RK-6048 Revision 7
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RK-6048 Revision 7
Raychem brand CONVOLEX
SCOPE
This Quality Assurance Specification establishes the quality standard for an irradiated,
thermally stabilized, non-heat shrinkable, convoluted, flexible, non-burning, modified
polyvinylidene fluoride sleeving.
Approved Signatories*
Tyco Electronics :
Approved electronically via DMTec
* This document is electronically reviewed and approved - therefore no signatures will appear.
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RK-6048 Revision 7
1.
Page 2 of 8
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REVISION HISTORY
Revision
Number
Change Request
Date
Incorporated By
6
CR98-DM-0199
September 1998
Linda Abrams
7
CR10-DM-009
3 August 2010
Paul Dixon
2.
REQUIREMENTS
2.1
Composition, Appearance and Colour
The sleeving shall be homogeneous and essentially free from pinholes, bubbles, cracks and
inclusions. The standard colour shall be black. Other colours may be possible by special contract.
2.2
2.3
Dimensions
Size
Minor Inside
Diameter
mm
Major Outside
Diameter
mm
Pitch
mm
Wall Thickness
mm
9/32
7.1 + 0, -1.1
10.0 0.6
3.3 0.6
0.33 0.20
3/8
9.4 + 0, -1.1
12.6 0.6
3.3 0.6
0.33 0.20
7/16
11.2 + 0, -1.1
14.6 0.6
3.8 0.7
0.38 0.20
1/2
12.7 + 0, -1.3
16.0 0.8
3.8 0.7
0.38 0.20
5/8
15.8 + 0, -1.3
19.0 0.8
3.8 0.7
0.38 0.20
3/4
19.1 + 0, -1.6
23.1 0.8
4.2 0.7
0.38 0.20
7/8
22.1 + 0, -1.6
26.4 1.0
4.2 0.7
0.38 0.20
1
25.4 + 0, -1.8
29.5 1.0
3.8 0.7
0.38 0.20
1-1/4
31.8 + 0, -1.8
35.6 1.0
3.8 0.7
0.46 0.20
1-5/8
41.4 + 0, -1.8
46.0 1.0
3.8 0.7
0.51 0.20
Test Requirements
The test requirements shall be as specified in Table 1.
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RK-6048 Revision 7
3.
TEST METHODS
3.1
Preparation of Test Specimens
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Unless otherwise specified, tests shall be carried out on specimens of sleeving in the as received
condition.
3.2
Dimensions
The test method shall be as specified in ASTM D876.
Three specimens shall be measured for minor inside diameter, major outside diameter, pitch and
wall thickness.
3.3
Breaking Load and Ultimate Elongation
The test method shall be as specified in ASTM D638.
For sizes 7/16 and smaller, three specimens of whole sleeving 150 mm in length shall be tested.
For sizes larger than 7/16, three strip specimens 150 mm long and 5 mm wide shall be cut and
tested. The specimens shall be tested using an initial jaw separation of 50 mm and a rate of jaw
separation of 50 mm per minute. Mean values for ultimate elongation as established from jaw
separation and the mean load to break shall be recorded.
3.4
Specific Gravity
The test method shall be as specified in Method A of ISO 1183.
3.5
Crush Resistance
Three specimens of sleeving of length as specified in Table 2 shall be crushed transversely
between parallel plates of diameter 50 mm minimum in a suitable tensile testing machine at a
rate of 5 mm per minute. The Crush Resistance shall be recorded as the mean force required to
reduce the outside diameter of the sleeving by 25%.
3.6
Compressive Flexibility
Three specimens of sleeving 300 mm long shall be compressed longitudinally in a suitable
tensile testing machine at a rate of 5 mm per minute. The sleeving shall slide freely over a
supporting mandrel of diameter 90 2% of the sleeving inside diameter. The Compressive
Flexibility shall be recorded as the mean value of the force required to compress the sleeving by
25%.
3.7
Flexibility
Three specimens of sleeving 300 mm long shall be secured to a flat horizontal surface such that
each specimen extends 150 mm beyond a 90° edge. The free end of each specimen shall be
loaded as specified in Table 2 and the vertical displacement shall be measured. The flexibility
shall be recorded as the mean value of displacement.
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TEST METHODS (continued)
3.8
Flex Life
Three tubular specimens 600 mm long shall be attached at one end to a 76 mm diameter mandrel
and at the other end to the load weight as specified in Table 2. The specimens shall then be
wound and unwound on the mandrel for 10,000 cycles at a rate of 10 cycles per minute. After
cycling the specimens shall be subjected to the dielectric withstand voltage test as specified in
Clause 3.13.
3.9
Abrasion Resistance
The abrasion resistance shall be determined using equipment similar to that described in
MIL-T-5438. Three tubular specimens shall be tested. Each specimen shall be drawn onto a
mandrel of diameter equal to the nominal inside diameter of the sleeving. The lengths of the
specimens shall be as specified in Table 2. Each specimen in turn shall be abraded with grade
4/0 abrasive tape at a rate of 1.5m per minute under load and of length as specified in Table 2.
After testing each specimen shall be examined visually for holes.
3.10
Low Temperature Flexibility
Three tubular specimens of sufficient length to be wound totally around a cylindrical metal
mandrel of 10 times the outside diameter of the sleeving under test shall be conditioned as
specified in Table 1. While still at the conditioning temperature the specimens shall be wrapped
360° around the mandrel in approximately 30 seconds. Each specimen shall be visually
examined for cracking and after stabilising to room temperature shall be subjected to the
dielectric withstand voltage test as described in Clause 3.13.
3.11
Heat Shock
Three tubular specimens 150mm long shall be suspended vertically in a fan assisted air circulating
oven as specified in Table 1. After conditioning the specimens shall be allowed to cool naturally in
air to ambient temperature and then examined for evidence of splitting, cracking, dripping or flowing.
3.12
Heat Ageing
For sizes 7/16 and smaller, three tubular specimens 150 mm long shall be tested. For sizes
larger than 7/16 three strip specimens 150 mm long and 5 mm wide shall be tested. The
specimens shall be laid on an oven tray and conditioned in a fan assisted air circulating oven as
specified in Table 1. After conditioning the specimens shall be removed, allowed to cool
naturally to room temperature and tested for breaking load and ultimate elongation as described
in Clause 3.3.
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RK-6048 Revision 7
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TEST METHODS (continued)
3.13
Dielectric Withstand Voltage Test
The test method shall be as specified in IEC 60243-1 (proof tests).
A conducting wire shall be inserted through each length of three 600 mm long specimens of
sleeving which shall be formed into a ‘U’ shape. The two wire ends of each specimen shall be
twisted together. The specimens shall then be filled with a 1% salt water solution serving as an
inner electrode and immersed to within 150 mm of their ends in a container of 1% salt water
solution serving as an outer electrode. The specimens shall remain immersed for one hour after
which a potential of 5 kV shall be applied between the electrodes. The potential shall be
gradually increased from zero to 5 kV within approximately 30 seconds and shall be held at that
voltage for one minute.
3.14
Copper Mirror Corrosion
The test method shall be as specified in ASTM D2671.
3.15
Flammability
The test method shall be as specified in ASTM D876.
3.16
Water Absorption
The test method shall be as specified in Method 1 of ISO 62.
3.17
Fluid Resistance
The test method shall be as specified in ISO 1817.
Five test specimens prepared as in Clause 3.3. shall be completely immersed in each of the
fluids for the times and temperatures specified in Table 1. The volume of the fluid shall not be
less than 20 times that of the specimen. After immersion, lightly wipe the specimens and allow
to air dry at 23 ± 2°C for 1h ± 15m. The Breaking Load and Ultimate Elongation of each
specimen shall be tested according to Clause 3.3. The test shall be repeated on the remaining
specified fluids.
3.18
Fungus Resistance
The test method shall be as specified in ISO 846 Method B.
Specimens shall be conditioned for 56 days followed by testing as per Clause 3.3.
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4.
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RELATED STANDARDS & issue
ASTM D638-03
Test Method For Tensile Properties Of Plastics
ASTM D876-09
Standard Test Methods for Non rigid Vinyl Chloride Polymer Tubing
Used for Electrical Insulation
ASTM D2671-09
Standard Test Methods for Heat-Shrinkable Tubing for Electrical Use
IEC 60243-1: 1998
Electrical Strength Of Insulating Materials - Test Methods Tests At Power Frequencies
ISO 62: 2008
Determination of Water Absorption
ISO 846: 1997
Plastics - Evaluation of the action of microorganisms.
ISO 1183-1: 2004
Plastics - Methods For Determining The Density Of Non-Cellular
Plastics - Part 1: Immersion Method, Liquid Pyknometer Method And
Titration Method
ISO 1817: 2005
Rubber, vulcanized - Determination of the effect of liquids
MIL-T-5438
Tester, Abrasion, Electrical Cable
Subsequent amendments to, or revisions of, any of the above publications apply to this
standard only when incorporated in it by updating or revision.
5.
SAMPLING
Tests shall be carried out on a sample taken at random from each batch of finished sleeving.
A batch of sleeving is defined as that quantity of sleeving extruded at any one time. Testing
frequency shall be Production Routine or Qualification. Production Routine tests consisting of
Visual Examination, Dimensions, Breaking Load, Ultimate Elongation, Crush Resistance,
Compressive Flexibility and Heat Shock shall be carried out on every batch of sleeving.
Qualification tests shall be carried out to the requirements of the Design Authority.
6.
PACKAGING
Packaging shall be in accordance with good commercial practice. Each package shall bear an
identification label showing material quantity, description, size, colour and batch number.
Additional information shall be supplied as specified in the contract or order.
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TABLE 1 Test Requirements
Test
Test Method
Dimensions
Test Requirements
In accordance with Clause 2.2
Breaking Load
ASTM D638
23 N minimum
Ultimate Elongation
ASTM D638
100 % minimum
Specific Gravity
ISO 1183
1.8 maximum
Crush Resistance
Clause 3.5
31 N minimum
Compressive Flexibility
Clause 3.6
In accordance with Table 2
Flexibility
Clause 3.7
76 mm minimum
Flex Life
Clause 3.8
- Dielectric Withstand Voltage
No breakdown after 10,000 cycles
Abrasion Resistance
Clause 3.9
Low Temperature Flexibility
Clause 3.10
No breakthrough
(4 h 15 min at -55 2C)
- Visual
No cracking
- Dielectric Withstand Voltage
No breakdown
Heat Shock
Clause 3.11
(4 h 15 min at 250 C
Heat Ageing
No dripping, cracking, splitting or
flowing
Clause 3.12
(168 2 h at 175 5°C)
- Break Load
23 N minimum
- Ultimate Elongation
75 % minimum
Dielectric Withstand Voltage
IEC 60243-1
No breakdown after 1 minute at 5kV
Copper Mirror Corrosion
ASTM D2671
No corrosion of mirrors
Flammability
ASTM D876
15 seconds maximum
Fungus Resistance
ISO 846
(16 h 15 min at 175 3°C)
- Breaking Load
23 N minimum
- Ultimate Elongation
150 % minimum
Water Absorption
ISO 62
0.5 % maximum
(24 2h immersion at 23 2°C)
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TABLE 1 Test Requirements (continued)
Test
Test Method
Fluid Resistance
Test Requirements
ISO 1817
24 2 h immersion at 23 2°C
Gasoline Fuel to ISO 1817
Test Liquid B
Hydraulic Fluid DTD900/4881
Hydraulic Fluid H-515
(MIL-H-5606)
Aviation Gasoline (100/130)
Salt Water (5% salt)
Lubricating Oil O-149
(MIL-L-23699)
Anti-Icing Fluid
(TT-I-735) (S737)
- Breaking Load
ASTM D638
- Ultimate Elongation
13N minimum
100% minimum
TABLE 2 - Performance Details
Size
Specimen Size
Crush and
Abrasion
Resistance
(Convolutes)
9/32
Test Load 3 %
Requirement*
Flexibility
(N)
Flex Life
(Kg)
Abrasion
Resistance
(N)
Compressive
Flexibility
(N) max
Abrasion
Resistance
(mm) of Tape
min
8
1.1
0.23
9
63.5
635
3/8
8
2.2
0.34
13
63.5
635
7/16
7
3.3
0.45
18
80.0
1270
1/2
7
4.4
0.45
18
80.0
1270
5/8
7
6.7
0.45
18
89.0
1270
3/4
7
8.9
0.91
18
111
1905
7/8
7
8.9
0.91
18
111
1905
1
7
8.9
0.91
18
111
1905
1-1/4
7
10.0
0.91
18
178
1905
1-5/8
7
11.1
0.91
18
178
1905
*See Table 1 for complete sleeving requirements
In line with a policy of continual product development, Tyco reserves the right to make changes
in construction, materials and dimensions without further notice. You are advised, therefore, to
contact Tyco Electronics, should it be necessary to ensure that this document is the latest issue.
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