HCTE-1000-0-SP

Tyco Electronics Corporation 300 Constitutional Drive Menlo Park, CA 94025 USA Specification This Issue: Date: Replaces: RT-1162 Issue 7 November 19, 1997 Issue 6 HELICAL CONVOLEX® TUBING HCTE Ethylene Tetrafluoroethylene, Modified, Radiation-Crosslinked 1. SCOPE This specification covers the requirements for one type of convoluted tubing that will provide mechanical protection for electrical wiring systems. 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-L-2104 MIL-G-3056 MIL-H-5606 MIL-T-5624 MIL-L-7808 MIL-A-8243 MIL-L-23699 MIL-C-43616 MIL-F-46162 MIL-L-46167 MIL-H-46170 MIL-T-81914 Lubricating Oil, Internal Combustion Engine, Heavy Duty Gasoline, Automotive, Combat Hydraulic Fluid, Petroleum Base, Aircraft, Missile and Ordnance Turbine Fuel, Aviation Grade JP-4, JP-5 and JP5/JP8 Lubricating Oil, Aircraft Turbine Engine, Synthetic Base Anti-Icing and Deicing - Defrosting Fluid Lubricating Oil, Aircraft Turbine Engine, Synthetic Base Cleaning Compound, Aircraft Surface Fuel, Diesel, Referee Grade Lubricating Oil, Internal Combustion Engine, Arctic Hydraulic Fluid, Rust Inhibited, Fire Resistance Synthetic Hydrocarbon Base Tubing, Plastic, Flexible, Convoluted, Conduit, General Specification for Federal O-S-1926 PC-437 VV-F-800 Sodium Chloride 5% Solution Cleaning compound, High Pressure (Steam Cleaner) Fuel Oil, Diesel If this document is printed it becomes uncontrolled. Check for the latest revision. Page 2 2.2 SPECIFICATION RT 1162- ISSUE 7 OTHER PUBLICATIONS American Society for Testing and Materials (ASTM) ASTM D 638 Standard Test Methods for Tensile Properties of Plastics ASTM D 792 Standard Test Methods for Specific Gravity and Density of Plastics by Displacement ASTM D 876 Standard Methods of Testing Nonrigid Vinyl Chloride Polymer Tubing Used for Electrical Insulation ASTM D 910 Standard Specification for Aviation Gasoline ASTM D 3032 Standard Methods of Testing Hookup Wire Insulation. ASTM G 21 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. 3. REQUIREMENTS 3.1 MATERIAL The tubing material shall be modified ethylene tetrafluoroethylene, radiation crosslinked. It shall be homogeneous and essentially free from flaws, defects, pinholes, cracks, and inclusions. 3.2 COLOR The tubing shall be black. 3.3 PROPERTIES The tubing shall meet the requirements of Table 3. 4. QUALITY ASSURANCE PROVISIONS 4.1 CLASSIFICATION OF TESTS 4.1.1 Qualification Tests Qualification tests are those performed on samples submitted for qualification as representative of standard product and shall consist of all tests listed in this specification. 4.1.2 Acceptance Tests Acceptance tests are those performed on tubing submitted for acceptance under contract. Acceptance tests shall consist of the following: Dimensions Tensile Strength Extensibility Crush Resistance Flammability Heat Shock Longitudinal Change If this document is printed it becomes uncontrolled. Check for the latest revision. SPECIFICATION RT 1162- ISSUE 7 Page 3 4.2 SAMPLING INSTRUCTIONS 4.2.1 Qualification Test Samples Qualification test samples shall consist of sufficient lengths of Sizes 0500 and 1500. These two sizes will qualify all sizes as follows. For Fluid Resistance, one size shall qualify all sizes. Qualification Size 0500 1500 4.2.2 Qualification Range Below 1000 1000 and above Acceptance Test Samples Acceptance test samples shall consist of not less than 10 feet (3 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. 4.3 TEST PROCEDURES 4.3.1 Tensile Properties (Tensile Strength & Extensibility) Test three 6-inch (150-mm) specimens of tubing, [cut 6 x 1/2 inch (150 x 12 mm) strips from tubing larger than Size 0437], in accordance with ASTM D 638, using an initial jaw separation of 3 inches (76 mm), 2-inch (50-mm) bench marks and a 2-inch (50-mm) per minute rate of jaw separation. Measure the benchmark separation and load at break. Report these values as the extensibility and tensile strength, respectively. 4.3.2 Crush Resistance Cut three specimens of tubing to provide the number of convolutions specified in Table 1. Place each specimen horizontally between plates larger than 2 inches (50 mm) square in a standard tensile testing machine that is arranged to measure and record compressive force. Operate the machine at a compressive speed of 0.2 inches (5 mm) per minute. Measure the average force required to reduce the outside diameter of the tubing by 25 percent and report this force as the crush resistance. If this document is printed it becomes uncontrolled. Check for the latest revision. Page 4 4.3.3 SPECIFICATION RT 1162- ISSUE 7 Compressive Flexibility Test three 12-inch (300-mm) specimens of tubing in a standard tensile testing machine that is arranged to measure and record the compressive stress of the specimen as it slides freely over an inner supporting mandrel (see Figure 1). Use a mandrel at least 12 inches (300 mm) long with an outside diameter of 90 ± 5 percent of the inside diameter of the tubing. Conduct the test at a cross head speed of 0.2 inches (5.08 mm) per minute . Compress the tubing to reduce its length by 25 percent and observe the maximum force required for this compression. Report the average value. Figure 1 4.3.4 Flexibility Secure three 12-inch (300-mm) specimens of tubing to a flat surface so that each specimen extends 6-inches (150-mm) beyond a 90 degree edge. Attach the weight specified in Table 1 to the free end of each specimen, measure the average vertical displacement of the weighted ends and report the average value as the flexibility. 4.3.5 Flex Life Attach three 24-inch (600-mm) specimens of tubing at one end to a mandrel 5 times the outside diameter of the specimen, and at the other end to the load weight specified in Table 1. Wind and unwind the specimens on the mandrel for 10,000 cycles at a rate of 10 cycles per minute. Subject the specimens to the dielectric withstand voltage test described in Section 4.3.9. If this document is printed it becomes uncontrolled. Check for the latest revision. SPECIFICATION RT 1162- ISSUE 7 4.3.6 Page 5 Heat Shock and Longitudinal Change Mark three 6-inch (150-mm) specimens of tubing with 4 ± 1/32 inch (100 ± 1 mm) benchmarks, centrally located. Suspend the tubing horizontally in an oven by inserting an 8 x 0.125-inch (200 x 3-mm) metal mandrel through the tubing and resting the ends of the mandrel on metal blocks. Condition the specimen for 4 hours at 300 ± 5°C (572 ± 9°F). Remove the test assembly from the oven and allow to cool at room temperature for one hour. Inspect the specimens for evidence of dripping, flowing or cracking. Measure the distance between benchmarks, calculate the percentage change in benchmark length and report this value as the longitudinal change. L1 - L0 x 100 L0 LC = Longitudinal Change [percent] L0 = Length Before Conditioning [inches (mm)] L1 = Length After Conditioning [inches (mm)] LC = Where: 4.3.7 Low Temperature Flexibility Prepare three 24-inch (600-mm) specimens of tubing and a test fixture . The test fixture shall consist of two 3.5-inch (88.9-mm) diameter mandrels mounted at right angles to a support plate with the distance between them slightly larger [approximately 1/16 inch (1.59 mm)] than the outside diameter of the specimens. Condition the specimens and the mandrel assembly for 4 hours at -55 ± 2°C (-67 ± 4°F), keeping the tubing straight and vertical. While at this temperature, place the tubing between the two mandrels, fixed at the lower end and alternately flexed 180 degrees around each mandrel for 5 cycles (Figure 2). A cycle shall consist of 180 degree bend in one direction, 180 degree bend in the other direction and the return to the original or vertical position. Complete the 5 bend cycles within 2 minutes. Examine the specimens for cracking and subject them to the dielectric withstand voltage test described in Section 4.3.9. 180º 180º 3.5" 3.5" Figure 2 If this document is printed it becomes uncontrolled. Check for the latest revision. Page 6 4.3.8 SPECIFICATION RT 1162- ISSUE 7 Heat Resistance Cut three 6-inch (150-mm) specimens of tubing, [6 x 1/2 inch (150 x 12 mm) strips from tubing larger than Size 0750], lay them on an oven tray and condition them for 168 hours in a 200 ± 5°C (392 ± 9°F) mechanical convection oven with an air velocity of 100 to 200 feet (30 to 60 m) per minute past the specimens. After conditioning, remove the specimens from the oven and cool to 23 ± 3°C (73 ± 5°F) within 1 hour. After cooling, test the specimens for Tensile Strength and extensibility in accordance with Section 4.3.1. 4.3.9 Dielectric Withstand at 12 kV Insert a non-insulated 20 gauge copper wire through each of three 24-inch (600-mm) specimens of tubing. Bend each specimen into a "U" shape and twist the ends of the wire together to hold the specimen in this shape (refer to Figure 3). Fill each specimen with an aqueous solution of 1 percent sodium chloride to within 6 inches (150 mm) of the end (the outer surface of the specimens must be kept dry). Immerse the specimens in an aqueous solution of 1 percent sodium chloride so that the ends of the specimens protrudes about 6 inches (150 mm) above the liquid surface. The level of the liquid in the specimen shall be above that in the container. After one hour immersion, apply 12 kV AC across the wire in each specimen and an electrode formed by immersing copper wire at the edge of the salt bath. The potential should be applied gradually from 0 to 12 kv over a period of about 30 seconds and then maintained for 1 minute. Observe and report evidence of dielectric breakdown. INNER ELECTRODE 6" MIN. 6" MIN. OUTER ELECTRODE Figure 3 If this document is printed it becomes uncontrolled. Check for the latest revision. SPECIFICATION RT 1162- ISSUE 7 4.3.10 Page 7 Fluid Resistance Prepare six specimens, three 6-inch (150-mm) tubing specimens and three tensile specimens prepared and measured in accordance with Section 4.3.1, and immerse for the time and temperature specified for each of the test fluids listed in Table 3. The volume of the fluid shall not be less than 20 times that of the specimens. Before and after immersion, rinse the specimens in methyl ethyl ketone to remove surface contamination and fluid residues. After immersion and rinsing, wipe the specimens lightly and air dry for 30 to 60 minutes at 23 ± 3°C (73 ± 5°F). Test the three specimens intended for the Tensile Strength and extensibility tests in accordance with Section 4.3.1. Weigh the other three specimens before and after immersion and calculate the weight change as a percentage. Report the average of the three values. 4.3.11 Flammability Perform flammability in accordance with ASTM D 876, except that the bottom of the chamber shall be within 9 inches (229 mm) of the point of flame impingement and covered with surgical cotton. Observe any ignition of the cotton from dripping or falling particles. 4.4 REJECTION AND RETEST Failure of any sample of tubing to conform to any one of the requirements of this specification shall be cause for rejection of the lot represented. Tubing which has been rejected may be replaced or reworked to correct the defect and then resubmitted for acceptance. Before resubmitting, full particulars concerning the rejection and the action taken to correct the defect shall be furnished to the inspector. 5. PREPARATION FOR DELIVERY 5.1 PACKAGING Unless otherwise specified, the tubing shall be supplied coiled on spools or reels and shall be packaged in accordance with good commercial practice. 5.2 MARKING Each spool or reel of tubing shall be permanently and legibly marked with the size, color, quantity, manufacturer’s identification, part number, and lot number. If this document is printed it becomes uncontrolled. Check for the latest revision. Page 8 SPECIFICATION RT 1162- ISSUE 7 TABLE 1 Size-Dependent Test Criteria Specimen Size (number of convolutions) Size Designation 0187 Crush Resistance 0281 8 0312 8 0375 8 0437 8 0500 7 0625 7 0750 6 0875 5 1000 5 1250 4 1500 4 1625 4 1750 4 2000 4 8 Test Load, LBS (kg), ± 3% Flexibility 0.25 (0.11) 0.50 (0.23) 0.75 (0.34) 0.75 (0.34) 0.87 (0.40) 1.00 (0.45) 1.50 (0.68) 2.00 (0.91) 2.00 (0.91) 2.00 (0.91) 3.50 (1.59) 3.50 (1.59) 3.75 (1.59) 4.00 (1.82) 4.00 (1.82) Flex Life 0.50 (0.23) 0.75 (0.34) 1.00 (0.45) 1.00 (0.45) 1.00 (0.45) 1.00 (0.45) 1.00 (0.45) 2.00 (0.91) 2.00 (0.91) 2.00 (0.91) 2.00 (0.91) 2.00 (0.91) 2.00 (0.91) 2.00 (0.91) 2.00 (0.91) *See Table 3 for complete tubing requirements. If this document is printed it becomes uncontrolled. Check for the latest revision. Requirement* Crush Resistance Room Temperature LBS (kg), Minimum 12 (5.45) 12 (5.45) 12 (5.45) 10 (4.55) 10 (4.55) 10 (4.55) 7 (3.18) 7 (3.18) 7 (3.18) 7 (3.18) 7 (3.18) 7 (3.18) 7 (3.18) 7 (3.18) 7 (3.18) Compressive Flexibility LBS (kg), Maximum 14 (6.36) 14 (6.36) 14 (6.36) 14 (6.36) 18 (8.17) 18 (8.17) 20 (9.08) 25 (11.35) 25 (11.35) 25 (11.35) 40 (18.16) 40 (18.16) 40 (18.16) 40 (18.16) 40 (18.16) SPECIFICATION RT 1162- ISSUE 7 Page 9 TABLE 2 Dimensions Inches (Millimeters) CONSTRUCTION DETAILS Helical (right hand) Size No. Designation 0187 0281 0312 0375 0437 0500 0625 0750 0875 1000 1250 1500 1625 1750 2000 Maximum Inside Diameter .187 (4.75) .281 (7.14) .312 (7.92) .375 (9.53) .437 (11.1) .500 (12.70) .625 (15.88) .750 (19.05) .875 (22.23) 1.000 (25.40) 1.250 (31.75) 1.500 (38.1) 1.625 (41.28) 1.750 (44.45) 2.000 (50.80) Minimum Inside Diameter .181 (4.60) .273 (6.93) .306 (7.77) .364 (9.25) .427 (10.85) .485 (12.32) .608 (15.44) .730 (17.90) .860 (21.84) .975 (24.77) 1.210 (30.74) 1.437 (36.50) 1.562 (39.67) 1.688 (42.67) 1.937 (49.20) Maximum Outside Diameter Maximum Wall Thickness Convolutions ± 1 Per Inch (25 mm) .320 (8.13) .414 (10.52) .450 (11.43) .510 (12.96) .571 (14.50) .650 (16.51) .780 (19.81) .930 (23.62) 1.073 (27.25) 1.226 (31.14) 1.539 (35.30) 1.832 (46.53) 1.975 (50.17) 2.082 (52.88) 2.332 (59.23) .018 (.46) .018 (.46) .018 (.46) .018 (.46) .018 (.46) .023 (.58) .023 (.58) .023 (.58) .023 (.58) .023 (.58) .023 (.58) .023 (.58) .023 (.58) .023 (.58) .023 (.58) 8 If this document is printed it becomes uncontrolled. Check for the latest revision. Maximum Weight lbs/100 ft. kg/100 m 1.2 (1.8) 8 1.5 (2.2) 8 1.8 (2.7) 8 2.0 (3.0) 8 2.5 (3.7) 7 3.5 (5.2) 7 4.3 (6.4) 6 5.0 (7.4) 5 6.5 (9.6) 5 7.6 (11.20 4 8.8 (13.0) 4 11.4 (16.9) 4 11.8 (17.7) 4 12.8 (19.2) 4 14.2 (21.3) Page 10 SPECIFICATION RT 1162- ISSUE 7 TABLE 3 Requirements PROPERTY PHYSICAL Dimensions Tensile Strength Extensibility Specific Gravity Crush Resistance Compressive Flexibility Flexibility Flex Life 10,000 cycles Followed by test for: Dielectric Withstand (12 kV) Low Temperature Flexibility 4 hours at -55°C (-67°F) for 5 cycles Followed by test for: Dielectric Withstand (12 kV) Heat Shock at 300°C (572°F) Followed by test for: Longitudinal Change Heat Aging 168 hours at 200°C (392°F) Followed by tests for: Tensile Strength Ultimate Extensibility ELECTRICAL Dielectric Withstand (12 kV) CHEMICAL Flammability Duration of Burning Fluid Resistance 24 hours at 23°C (73°F) Gasoline, Automotive (MIL-G-3056) Gasoline, Aviation, Grade 100 (ASTM D 910) (MIL-T-81533) Coolanol 25* Followed by tests for: Tensile Strength Ultimate Extensibility Weight Change UNIT REQUIREMENTS TEST METHOD Inches (mm) psi. (MPa) Percent --Lbs. (kg) Lbs. (kg) Inches (mm) --- In accordance with Table 2 2000 (13.8) minimum 150 minimum 1.8 maximum In accordance with Table 1 In accordance with Table 1 3 (76.2) minimum --- ASTM D 876 Section 4.3.1 ASTM D 638 ASTM D 792 Section 4.3.2 Section 4.3.3 Section 4.3.4 Section 4.3.5 ----- No breakdown No visible cracks Section 4.3.9 Section 4.3.7 ----- No breakdown No dripping, flowing or cracking 20 maximum Section 4.3.9 Section 4.3.6 Percent --- --- Section 4.3.6 Section 4.3.8 psi. (MPa) Percent 2000 (13.8) minimum 100 minimum Section 4.3.1 ASTM D 638 --- No breakdown Section 4.3.9 Seconds --- 15, maximum No dripping or flowing; no burning or charring of indicator; no flaming of cotton. --- psi. (MPa) Percent Percent 2000 (13.8) minimum 100 minimum 3 maximum Section 4.3.11 If this document is printed it becomes uncontrolled. Check for the latest revision. Section 4.3.10 Section 4.3.1 ASTM D 638 SPECIFICATION RT 1162- ISSUE 7 Page 11 TABLE 3 Requirements (continued) PROPERTY CHEMICAL (continued) Fluid Resistance 24 hours at 50°C (122°F) JP-4, JP-5 and JP5/JP8(MIL-T-5624) Fuel, Diesel, Referee Grade (MIL-F-46162) Deicing Fluid (MIL-A-8243) Cleaning Compound (MIL-C-43616) 5% Salt Solution (O-S-1926) Cleaning Compound (PC-437) Fuel Oil, Diesel (VV-F-800) Followed by tests for: Tensile Strength Ultimate Extensibility Weight Change Fluid Resistance 24 hours at 75°C (167°F) Hydraulic Fluid (MIL-H-5606) Skydrol* 500 Lubricating Oil (MIL-L-7808) Lubricating Oil (MIL-L-23699) Followed by tests for: Tensile Strength Ultimate Extensibility Weight Change UNIT --- REQUIREMENTS --- TEST METHOD Section 4.3.10 psi. (MPa) Percent Percent --- 2000 (13.8) minimum 100 minimum 3 maximum --- Section 4.3.1 ASTM D 638 psi. (MPa) Percent Percent 2000 (13.8) minimum 100 minimum 3 maximum Section 4.3.1 ASTM D 638 *Trademark, Monsanto Company If this document is printed it becomes uncontrolled. Check for the latest revision. Section 4.3.10