Diameter Minimum mm In .125 3.18 .187 4.75 .250 6.35 .375 9.53 .500 12.70 .625 15.88 .750 19.05 1.000 25.40 1.250 31.75 1.500 38.10 2.000 50.80 Inside Diameter Maximum mm in .062 1.57 .093 2.36 .125 3.18 .187 4.75 .250 6.35 .313 7.95 .375 9.53 .500 12.70 .625 15.88 .750 19.05 1.000 25.40 Recovered Dimensions Wall Thickness Minimum Maximum mm mm in in .010 .25 .016 .41 .011 .28 .018 .46 .013 .33 .020 .51 .016 .41 .023 .58 .016 .41 .023 .58 .019 .48 .026 .66 .024 .61 .031 .79 .028 .71 .035 .89 .030 .76 .037 .94 .034 .86 .041 1.04 .037 .94 .044 1.12 Nominal mm in .012 .30 .014 .36 .016 .41 .019 .48 .019 .48 .022 .56 .027 .69 .031 .79 .033 .84 .037 .94 .040 1.02 TABLE 2 Mandrel Dimensions for Low Temperature Flexibility and Heat Shock Testing Mandrel Diameter Tubing Size 1/8 through 3/8 1/2 through 2 in 5/16 7/16 If this document is printed it becomes uncontrolled. Check for the latest revision. (c) 2006 Tyco Electronics Corporation. All rights reserved mm 7.9 11.1 SPECIFICATION RT-555 ISSUE 6 Page 7 TABLE 3 Requirements PROPERTY PHYSICAL Dimensions Longitudinal Change Concentricity as Supplied Tensile Strength Ultimate Elongation 2% Secant Modulus (Expanded) Specific Gravity Low Temperature Flexibility 4 hours at -65 3C (-85 5F) Heat Shock 4 hours at 300 5C (572 9F) Heat Resistance 336 hours at 250 3C (482 5F) Followed by test for Ultimate Elongation Vacuum Outgassing TML (Total Mass Loss) VCM (Volatile Condensible Material) Copper Stability 16 hours at 200 3C (392 5F) Followed by test for Ultimate Elongation ELECTRICAL Dielectric Strength Radiation Resistance Followed by tests for: Tensile Strength Ultimate Elongation CHEMICAL Copper Mirror Corrosion 16 hours at 200 3C (392 5F) Flammability After fluid immersion 24 hours at 23 3C (73 5F) ASTM D 4814 Gasoline, Automotive Combat 24 hours at 50 3C (122 5F) A-A-52557 Fuel Oil, Diesel MIL-DTL-83133 Turbine Fuel, Aviation, Grade JP-8 Fungus Resistance Water Absorption 24 hours at 23 3C (73 5F) UNIT REQUIREMENT TEST METHOD Inches (mm) Percent Percent Psi (MPa) Percent Psi (MPa) ----- In accordance with Table 1 +0, -10 60% minimum 4000 minimum (27.6) 200 minimum 50,000 maximum (345) 2.0 maximum No cracking Section 4.3.2 ASTM D 2671 ASTM D 2671 ASTM D 792 Section 4.3.3 --- No dripping, flowing or cracking Section 4.3.4 --- --- Section 4.3.5 Percent 150 minimum Percent Percent --- 1.0 maximum 0.1 maximum No brittleness, glazing or severe discoloration of tubing. No pitting or blackening of copper. Percent 150 minimum Volts/mil 200 minimum Psi (MPa) Percent 3500 minimum (24.1) 150 minimum Percent Copper removal 8% maximum --- 1) 25% maximum flag burn 2) No burning of cotton 3) No flaming or glowing longer than 60 seconds 1) 25% maximum flag burn 2) No burning of cotton 3) No flaming or glowing longer than 60 seconds --- --Percent Rating of 1 or less 0.5 maximum If this document is printed it becomes uncontrolled. Check for the latest revision. (c) 2006 Tyco Electronics Corporation. All rights reserved Section 4.3.1 ASTM D 2671 Section 4.3.2 ASTM D 2671 NASA Specification SP-R-0022A Section 4.3.6 Section 4.3.2 ASTM D 2671 ASTM D 2671 Section 4.3.10 Section 4.3.7 ASTM D 2671 Procedure A ASTM D 2671 Procedure C Section 4.3.9 ASTM D 2671, Procedure C ASTM G 21 ASTM D 2671 Page 8 SPECIFICATION RT-555 ISSUE 6 TABLE 3 Requirements (continued) PROPERTY CHEMICAL (continued) Fluid Resistance 24 hours at 23 3C (73 5F) Gasoline, Aviation Grade 100 (ASTM D 910) Coolanol 25* Followed by tests for: Tensile Strength Ultimate Elongation Fluid Resistance 24 hours at 50 3C (122 5F) JP-8 (MIL-DTL-83133) Deicing Fluid (SAE-AMS 1424) Cleaning Compound (MIL-PRF-372) 5% Salt Solution Fuel Oil, Diesel (A-A-52557) Followed by tests for: Tensile Strength Ultimate Elongation Fluid Resistance 24 hours at 75 3C (167 5F) Hydraulic Fluid (MIL-PRF-5606) Lubricating Oil (MIL-PRF-2104) Lubricating Oil (MIL-PRF-7808) Followed by tests for: Tensile Strength Ultimate Elongation *Trademark Solutia, Inc. UNIT REQUIREMENT TEST METHOD --- --- Section 4.3.8 Psi (MPa) Percent --- 3500 minimum (24.1) 150 minimum --- Section 4.3.2 ASTM D 2671 Section 4.3.8 Psi (MPa) Percent --- 3500 minimum (24.1) 150 minimum --- Section 4.3.2 ASTM D 2671 Section 4.3.8 Psi (MPa) Percent 3500 minimum (24.1) 150 minimum Section 4.3.2 ASTM D 2671 If this document is printed it becomes uncontrolled. Check for the latest revision. (c) 2006 Tyco Electronics Corporation. All rights reserved