Tyco Electronics Corporation 300 Constitutional Drive Menlo Park, CA 94025 USA Specification This Issue: Date: Replaces: RT-220 Issue 3 July 20, 1997 Issue 2 THERMOFIT(R) RT-220 TUBING Flexible, Heat-Shrinkable, Flame-Retarded Modified Fluoropolymer - Low Outgassing 1. SCOPE This specification covers the requirements for flexible electrical insulating, extruded tubing whose diameter will reduce to a predetermined size upon the application of heat in excess of 150C (302F). Tubing shall be flame retarded and shall be black or white. 2. APPLICABLE DOCUMENTS This specification takes precedence over documents referenced herein. Unless otherwise specified, the latest issue of reference documents applies. The following documents form a part of this specification to the extent specified herein. 2.1 GOVERNMENT-FURNISHED DOCUMENTS Military MIL-G-5572 MIL-H-5606 MIL-T-5624 MIL-L-23699 MIL-STD-104 2.2 Gasoline, Aviation, Grades 80/87, 100/130, and 115/145 Hydraulic Fluid, Petroleum Base, Aircraft, Missile and Ordnance Turbine Fuel, Aviation, Grades JP-4 and JP-5 Lubricating Oil, Aircraft Turbine Engine, Synthetic Base Limits for Electrical Insulation Color OTHER PUBLICATIONS American Society for Testing and Materials (ASTM) D 2671 Standard Methods of Testing Heat-Shrinkable Tubing for Electrical Use D 3032 Method of Testing Hookup Wire Insulation E 595 Test Method for Total Mass Loss and Collected Volatile Condensable Materials from Outgassing in a Vacuum Environment 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.) Underwriters Laboratories UL 224 Standard for Extruded Insulating Tubing (Copies of UL publications may be obtained from Underwriters Laboratories Inc., 1285 Walt Whitman Road, Melville, Long Island, New York 11746.) If this document is printed it becomes uncontrolled. Check for the latest revision. Page 2 SPECIFICATION RT-220 ISSUE 3 3. REQUIREMENTS 3.1 MATERIALS The tubing shall be fabricated from thermally stabilized, modified fluoropolymer and shall be crosslinked by irradiation. It shall be homogeneous and essentially free from flaws, defects, pinholes, bubbles, seams, cracks, and inclusions. 3.2 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 tubing 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 tubing submitted for acceptance under contract. Acceptance tests shall consist of the following: dimensions, concentricity, longitudinal change, recovery angle, tensile strength, ultimate elongation, secant modulus, flammability, and heat shock. 4.2 SAMPLING INSTRUCTIONS 4.2.1 Qualification Test Samples Qualification test samples shall consist of 50 feet (15 m) of tubing. Qualification of any size within each size range specified below shall qualify all sizes within that size range. Range of Sizes 3/64 through 1/4 3/8 through 1 For Dynamic Cut-Through test, size 3/16 shall qualify all sizes. For Fungus Resistance test, any size shall qualify all sizes. 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. If this document is printed it becomes uncontrolled. Check for the latest revision. SPECIFICATION RT-220 ISSUE 3 4.3 Page 3 TEST PROCEDURES Unless otherwise specified, tests shall be performed on specimens which have been fully recovered by conditioning for 3 minutes in a 200 5C (392 9F) oven. 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 and Longitudinal Change Three 6-inch (150-mm) specimens of tubing, as supplied, shall be measured for length 1/32 inch ( 1 mm), and inside diameter in accordance with ASTM D 2671, conditioned for 3 minutes in a 200 5C (392 9F) oven, cooled to 23 3C (73 5F) and then remeasured. Prior to and after conditioning, the dimensions of the tubing shall be in accordance with Table 1 and the longitudinal change shall be in accordance with Table 3. The longitudinal change shall be calculated as follows: C = Where: 4.3.2 L1 - L0 x 100 L0 C = Longitudinal Change [Percent] L0 = Length Before Conditioning L1 = Length After Conditioning Concentricity as Supplied Three 6-inch (150-mm) specimens of tubing, as supplied, shall be measured for minimum and maximum wall thickness. Concentricity shall be calculated as follows: Wmin x 100 C = W max Where: 4.3.3 C = Concentricity [Percent] Wmin = Minimum Wall Thickness Wmax = Maximum Wall Thickness Weight Per Length A 12 1/32 inch (305 0.8 mm) length of tubing, as supplied, shall be weighed. The weight shall be multiplied by 100 and reported as pounds/100 ft (kg/100 m). 4.3.4 Recovery Angle A length of tubing shall be cut such that the end of the tubing is 90 degrees to the longitudinal axis. The tubing shall be recovered in accordance with Section 4.3, and by means of an optical comparitor or equivalent, the angle between the end and the longitudinal axis shall be measured. The deviation from 90 degrees shall be reported as the recovery angle. 4.3.5 Tensile Strength and Ultimate Elongation The tensile strength and ultimate elongation of the tubing shall be determined in accordance with ASTM D 2671 using 1-inch (25-mm) bench marks and a 1-inch (25-mm) initial jaw separation. The speed of jaw separation shall be 20 2 inches (500 50 mm) per minute. If this document is printed it becomes uncontrolled. Check for the latest revision. Page 4 4.3.6 SPECIFICATION RT-220 ISSUE 3 Low Temperature Flexibility For tubing of expanded diameter 1/4 inch (6 mm) or greater, three strip specimens, 1/4 inch (6 mm) wide and 12 inches (300 mm) long, shall be cut from the expanded tubing. For tubing of expanded diameter less than 1/4 inch (6 mm) three tubular specimens, 12 inches (300 mm) long, shall be cut from the expanded tubing. The specimens shall be recovered in accordance with Section 4.3 and conditioned with appropriate mandrels for 4 hours at -55 2C (-67 4F). The mandrel diameter shall be 10 times the specimen thickness, 10 percent. For tubular specimens, the specimen thickness shall be equivalent to the outside diameter. While at the specified temperature, and without removing the specimens from the cold chamber, the specimens shall be wrapped 360 degrees around the mandrel in approximately 2 seconds. Any side cracking, caused by flattening of the specimens on the mandrel, shall be disregarded. 4.3.7 Heat Shock Three 6-inch (150-mm) specimens of tubing shall be conditioned for 4 hours in a 250 5C (482 9F) oven. The specimens shall be removed from the oven, cooled to 23 3C (73 5F), wrapped 180 degrees around a mandrel selected in accordance with Table 2, and then visually examined for evidence of dripping, flowing, or cracking. Any side cracking caused by flattening of the specimen on the mandrel shall not constitute failure. 4.3.8 Dynamic Cut-Through at Temperature Two 6-inch (150-mm) lengths of size 3/16-inch tubing shall each be recovered on a 7-inch (175-mm) length of 3/32-inch (2.38-mm) oil hardened drill rod, by placing in a 200 5C (392 9F) mechanical convection oven for 3 minutes. The cut-through tests shall be performed at 135 3C (275 5F) in accordance with ASTM D 3032 using the optional cutting edge. Four readings shall be taken on each of the assemblies. 4.3.9 Heat Resistance Specimens in accordance with Section 4.3.5 shall be conditioned for 336 hours in a 225 3C (437 5F) oven. The specimens shall be removed from the oven, cooled to 23 3C (73 5F) and tested for elongation in accordance with Section 4.3.5. 4.3.10 Copper Stability Three 6-inch (150-mm) specimens of tubing shall be slid over a snug-fitting, straight, clean, bare copper conductor. For tubing sizes 1/4 and smaller, a solid conductor shall be used; for tubing sizes 3/8 and larger, a solid or tubular conductor shall be used. The specimens on the conductors shall be conditioned for 24 hours in a desiccator or similar humidity chamber at 90 to 95 percent relative humidity and 23 3C (73 5F). The specimens on the conductors then shall be conditioned for 168 hours in a 180 3C (356 5F) oven. After conditioning, the specimens shall be removed from the oven and cooled to 23 3C (73 5F). The copper conductor then shall be removed from the tubing, and the tubing and conductor shall be examined. Darkening of the copper due to normal air oxidation shall not be cause for rejection. The tubing shall be tested for elongation in accordance with 4.3.5. If this document is printed it becomes uncontrolled. Check for the latest revision. SPECIFICATION RT-220 ISSUE 3 4.3.11 Corrosive Effect 4.3.11.1 Copper Mirror Corrosion Page 5 The tubing shall be tested for copper mirror corrosion in accordance with ASTM D 2671, Procedure A, for 16 hours at 160 3C (320 5F). For tubing sizes 1/8 and larger, specimens shall consist of 1/4 x 1 inch (6 x 25 mm) strips cut longitudinally. Evidence of corrosion shall be the removal of copper from a mirror, leaving an area of transparency greater than 5 percent of its total area. 4.3.11.2 Corrosion in Contact with Copper The tubing shall be tested for corrosion in contact with copper for 16 hours at 175 3C (347 5F) in accordance with ASTM D 2671, Procedure B. 4.3.12 Fluid Resistance Six 6-inch (150-mm) specimens of tubing, prepared and measured in accordance with ASTM D 2671 solvent resistance, shall be completely immersed in each listed fluid for 24 2 hours at 50 3C (122 5F). The volume of the fluid shall be not less than 20 times that of the specimens. After immersion, the specimens shall be lightly wiped and air-dried for 30 to 60 minutes at room temperature. Three specimens then shall be tested for dielectric strength and the other three for tensile strength. 4.3.13 Vacuum Outgassing Three 0.5 .05 gram specimens shall be recovered for 3 minutes at 200C and then tested for percent total weight loss and percent volatile condensable materials. The conditions for testing are: exposure time, 24 hours; sample temperature 125 3C; condensing surface temperature, 18 3C; and pressure, not greater than 1 x 10-5 torr. The vacuum shall be provided by a diffusion pump, liquid nitrogen trap vacuum system. The apparatus shall consist of a glass sample chamber, refluxing liquid heat source and a polished stainless steel plate in close contact with a copper cold finger cooled internally by circulating water. The axis of the exit of the sample chamber shall be perpendicular to and approximately 15mm from the cooled condensing plate. A Cahn RG micro balance or equivalent shall be used for weighing. The specimen shall be weighed before and after conditioning and total weight loss calculated and the condensing plate shall be weighed before and after to calculate percent volatile condensable material. 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 defects and resubmitted for acceptance. Before resubmitting, full particulars concerning previous rejection and action taken to correct the defects shall be furnished to the inspector. 5. PREPARATION FOR DELIVERY 5.1 FORM The tubing shall be supplied on spools, unless otherwise specified. If this document is printed it becomes uncontrolled. Check for the latest revision. Page 6 5.2 SPECIFICATION RT-220 ISSUE 3 PACKAGING Packaging shall be in accordance with good commercial practice. The shipping container shall not be less than 125-pound-test fiberboard. 5.3 MARKING Each container of tubing shall be permanently and legibly marked with the size, quantity, manufacturer's identification, specification number, color, lot number and date of manufacturing. If this document is printed it becomes uncontrolled. Check for the latest revision. SPECIFICATION RT-220 ISSUE 3 Page 7 TABLE 1 Inside Diameters and Wall Thicknesses of Tubing Size 3/64 1/16 3/32 1/8 3/16 1/4 3/8 1/2 3/4 1 Expanded As Supplied Inside Dia. Minimum mm. in. 0.046 1.17 0.063 1.60 0.093 2.36 0.125 3.18 0.187 4.75 0.250 6.35 0.375 9.53 0.500 12.70 0.750 19.05 1.000 25.40 Recovered Dimension -- After Heating Inside Dia. Wall Thickness Maximum Minimum Maximum Nominal mm. mm. mm. mm. in. in. in. in. 0.023 0.58 0.007 0.18 0.012 0.30 0.009 0.23 0.031 0.79 0.007 0.18 0.012 0.30 0.009 0.23 0.046 1.17 0.007 0.18 0.012 0.30 0.009 0.23 0.062 1.60 0.007 0.18 0.012 0.30 0.009 0.23 0.093 2.36 0.007 0.18 0.012 0.30 0.009 0.23 0.125 3.18 0.008 0.20 0.015 0.38 0.011 0.28 0.187 4.75 0.008 0.20 0.015 0.38 0.011 0.28 0.250 6.35 0.008 0.20 0.015 0.38 0.011 0.28 0.375 9.53 0.013 0.33 0.020 0.51 0.016 0.41 0.500 12.70 0.015 0.38 0.022 0.56 0.018 0.46 TABLE 2 Mandrel Dimensions for Heat Shock Tubing 3/64 1/4 to to 3/16 inclusive 1 inclusive If this document is printed it becomes uncontrolled. Check for the latest revision. Mandrel Diameter in. mm. 5/16 7.9 3/4 19.1 Weight, As Supplied, Maximum kg/ lbs/ 100 ft 100 m 0.10 0.15 0.13 0.19 0.17 0.25 0.22 0.33 0.31 0.46 0.40 0.60 0.73 1.09 0.96 1.43 1.92 2.85 2.78 4.14 Page 8 SPECIFICATION RT-220 ISSUE 3 TABLE 3 Requirements PROPERTY PHYSICAL Dimensions Longitudinal Change Concentricity as Supplied Weight Per Length as Supplied UNIT REQUIREMENT TEST METHOD Inches (mm) Percent Percent lbs/100 ft (kg/100 m) maximum Degrees psi (MPa) Percent psi (MPa) --- In accordance with Table 1 +0, -10 70% minimum In accordance with Table 1 Section 4.3.1 ASTM D 2671 Section 4.3.2 Section 4.3.3 5 maximum 4000 minimum (27.6) 300 minimum 50,000 maximum (345) No cracking Section 4.3.4 Section 4.3.5 ASTM D 2671 ASTM D 2671 Section 4.3.6 --- No dripping, flowing, or cracking Section 4.3.7 lbs (kg) 5 minimum (2.3) --- --- Percent 250 minimum --- No brittleness, glazing or severe discoloration of tubing. No pitting or blackening of copper. Percent 250 minimum --- MIL-STD-104, Class I Section 4.3.5 ASTM D 2671 MIL-STD-104 500 minimum (19,680) ASTM D 2671 Volume Resistivity Volts/ mil (volts /mm) ohm-cm 1011 minimum ASTM D 2671 CHEMICAL Corrosive Effect --- Noncorrosive Copper Mirror Corrosion 16 hours at 160C (320F) --- Copper Removal 5%, maximum Copper Contact Corrosion 16 hours at 175C (347F) --- No blackening or pitting of copper Flammability --- 1) 25% maximum flag burn 2) no burning of cotton 3) no flaming, or glowing longer than 60 seconds Section 4.3.11 ASTM D 2671 Section 4.3.11.1 ASTM D 2671 Procedure A Section 4.3.11.2 ASTM D 2671 Procedure B UL 224, VW-1 ASTM D 2671 Procedure C Recovery Angle Tensile Strength Ultimate Elongation Secant Modulus Low Temperature Flexibility 4 hours at -55C (-67F) Heat Shock 4 hours at 250C (482F) Dynamic Cut-Through at 135C (275F) Heat Resistance 336 hours at 225C (437F) Followed by test for: Ultimate Elongation Copper Stability 168 hours at 180C (356F) Followed by test for Ultimate Elongation Color ELECTRICAL Dielectric Strength If this document is printed it becomes uncontrolled. Check for the latest revision. Section 4.3.8 ASTM D 3032 Section 4.3.9 Section 4.3.5 ASTM D 2671 Section 4.3.10 SPECIFICATION RT-220 ISSUE 3 Page 9 TABLE 3 Requirements (continued) PROPERTY CHEMICAL (continued) Fungus Resistance Water Absorption 24 hours at 23C (73F) Fluid Resistance 24 hours at 50C (122F) JP-4 Fuel (MIL-T-5624) Hydraulic Fluid (MIL-H-5606) Aviation Gasoline (100/130) (MIL-G-5572) Water Trichloroethane Lubricating Oil MIL-L-23699 Followed by tests for: Dielectric Strength Tensile Strength Vacuum Outgassing TML (Total Mass Loss) VCM (Volatile Condensable Materials) UNIT REQUIREMENT TEST METHOD --Percent Rating of 1 or less 0.5 maximum ASTM G 21 ASTM D 2671 --- --- Section 4.3.12 ASTM D 2671 Volts/mil (volts /mm) psi (MPa) 400 minimum (15,760) ASTM D 2671 2000 minimum (13.8) Percent 1.0 maximum Section 4.3.5 ASTM D 2671 Section 4.3.13 Percent 0.1 maximum ASTM E 595 If this document is printed it becomes uncontrolled. Check for the latest revision.