SPECIFICATION:
THIS ISSUE:
DATE:
REPLACES:
Raychem Wire and Cable
Issue 2
24 September 2020
Amendment 3, Issue 1
PAGE:
501 Oakside Avenue, Redwood City, CA 94063-3800
80
1 of 19
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 fluoropolymerinsulated 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.
1.3
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.
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.
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Page 2 of 19
2.1.1
SPECIFICATION 80, Review Issue 2
Department of Defense
SPECIFICATIONS
Federal
UU-T-450
Tissue, Facial
Military
MIL-PRF-5606
MIL-DTL-5624
MIL-PRF-7808
MIL-PRF-23699
MIL-DTL-83133
Hydraulic Fluid, Petroleum Base; Aircraft, Missile, and Ordnance
Turbine Fuel, Aviation, Grades JP-4 and JP-5
Lubricating Oil, Aircraft Turbine Engine, Synthetic Base
Lubricating Oil, Aircraft Turbine Engine, Synthetic Base
Turbine Fuel, Aviation, Kerosene Type, JP-8 (NATO F-34), NATO F-35.
And JP-8+100 (NATO F-37)
STANDARDS
Federal
FED-STD-228
Cable and Wire Insulated; Methods of Testing
Military
MIL-STD-104
MIL-STD-129
MIL-STD-681
MIL-STD-2223
Limits for Electrical Insulation Color
Marking for Shipment and Storage
Identification Coding and Application of Hook Up and Lead Wire
Test Methods for Insulated Electric Wire
(Copies of Department of Defense documents may be obtained from the Naval Publications
and Forms Center, Standization Documents Order Desk, Bldg. 4D, 700 Robbins Ave.,
Philadelphia, PA 19111-5094; or at https://quicksearch.dla.mil.)
2.1.2
Department of Transportation, Federal Aviation Administration
FEDERAL AVIATION REGULATIONS (FAR)
Part 25
Airworthiness Standards: Transport Category Airplanes
(Copies of Department of Transportation, Federal Aviation Administration documents may be
obtained from the Superintendent of Documents, Government Printing Office, Washington,
D.C. 20402; or at www.faa.gov.)
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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NOTE:
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SPECIFICATION 80, Review Issue 2
2.2.1
Page 3 of 19
American Society for Quality (ASQ)
Z1.4
Sampling Procedures and Tables for Inspection by Attributes
(Copies of ASQ documents may be obtained from the American Society for Quality, 600 North
Plankinton Avenue, Milwaukee, WI 53203; or at www.asq.org.)
2.2.2
American Society for Testing and Materials (ASTM)
D 770
D 882
Isopropyl Alcohol
Tensile Properties of Thin Plastic Sheeting
(Copies of ASTM publications may be obtained from the American Society for Testing and
Materials, 100 Barr Harbor Drive, West Conshohocken, PA 19428-2959; or at www.astm.org.)
2.2.3
International Organization for Standardization (ISO)
8402
Quality Management and Quality Assurance – Vocabulary
(Copies of ISO documents may be obtained from the International Organization for
Standardization; or at www.iso.org.)
2.2.4
National Electrical Manufacturers Association (NEMA)
WC 27500 Standard for Aerospace and Industrial Electrical Cable
(Copies of NEMA documents may be obtained from the National Electrical Manufacturers
Association, 1300 North 17th Street, Rosslyn, VA 22209; or at www.nema.org.)
2.2.5
Society of Automotive Engineers, Inc. (SAE)
AS1241
AS22759
AS29606
Fire Resistant Phosphate Ester Hydraulic Fluid for Aircraft
Wire, Electrical, Fluoropolymer-Insulated, Copper or Copper Alloy
Wire, Electrical, Stranded, Uninsulated Copper, Copper Alloy, or Aluminum, or
Thermocouple Extension, General Specification For
(Copies of SAE aerospace standards may be obtained from SAE International, 400
Commonwealth Drive, Warrendale, Pennsylvania 15096-0001; or at www.sae.org .)
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.
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Page 4 of 19
3.2
SPECIFICATION 80, Review Issue 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 AS29606 conductor (81 series part
numbers) constructions shall be in accordance with AS29606. 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. 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.
3.3.2
Shield
Shield strands shall conform to the requirements for conductor materials (3.3.1) and shall be
constructed in accordance with WC 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.
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NOTE:
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SPECIFICATION 80, Review Issue 2
3.4
IN-PROCESS REQUIREMENTS
3.4.1
Conductor Elongation and Break Strength (High-Strand-Count Conductor)
3.4.1.1
Soft or Annealed Copper
Page 5 of 19
The elongation for high-strand-count soft or annealed copper conductors 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, removed from the finished wire.
There shall be no break strength requirements for soft or annealed copper conductors.
3.4.1.2
High-Strength Copper Alloy
The elongation for high-strand-count high-strength copper alloy conductors shall be 5 percent,
minimum average, for the whole stranded conductor removed from the finished wire. The
minimum break strength for high-strength copper alloy conductors shall conform to the
following:
AWG
Size
28
26
24
22
20
18
16
3.4.2
Minimum
Break Strength (lbs)
7.10
10.7
17.8
24.0
40.0
70.3
110.
Conductor Splices
Splices shall be in accordance with AS29606.
3.4.3
Insulation Flaws
One hundred percent of the wire shall pass the impulse dielectric test or the spark test of
AS22759 at any designated point or points in the manufacturing process prior to completion 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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Page 6 of 19
SPECIFICATION 80, Review Issue 2
TABLE 1
REQUIREMENTS FOR FINISHED WIRE AND CABLE
EXAMINATION OR TEST
TEST
METHOD
TEST
TYPE 1/
3.5.1 and AS22759
3.5.2
Specification Sheet
3.5.3 and WC 27500
Specification Sheet
AS22759
4.6.6
AS22759
WC 27500
4.6.2
Q
1
2
3
1
AS29606
AS29606
1
3.4.1
3.3.1
Specification Sheet
Specification Sheet
Specification Sheet and 3.5.4
Specification Sheet
3.5.5
Specification Sheet
3.5.6
3.5.7
Specification Sheet
Specification Sheet and 3.5.8
3.3.3
3.5.9
Specification Sheet
3.5.12
3.5.13 and AS22759
AS22759
3.5.14
Specification Sheet
Specification Sheet
AS22759
4.6.3
4.6.6
AS29606
4.6.6
4.6.4
4.6.2
4.6.7
AS22759
4.6.6
4.6.8
4.6.9
AS22759
4.6.6
AS22759
4.6.6
4.6.12
AS22759
AS22759
4.6.13
AS22759
AS22759
AS22759
1
1
1
1
2
1
Q
1
1
Q
1
3
1
Q
2
Q
Q
1
Q
2
1
1
REQUIREMENT
Finished Wire
Blocking
Color
Concentricity
Conductor Continuity (AWG 8 & larger only)
Conductor Diameter
Conductor Elongation and Break Strength:
– Standard AS29606 Conductor
(81 series part numbers)
– High-Strand-Count Conductor
(82 series part numbers)
Conductor Material
Conductor Resistance
Conductor Stranding
Crosslinking Proof Test
Finished Wire Diameter
Flammability
Identification and Color Striping Durability
Identification of Product
Immersion
Insulation Elongation and Tensile Strength
Insulation Flaws
Insulation Material and Construction
Insulation Resistance
Insulation Thickness
Life Cycle
Low Temperature-Cold Bend
Removability of Insulation
Secant Modulus
Shrinkage
Weight
Workmanship
(continued)
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SPECIFICATION 80, Review Issue 2
Page 7 of 19
TABLE 1 (CONTINUED)
REQUIREMENTS FOR FINISHED WIRE AND CABLE
EXAMINATION OR TEST
REQUIREMENT
TEST
METHOD
TEST
TYPE 1/
WC 27500
WC 27500
WC 27500
4.6.4
WC 27500
4.6.6
4.6.7.1
4.6.6
4.6.8
4.6.6
4.6.10
4.6.9
4.6.11
4.6.6
4.6.6
4.6.12
WC 27500
4.6.13
WC 27500
WC 27500
4.6.15
WC 27500
Q
1
3
2
3
1
Q
1
Q
1
2
1
3
1
2
Q
Q
Q
1
1
1
1
Finished Cable
Blocking
Cabling
Conductor and Shield Continuity
Crosslinking Proof Test
Dielectric Withstand
Dimensions
Flammability
Identification of Product
Immersion
Jacket Color
Jacket Concentricity
Jacket Elongation and Tensile Strength
Jacket Flaws
Jacket Material and Construction
Jacket Thickness
Life Cycle
Low Temperature-Cold Bend
Secant Modulus
Shield Material and Construction
Shield Coverage
Weight
Workmanship
3.5.1 and WC 27500
WC 27500
3.5.3 and WC 27500
Specification Sheet and 3.5.4
Specification Sheet
Specification Sheet
3.5.5
3.5.6
3.5.7
3.5.2
3.5.10
Specification Sheet
Specification Sheet and 3.5.11
3.3.3
Specification Sheet
3.5.12
3.5.13 and WC 27500
3.5.14
3.3.2
Specification Sheet
Specification Sheet
WC 27500
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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Page 8 of 19
3.5.2
SPECIFICATION 80, Review Issue 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 and AWG 8 and larger finished wire is tested in accordance with WC
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
When qualification samples are tested in accordance with 4.6.7, the burn length shall not
exceed 3 inches (76 mm), the afterburn time shall not exceed 3 seconds, and there shall be no
flaming of the facial tissue.
3.5.6
Identification of Product
When specified by the procuring activity, finished wire or cable shall be identified by a
marking applied to the outer surface. The identification shall consist of the appropriate mark
as specified by the contract or the applicable specification sheet. For wire sizes AWG 10 and
smaller, the legend shall be printed in black ink, except where black ink is difficult to read, the
printing shall be in a contrasting color. For wire sizes AWG 8 and larger, the legend shall be
printed in black ink preferably. For all other marking surfaces, the legend shall be printed in a
contrasting color. Identification shall be applied with the vertical axis of the printed characters
parallel to the longitudinal axis of the wire or cable when the nominal diameter of the marking
surface is 0.050 inch (1.3 mm) or smaller. The vertical axis of the printed characters may be
either perpendicular or parallel to the longitudinal axis of the wire or cable when the nominal
diameter of the marking surface exceeds 0.050 inch (1.3 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
AS22759 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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SPECIFICATION 80, Review Issue 2
3.5.9
Page 9 of 19
Insulation Resistance
The minimum insulation resistance for 1000 feet of the wire specimens shall be 500 megohms
(152.4 MΩ-1 km) for AWG 22 and 20, and 100 megohms (30.5 MΩ-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. The test mandrels and weights specified for the
corresponding wire sizes in AS22759/34 and in AS22759/32 shall be used for the 81A081x
and 82A011x wire samples, respectively.
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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Page 10 of 19
4.2.1
SPECIFICATION 80, Review Issue 2
Qualification Samples
Qualification samples shall consist of the following part numbers (insulation/jacket colors
shall be optional):
81A081x-22
81A081x-8
82A011x-20
82A112x-20
(will qualify all dual-wall primary wire, AWG 10 and smaller)
(will qualify all dual-wall primary wire, AWG 8 and larger)
(will qualify all single-wall primary wire)
(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
Name of Manufacturer
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
ISO 8402 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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SPECIFICATION 80, Review Issue 2
4.3.1.3
Page 11 of 19
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 ASQ Z1.4; 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 ASQ Z1.4.
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
Conductor material
Shield material
Insulating and jacketing material
Conductor splices
Insulation flaws
Requirement
3.3.1
3.3.2
3.3.3
3.4.2
3.4.3
Test Method
4.6.6
4.6.6
4.6.6
4.6.6
AS22759
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Page 12 of 19
SPECIFICATION 80, Review Issue 2
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
number 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 ASQ
Z1.4.
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 AS22759.
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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SPECIFICATION 80, Review Issue 2
Page 13 of 19
TABLE 3
MANDREL DIAMETERS FOR CABLES FOR BEND TEST
(POST-ENVIRONMENTAL)
Finished Cable Diameter
inch
mm
≤ 0.083
> 0.083 and ≤ 0.111
> 0.111 and ≤ 0.139
> 0.139 and ≤ 0.194
> 0.194 and ≤ 0.250
> 0.250 and ≤ 0.334
> 0.334 and ≤ 0.444
> 0.444 and ≤ 0.556
> 0.556 and ≤ 0.667
> 0.667 and ≤ 0.889
> 0.889 and ≤ 1.111
> 1.111 and ≤ 1.556
> 1.556 and ≤ 2.000
4.6.2
≤ 2.11
>2.11 and ≤ 2.82
>2.82 and ≤ 3.53
>3.53 and ≤ 4.93
>4.93 and ≤ 6.35
>6.35 and ≤ 8.48
>8.48 and ≤ 11.3
>11.3 and ≤ 14.1
>14.1 and ≤ 16.9
>16.9 and ≤ 22.6
>22.6 and ≤ 28.2
>28.2 and ≤ 39.5
>39.5 and ≤ 50.8
Mandrel Diameter
inch
mm
.750
1.00
1.25
1.75
2.25
3.00
4.00
5.00
6.00
8.00
10.0
14.0
18.0
19
25
32
44
57
76
102
127
152
203
254
356
457
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,
measurements 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 measurements 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 and Break Strength (High-Strand-Count Conductor)
4.6.3.1
Soft or Annealed Copper
Elongation tests of soft or annealed copper conductors shall be tested in accordance with MILSTD-2223, Method 5002, using a 10-inch (254-mm) initial jaw separation and a jaw separation
speed of 10 ± 2 inches (254 ± 51 mm) per minute. The test shall be performed upon the whole
conductor for regular bunch-stranded constructions, or upon one whole member removed from
rope bunch-stranded constructions, as applicable, taken from the finished wire. In either case,
elongation shall be measured upon breakage of the first strand of the whole conductor or
member, as applicable. Elongation shall be determined by the distance the jaw has traveled.
Breaks occurring at the jaws shall be discounted and a new specimen shall be tested.
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Page 14 of 19
4.6.3.2
SPECIFICATION 80, Review Issue 2
High-Strength Copper Alloy
Elongation and break strength tests of high-strength copper alloy conductors shall be tested in
accordance with MIL-STD-2223, Method 5002 on the whole conductor removed from the
finished wire, using a 10-inch (254-mm) initial jaw separation and a jaw separation speed of 2
± 0.5 inches (51 ± 13 mm) per minute. Elongation shall be determined by the distance the jaw
has traveled. Breaks occurring at the jaws shall be discounted and a new specimen shall be
tested.
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.
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
specification and the applicable specification sheet with regard to requirements not covered by
specific test methods.
4.6.7
Flammability
The following test method conforms to FAR Part 25, Appendix F, Part I, and includes a
provision for the detection of incendiary dripping.
4.6.7.1
Test Apparatus
The test shall be performed within a test chamber approximately 1-foot (0.30 m) square by
2 feet (0.61 m) in height, open at the top and front to provide adequate ventilation for
combustion but to prevent drafts. The specimen holder shall be so designed that the lower end
of a 24-inch (610-mm) specimen is held by a clamp, while the upper end of the specimen
passes over a pulley and can be suitably weighted to hold the specimen taut at an angle of
60 degrees with the horizontal, in a plane parallel to and approximately 6 inches (152 mm)
from the back of the chamber. The test flame shall originate from a Bunsen type gas burner
with a 0.250-inch (6.4-mm) inlet, a needle valve in the base for gas adjustment, a nominal bore
of 0.375 inch (9.5 mm), and a barrel length of approximately 4 inches (102 mm) above the air
inlets. The burner shall be adjusted to furnish a 3-inch (76-mm) high conical flame with an
inner cone approximately 1 inch (25 mm) in length and a flame temperature not less than
954°C at its hottest point, as measured with an accurate thermocouple pyrometer. A sheet of
facial tissue conforming to UU-T-450 shall be suspended taut and horizontal 9.5 inches (241
mm) below the point of application of the flame to the specimen and at least 0.50 inch (13 mm)
from the chamber floor, so that any material dripping from the specimen shall fall upon the
tissue.
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SPECIFICATION 80, Review Issue 2
4.6.7.2
Page 15 of 19
Test Procedure
A 24-inch (610-mm) specimen shall be marked at a distance of 8 inches (203 mm) from its
lower end to indicate the point for flame application and shall be placed in the specified 60degree position in the test chamber. The lower end of the specimen shall be clamped in
position in the specimen holder and the upper end shall be passed over the pulley of the holder
and the appropriate weight shall be attached. Weight shall be sufficient to hold the specimen
taut throughout the test. With the burner held perpendicular to the specimen and at an angle of
30 degrees from the vertical plane of the specimen (see Figure 1), the hottest portion of the
flame shall be applied to the lower side of the specimen at the test mark. The period of test
flame application shall be 30 seconds and the test flame shall be withdrawn immediately at the
end of that period. The distance of flame travel upward along the specimen from the test mark
and the time of burning after removal of the test flame shall be recorded; also, the presence or
absence of flame in the facial tissue due to incendiary dripping from the specimen. Charred
holes or charred spots in the tissue shall be ignored in the absence of actual flame. Breaking
of the specimen shall not be considered as failure, provided the requirements for flame travel
limits, duration of flame, and the absence of incendiary dripping are met.
Pulley
3 in. (75 mm)
Weight
8 in. (200 mm)
60°
Specimen clamped
in place
FIGURE 1.
Flammability Test Apparatus (shown without chamber)
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,
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Page 16 of 19
SPECIFICATION 80, Review Issue 2
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, using 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
(a)
(b)
(c)
(d)
(e)
(f)
4.6.9
TEST FLUID
TEST TEMPERATURE
MIL-PRF-23699, Lubricating Oil, Aircraft
48 to 50°C (118 to 122°F)
Turbine Engine, Synthetic Base
MIL-PRF-5606, Hydraulic Fluid, Petroleum Base, 48 to 50°C (118 to 122°F)
Aircraft, Missile and Ordnance
ASTM D 770, Isopropyl Alcohol
20 to 25°C (68 to 77°F)
MIL-DTL-5624, Turbine Fuel, Aviation, Grade
20 to 25°C (68 to 77°F)
JP-4, or JP-8 per MIL-DTL-83133
AS1241, Fire Resistant Phosphate Ester
48 to 50°C (118 to 122°F)
Hydraulic Fluid for Aircraft
MIL-PRF-7808, Lubricating Oil, Aircraft Turbine 118 to 121°C (244 to 250°F)
Engine, Synthetic Base; or NATO 148
IMMERSION
TIME
20 hours
20 hours
168 hours
168 hours
20 hours
30 minutes
Insulation/Jacket 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 thickness 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.
4.6.11
Jacket Flaws
Finished cable shall be tested in accordance with the jacket flaws test of WC 27500, or the
impulse dielectric test procedure of AS22759, 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
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SPECIFICATION 80, Review Issue 2
Page 17 of 19
cool, the finished wire specimens shall be freed from tension, removed from the mandrel, and
straightened. All finished wire and cable specimens shall then be subjected to the bend test
(4.6.1). The voltage withstand test (4.6.14) shall then be conducted on finished wire and
shielded-and-jacketed specimens only.
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) specimen 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
specimen 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 (except that for 200°C rated wire, AWG 22 and 20, the weight shall
be 25 percent of that specified for the Crosslinking Proof Test), so that the portion of the
insulation between the conductor and mandrel is under compression while the conductor is
under tension. This specimen, so prepared on the mandrel, shall be conditioned and tested as
specified in 4.6.12.
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
in 4.6.12.
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
separation, 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%) =
lbsf
CSA x 0.2
Where: CSA = cross sectional area
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.
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Page 18 of 19
4.6.15
SPECIFICATION 80, Review Issue 2
Weight
The weight of each lot of finished cable shall be determined in accordance with the procedure
specified for finished wire in AS22759.
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).
TABLE 5
FINISHED WIRE LENGTHS
Wire Size Range
5.1.3
Minimum Percentage of Total Length in
Shipment with Lengths Greater Than:
AWG
mm2
500 ft (152 m)
100 ft (30.5 m)
50 ft (15.2 m)
30 through 10
8 through 0000
0.057 through 4.74
8.60 through 106.9
50
---
100
---
--100
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.
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SPECIFICATION 80, Review Issue 2
5.1.4
Page 19 of 19
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 transpotation 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)
Name of Manufacturer
6.
NOTES
6.1
ORDERING DATA
Procurement documents should specify the following:
(a)
(b)
(c)
(d)
6.2
Title, number, and revision of this specification
Applicable specification sheet part number
Quantity
Special preparation for delivery requirements, if applicable
METRIC UNITS
Metric units are for information only.
6.3
AS22759
Whenever AS22759 refers to the “application detail specification”, use the applicable TE
specification sheet (3.1).
6.4
TRADEMARKS
FlexLine, Raychem, TE Connectivity, and TE connectivity (logo) are trademarks.
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