VERSAFIT-1/16-2-SP (8548654003) - Tyco Electronics

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Tyco Electronics Corporation

300 Constitutional Drive

Menlo Park, CA 94025 USA

Specification

This Issue:

Date:

Replaces:

RW-3009

Issue 3

July 18, 2003

Issue 2

VERSAFIT® TUBING

Polyolefin, Flexible, Heat-Shrinkable, Flame Retardant

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 90°C (194°F).

This tubing meets the requirements of SAE-AMS-DTL-23053/5 with a continuous operating temperature

range of -55° C to +135° C. Versafit is free of polybrominated biphenyls (PBB) and polybrominated

biphenyl oxides (PBBO). Versafit is also a 125°C, VW-1 rated, UL recognized tubing meeting the

requirements of UL 224 as well as meeting the requirements of Standard C22.2 No. 198.1 and is CSA

certified.

2. APPLICABLE DOCUMENTS

This specification takes precedence over documents referenced herein. Unless otherwise specified, the latest

issued of referenced documents applies. The following documents form a part of this specification to the

extent specified herein.

2.1 UNDERWRITERS LABORATORIES, INCORPORATED

UL Subject 224 Extruded Insulating Tubing

(Copies of UL publication may be obtained from Underwriters Laboratories, Inc., 1285 Walt Whitman Road,

Melville, Long Island, New York 11746.)

2.2 CANADIAN STANDARDS ASSOCIATION

C22.2 No. 198.1 Extruded Insulating Tubing

(Copies of CSA publications may be obtained from Canadian Standards Association, 1897 Rexdale

Boulevard, Rexdale, Ontario, Canada M9W 1R3.)

2.3 OTHER PUBLICATIONS

ISO 846 Plastics-Evaluation of the action of microorganisms.

American Society for Testing and Materials (ASTM)

ASTM D 2671 Standard Methods of Testing Heat-Shrinkable Tubing for Electrical Use

(Copies of ASTM publications may be obtained from the American Society for Testing and Materials, 1916

Race Street, Philadelphia, Pennsylvania 19103.)

Page 2 SPECIFICATION RW-3009 ISSUE 3

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3. REQUIREMENTS

3.1 MATERIAL

The tubing shall be fabricated from thermally stabilized, flame-retardant, modified polyolefin 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 2.

3.3 COLOR

The tubing shall be available in black, white, red, yellow, blue, green, brown, orange, violet and gray.

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

Longitudinal Change

Tensile Strength

Ultimate Elongation

Statistical process control data may be used to demonstrate conformance for dimensions.

4.2 SAMPLING INSTRUCTIONS

4.2.1 Qualification Test Samples

Qualification test samples shall consist of 15mm (50 feet) of tubing of the size and color specified.

Qualification of one size or color shall qualify all sizes and colors.

4.2.2 Acceptance Test Samples

Acceptance test samples shall consist of not less than 5 m (16 feet) 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.

SPECIFICATION RW-3009 ISSUE 3 Page 3

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4.3 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 specimen (and measurement gauges, when

applicable) shall be conditioned for 3 hours at 23 ± 3°C (73 ± 5°F) 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 30 - 60 m

(100 to 200 feet) per minute.

4.3.1 Dimensions and Longitudinal Change

Three 150-mm (6-inch) specimens of tubing, as supplied, shall be measured for length, to an accuracy of ± 1

mm (±1/32 inch), and inside diameter in accordance with ASTM D 2671. The specimens then shall be

conditioned for 3 minutes in a 200 ± 3°C (392 ± 5°F) oven, removed from the oven, cooled to 23 ± 3°C (73 ±

5°F), re-measured for length, inside diameter, and wall thickness in accordance with ASTM D 2671. The

longitudinal change shall be calculated as follows:

C = L1 - L0

L0 x 100

Where: C = Longitudinal Change (percent)

0 = Length Before Conditioning [mm (inches)]

1 = Length After Conditioning [mm (inches)]

4.3.2 Tensile Strength and Ultimate Elongation

The tensile strength and ultimate elongation of the tubing shall be determined in accordance with ASTM D

2671 using 25-mm (1-inch) benchmarks and a 25-mm (1-inch) initial jaw separation. The speed of jaw

separation shall be 500 ± 50 mm (20 ± 2 inches) per minute.

4.3.3 Secant Modulus

The secant modulus of the tubing shall be tested using tubing as supplied in accordance with ASTM D 2671.

4.3.4 Copper Stability

Three 150-mm (6-inch) specimens of tubing shall be slipped over a snug filling, 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 ± 3°C (73 ± 5°F).

Three specimens shall be conditioned for 7 days in 158.0 ± 1.0°C (316.4± 1.8°F) oven. After conditioning,

the specimens shall be removed from the oven and cooled to 23 ± 3°C (73 ± 5°F). The copper conductor

than shall be removed from the tubing, and the tubing and conductor shall then be examined. Darkening of

the copper due to normal air oxidation shall not be cause for rejection. The tubing then shall be conditioned

at room temperature for 16 to 96 hours and tested for ultimate elongation in accordance with 4.3.2.

Page 4 SPECIFICATION RW-3009 ISSUE 3

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4.3.5 Dielectric Withstand, Breakdown, and Strength

The dielectric strength of the tubing shall be measured under oil in accordance with ASTM D 2671. Five

150-mm (6-inch) specimens of tubing shall be recovered over a metal mandrel by conditioning for 3 minutes

in a 200 ± 3°C (392 ± 5°F) oven. The mandrel diameter shall be slightly larger than the fully recovered

inside diameter of the tubing being tested. The metal mandrel shall serve as one electrode and a 25mm (1-

inch) wide strip of lead foil wrapped around the outside of the tubing as the other electrode. The test voltage

shall be applied at a rate of rise of 500 volts per second. Thickness measurements for calculating dielectric

strength shall be made adjacent to the point of breakdown. Specimens for dielectric withstand shall be held

for 60 seconds at 2500 volts.

4.3.6 Corrosive Effect

Three specimens of tubing shall be tested for copper contact corrosion in accordance with ASTM D 2671,

Procedure B. Three specimens shall be conditioned for 7 days in a 158.0 ± 1.0°C (316.4 ± 1.8°F) oven.

After conditioning, the specimens shall be visually examined for evidence of corrosion.

4.4 REJECTION AND RETEST

Failure of any samples 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 FORM

The tubing shall be supplied on spools, unless otherwise specified.

5.2 PACKAGING

Packaging shall be in accordance with good commercial practice.

5.3 MARKING

Each container of tubing shall be permanently and legibly marked with the size, quantity, manufacturer's

identification, specification number, product designation, and lot number.

SPECIFICATION RW-3009 ISSUE 3 Page 5

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TABLE 1

Versafit

TUBING DIMENSIONS,

IMPERIAL

(USA CUSTOMARY)

AS SUPPLIED RECOVERED

Inside Diameter Inside Diameter Wall Thickness

Size Maximum Minimum Maximum Nominal

Mm in mm in mm in mm in mm in

3/64 1.63±.2 .064±.008 0.58 .023 0.32 .013 0.48 .019 0.40 .016

1/16 1.85± .2 .073±.007 0.79 .031 0.35 .014 0.51 .020 0.43 .017

3/32 2.79± .2 .110±.007 1.17 .046 0.43 .017 0.59 .023 0.51 .020

1/8 3.43± .2 .135±.007 1.57 .062 0.43 .017 0.59 .023 0.51 .020

3/16 5.21± .3 .205±.010 2.36 .093 0.43 .017 0.59 .023 0.51 .020

1/4 7.11± .3 .280±.010 3.17 .125 0.56 .022 0.72 .028 0.64 .025

3/8 10.16± .4 .400±.015 4.74 .187 0.56 .022 0.72 .028 0.64 .025

1/2 13.72± .4 .540±.015 6.35 .250 0.56 .022 0.72 .028 0.64 .025

5/8 16.90± .4 .665±.015 8.0 .315 0.68 .027 0.84 .033 0.76 .030

3/4 20.45± .4 .805±.015 9.52 .375 0.68 .027 0.84 .033 0.76 .030

1 26.80± .4 1.055±.015 12.70 .500 0.76 .030 1.01 .040 0.88 .035

1-1/4 33.40± .7 1.315±.025 15.88 .625 0.86 .034 1.17 .046 1.01 .040

1-1/2 39.88± .8 1.570±.030 19.05 .750 0.86 .034 1.17 .046 1.01 .040

2 52.83±.1.0 2.080±.040 25.40 1.000 0.96 .038 1.32 .052 1.14 .045

3 78.49±.1.0 3.090±.040 38.10 1.500 1.06 .042 1.47 .058 1.27 .050

4 104.14±.1.3 4.100± 50.80 2.000 1.17 .046 1.63 .064 1.39 .055

Versafit 3X

AS SUPPLIED RECOVERED

Inside Diameter Inside Diameter Wall Thickness

Size Minimum Maximum Minimum Maximum Nominal

in. mm. in. mm. in. mm. in. mm. in. mm.

1/8 .125 3.2 .042 1.1 .020 0.50 .026 0.66 .023 0.58

1/4 .250 6.4 .083 2.2 .020 0.50 .026 0.66 .023 0.58

3/8 .375 9.5 .125 3.2 .021 0.53 .027 0.69 .024 0.61

1/2 .500 12.7 .166 4.3 .021 0.53 .027 0.69 .024 0.61

3/4 .750 19.1 .250 6.4 .021 0.53 .027 0.69 .024 0.61

1 1.000 25.4 .333 8.5 .022 0.56 .028 0.72 .025 0.64

Page 6 SPECIFICATION RW-3009 ISSUE 3

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TABLE 2

Requirements

PROPERTY UNIT REQUIREMENT TEST

METHOD

PHYSICAL

Dimensions

mm(inches)

In accordance with Table 1

Section 4.3.1

Dimensional Recovery ASTM D 2671

Longitudinal Change Section 4.3.1

ASTM D 2671 Percent +1, -5 ASTM D 2671

ASTMD 2671 (Over-expanded sizes) Percent +0, -15 ASTMD 2671

UL 224 Percent +3, -3 UL 224

Eccentricity (Recovered) Percent 30 maximum ASTM D 2671

Tensile Strength MPa (psi) 10.3 minimum (1500) Section 4.3.2

Ultimate Elongation Percent 200 minimum ASTM D 2671

Secant Modulus (expanded) MPa (psi) 172 maximum(2.5 x 104) Section 4.3.3

ASTM D 2671

Low Temperature Flexibility

1 hour at -30°C (-22°F)

-- No cracking UL 224

Heat Shock

4 hours at 250°C (482°F)

-- No cracking UL 224

Heat Aging

7 days at 158°C (316°F)

Followed by tests for:

-- -- UL 224

Tensile Strength MPa (psi) 70% minimum of unaged

specimens

Section 4.3.2

UL 224

Ultimate Elongation Percent 100 minimum

Flexibility -- No cracking

Dielectric Withstand at 2500 V Seconds 60 minimum

Dielectric Breakdown Volts 50% minimum of unaged specimen Section 4.3.5

ASTM D 2671

Dielectric Strength kV/mm

(Volts/mil)

19.7 minimum (500)

Copper Stability

7 days at 158°C (316°F)

Followed by test for

No brittleness, glazing, cracking or

severe discoloration of tubing. No

pitting or blackening of copper.

Section 4.3.4

ASTM D 2671

Ultimate Elongation Percent 100 minimum Section 4.3.2

Restricted Shrinkage -- Pass UL 224

ELECTRICAL

Dielectric Withstand at 2500 V

Seconds

60 minimum

UL 224

Dielectric Strength kV/mm

(Volts/mil)

19.7 minimum (500) Section 4.3.5

Volume Resistivity Ohm-cm 1014 minimum ASTM D 2671

SPECIFICATION RW-3009 ISSUE 3 Page 7

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TABLE 2

Requirements

(continued)

PROPERTY UNIT REQUIREMENT TEST

METHOD

CHEMICAL (continued)

Corrosive Effect

7 days at 158°C (316°F)

No Corrosion

Section 4.3.6

ASTM D 2671

Flammability -- Pass UL 224, VW-1

Water Absorption (Recovered)

24 hrs. at 23°C (73°F)

Percent 0.5 maximum ASTM D 2671

Fungus Resistance

Followed by tests for:

Tensile Strength

Ultimate Elongation

Dielectric Strength

psi (Mpa)

percent

Volts per mil

(volts per mm)

1500 minimum (10.3)

200 minimum

500 minimum (19,700)

ISO 846

Method B

Section 4.3.2

ASTM D 2671