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observed after 500 hours of testing as after 250 hours, but the severity of the conditions had
increased. (The complete results from the inspections are shown in appendix C.)
5.1.2 Electrical Testing.
Following 100, 250, and 500 hours of vibration exposure, the test bundles were electrically
tested for insulation resistance (IR) and dielectric withstand voltage (DWV) in the dry condition.
After 500 hours of vibration, the bundles were submerged in a saltwater bath for wet electrical
testing.
No dry IR or DWV failures were detected after 100 hours of vibration conditioning. However,
failures were observed following 250 and 500 hours of vibration exposure. Not as many failures
were detected during dry electrical testing as during wet testing. This might be due to the
position of the wear on a wire, whether from other wires, support hardware, or the test fixture,
could be such that it was isolated from other circuits. During the wet electrical testing, the
individual wires were immersed in a saltwater bath so that the complete external surface of the
wire could be tested for failures. For this analysis, a wire was not considered to have failed if it
passed the DWV test, even if the IR was below the selected pass/fail threshold. No electrical
10
failures were detected on the PVC/glass/nylon, PI, XLETFE, or PI/PTFE alloy wire types (codes
1, 2, 4, and 11 in table 1) in either the mixed or nonmixed bundles.
Only one dry electrical test failure was confirmed by wet electrical testing; however, all wet
electrical failures were confirmed through visual examination of the test bundles. For this
reason, the dry electrical results were considered suspect. Occasional DWV failures related to
wire aging is expected. This was not considered significant unless several instances occurred in
one bundle or moderate to severe wear was noted during visual examination. (A complete
summary of the dry and wet IR and DWV failures is provided in appendix C, tables C-2 through
C-4.)
5.1.3 Wire-to-Wire Wear.
The visual examination data from the unassembled bundles is compiled in appendix C, table C-5.
The results are summarized by wire type in table C-6 of appendix C so that wire-to-wire wear
data for each type, in mixed and nonmixed bundles, could be analyzed. Each column in
table C-6 provides a comparison of the nonmixed bundle to the mixed bundle combinations
selected. The table also identifies which bundles were slipping within the cushion clamps after
100 hours of vibration, provides a damage rating for the wires rubbing against the fixture plate,
and quantifies the electrical failures that were detected.
A graphical representation of the group I wire-to-wire wear for each wire type in mixed and
nonmixed configurations is provided in figures 1 through 10. The damage severity ratings of 0,
1, 2, and 3 in the charts correspond to none, low, moderate, and severe ratings, respectively, and
were assigned based upon subjective visual observations. No bars shown for a particular wire
code indicates that the combination was not tested.
0
1
2
3
1 2 3 4 5 6 7 9 10 11
with Wire Code
Severity of Damage (0 - 3)
Wear to wire
Wear from
clamps
wear from
plate
FIGURE 1. GROUP I TESTING: PVC/GLASS/NYLON (WIRE CODE 1) WIRE DAMAGE
AFTER 500 HOURS OF VIBRATION CONDITIONING
11
0
1
2
3
1 2 3 4 5 6 7 9 10 11
with Wire Code
Severity of Damage (0 - 3)
Wear to
wire
Wear from
clamps
wear from
plate
FIGURE 2. GROUP I TESTING: PI (WIRE CODE 2) WIRE DAMAGE AFTER 500 HOURS
OF VIBRATION CONDITIONING
0
1
2
3
1 2 3 4 5 6 7 9 10 11
with Wire Code
Severity of Damage (0 - 3)
Wear to wire
Wear from
clamps
wear from
plate
FIGURE 3. GROUP I TESTING: ALIPHATIC PI, ALLOY (WIRE CODE 3) WIRE
DAMAGE AFTER 500 HOURS OF VIBRATION CONDITIONING
12
0
1
2
3
1 2 3 4 5 6 7 9 10 11
with Wire Code
Severity of Damage (0 - 3)
Wear to wire
Wear from
clamps
wear from
plate
FIGURE 4. GROUP I TESTING: XLETFE (WIRE CODE 4) WIRE DAMAGE AFTER 500
HOURS OF VIBRATION CONDITIONING
0
1
2
3
1 2 3 4 5 6 7 9 10 11
with Wire Code
Severity of Damage (0 - 3)
Wear to wire
Wear from
clamps
wear from
plate
FIGURE 5. GROUP I TESTING: XLETFE, ALLOY (WIRE CODE 5) WIRE DAMAGE
AFTER 500 HOURS OF VIBRATION CONDITIONING
13
0
1
2
3
1 2 3 4 5 6 7 9 10 11
with Wire Code
Severity of Damage (0 - 3)
Wear to wire
Wear from
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