DLA MIL-DTL-13169 E-2011 WIRE ELECTRICAL (FOR INSTRUMENT TEST LEADS).pdf

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1、AMSC N/A FSC 6145 INCH-POUND MIL-DTL-13169E 3 November 2011 SUPERSEDING MIL-DTL-13169D 11 November 2006 DETAIL SPECIFICATION WIRE, ELECTRICAL (FOR INSTRUMENT TEST LEADS) Inactive for new design after 16 June 1997. This specification is approved for use by all Departments and Agencies of the Departme

2、nt of Defense. 1. SCOPE 1.1 Scope. This specification covers one type of single-conductor, AWG No 18, stranded, electrical wire, insulated for voltages up to and including 1,000 volts root mean square (rms) with Buna-S compound. Wire covered by this specification is classified as type TL-G. This wir

3、e is primarily intended for use as instrument test leads. 2. APPLICABLE DOCUMENTS 2.1 General. The documents listed in this section are specified in sections 3, 4, or 5 of this specification. This section does not include documents cited in other sections of this specification or recommended for add

4、itional information or as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all specified requirements of documents cited in sections 3, 4, or 5 of this specification, whether or not they are listed. 2.2 Government do

5、cuments. 2.2.1 Specifications, standards, and handbooks. The following specifications, standards, and handbooks form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract. Comments, suggestion

6、s, or questions on this document should be addressed to DLA Land and Maritime, ATTN: VAI, P.O. Box 3990, Columbus, OH 43218-3990, or email to WireCabledla.mil. Since contact information can change, you may want to verify the currency of this address information using the ASSIST Online database at ht

7、tps:/assist.daps.dla.mil. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-DTL-13169E 2 FEDERAL STANDARD FED-STD-228 - Cable and Wire, Insulated; Methods of Testing COMMERCIAL ITEM DESCRIPTION A-A-59551 - Wire, Electrical, Copper, (Uninsulated) DE

8、PARTMENT OF DEFENSE SPECIFICATION MIL-C-572 - Cords, Yarns and Monofilaments Organic Synthetic Fiber DEPARTMENT OF DEFENSE STANDARD MIL-STD-104 - Limits for Electrical Insulation Color (Copies of these documents are available online at https:/assist.daps.dla.mil/quicksearch/ or from the Standardizat

9、ion Document Order Desk, 700 Robbins Avenue, Building 4D, Philadelphia, PA 19111-5094.) 2.3 Non-Government publications. The following documents form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation

10、or contract. NCSL INTERNATIONAL NCSL Z540.3 - General Requirements for Calibration of Measuring and Test Equipment (Copies of these documents are available online at http:/www.ncsli.org or from NCSL International, 2995 Wilderness Place, Suite 107 Boulder, Colorado 80301-5404.) 2.4 Order of precedenc

11、e. Unless otherwise noted herein or in the contract, in the event of a conflict between the text of this document and the references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has

12、 been obtained. 3. REQUIREMENTS 3.1 Material. The material for the wire shall be as specified herein. The best material commercially available for the intended purpose shall be used when a definite material is not designated. 3.1.1 Recycled, recovered, or environmentally preferable materials. Recycl

13、ed, recovered, or environmentally preferable materials should be used to the maximum extent possible, provided that the material meets or exceeds the operational and maintenance requirements, and promotes economically advantageous life cycle costs. 3.1.2 Copper strands. The strands used in the manuf

14、acture of the conductor shall be tin-coated, soft or drawn and annealed copper wire conforming to A-A-59551. 3.1.3 Separator. A separator may be used to provide free stripping of the insulation. If used, the separator shall completely cover the conductor. The separator shall be type AR, form Y (acet

15、ate-rayon) Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-DTL-13169E 3 or type P (polyamide) thread, conforming to MIL-C-572. The separator may be omitted if a free stripping insulation is used. 3.1.4 Insulation compound. The insulation compound

16、 shall be Buna-S made with such fillers, antioxidants, organic accelerators, and curing agents as are necessary to provide a compound having long life in service and in storage. The compound used shall contain no more than .5 percent of free sulfur. The material shall be homogeneous, tough, and elas

17、tic, and shall be properly vulcanized (cured). The insulation shall be free of blisters, wrinkles, cracks, or other defects that could affect the end use of the finished wire. 3.1.4.1 Sun-proofing wax. For each 100 pounds of Buna-S polymer, a minimum of 4 pounds of sun-proofing wax shall be used. 3.

18、1.4.2 Color. The color of the insulation shall be black, red, or green (see 6.2), and the color shade shall fall within the light and dark limits conforming to MIL-STD-104. 3.2 Construction. 3.2.1 Conductor. The conductor shall be AWG size 18, type B, class 0 (for severe flexing service) wire confor

19、ming to A-A-59551. 3.2.2 Insulation thickness. The insulation over the conductor shall be centered and shall have a thickness of not less than 40 mils. 3.2.3 Outside diameter. The outside diameter of the finished wire shall not exceed 150 mils. 3.3 Physical properties of insulation. The vulcanized B

20、una-S insulation shall conform to the physical property requirements listed in table I. TABLE I. Physical property requirements of Buna-S insulation. Physical property Requirement Unaged: Tensile strength, minimum, psi 1,000 Elongation, minimum, inches 8 1/ Set, maximum, inch .5 1/After 94 hours in

21、an oxygen-bomb at 70 C: Tensile strength, minimum, percent of original 75 Elongation, minimum, inches 6 1/Cold-tension recovery, minimum, percent 20 1/ See applicable test method for specimen length. 3.3.1 Cold bend. The wire shall show no evidence of cracking of the outer surface of the insulation

22、after being exposed to a temperature of -40 C for 7 days and then bent around a .188-inch (4.78 mm) diameter mandrel. 3.4 Performance. 3.4.1 Insulation flaws. The finished wire shall withstand a spark-test potential of 8,000 V rms at 60Hz, without breakdown. 3.4.2 Dielectric strength. The finished w

23、ire shall withstand 4,000 V rms without breakdown. 3.4.3 Insulation resistance. The insulation resistance of the finished wire shall be not less than 1,000 megohms per 1,000 feet. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-DTL-13169E 4 3.4.4

24、 Continuity. The finished wire shall have continuous continuity. 3.5 Workmanship. The wire shall be uniform in quality and free from defects that affect performance, serviceability, or appearance, such as lumps, kinks, splits, abrasions, scrapes, corroded surfaces, and skin impurities. 4. VERIFICATI

25、ON 4.1 Classification of inspections. The inspection requirements specified herein are classified as follows: Conformance inspection (see 4.2). 4.2 Conformance inspection. Conformance inspection shall consist of the inspections listed for groups A, B, and C inspection in tables II, III, and IV, resp

26、ectively. Unless otherwise specified, conformance inspection shall be performed on every lot of wire procured under this specification (see 6.2). TABLE II. Group A inspection. Inspection Requirement Verification Visual Materials Copper strand 3.1.2 Separator 3.1.3 Insulation compound 3.1.4 4.3.1 Con

27、struction Conductor 3.2.1 Workmanship 3.5 Performance Insulation flaws 3.4.1 4.3.6 Continuity 3.4.4 4.3.5 TABLE III. Group B inspection. Inspection Requirement Verification Insulation thickness 3.2.2 4.3.1.1 Outside diameter 3.2.3 4.3.1.2 Unaged physical property Tensile strength 3.3 4.3.2 Elongatio

28、n 3.3 4.3.2 Set 3.3 4.3.2 Dielectric strength 3.4.2 4.3.3 Insulation resistance 3.4.3 4.3.4 Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-DTL-13169E 5 TABLE IV. Group C inspection. Inspection Requirement Verification Aged (oxygen bomb): Tensile

29、 strength 3.3 4.3.2 1/ Elongation 3.3 4.3.2 1/Low temperature: Cold tension recovery 3.3 4.3.2 2/Cold bend 3.3.1 4.3.2 2/1/ Six specimens from the first lot presented for conformance inspection, and then six specimens from each 100,000 feet produced. 2/ Three specimens from the first lot presented f

30、or conformance inspection, and then three specimens from each 100,000 feet produced. 4.2.1 Inspection lot. Unless otherwise specified (see 6.2), an inspection lot shall consist of all wire of the same Part or Identifying Number (PIN), produced under essentially the same conditions on the same machin

31、e, that is presented for inspection and shipment at one time. 4.2.2 Unit of product. The unit of product for determining lot size for sampling shall be the quantity of wire offered for inspection on one coil, one reel, or one spool, as applicable. 4.2.3 Specimen length. Specimens for groups A, B, an

32、d C inspections shall be of the length specified in the applicable test method. 4.2.4 Group A inspection. Group A inspection shall consist of the inspections specified in table II and shall be performed on each lot of wire acquired under the specification. Group A inspections may be performed at an

33、appropriate stage of the manufacturing operation rather than on the finished wire. 4.2.5 Group B inspection. Group B inspection shall consist of the inspections specified in table III. Group B inspection shall normally be performed on sample units that have been subjected to and have passed the grou

34、p A inspection. 4.2.6 Sampling. A random sample shall be selected from the lot. The sample size shall be based on the inspection lot size from which the sample was selected for group B inspection. Sampling inspection shall be in accordance with table V. TABLE V. Inspection sample. Inspection lot siz

35、e 1/ Sample size 1 1 2 to 8 2 9 to 90 3 91 to 150 12 151 to 280 19 281 to 500 21 501 to 1,200 27 1,201 to 3,200 36 3,201 to 10,000 38 10,001 to 35,000 46 1/ Lot size is based on the number of units of product 4.2.7 Group C inspection. Group C inspection shall consist of the inspections specified in

36、table IV. Group C inspection shall normally be performed on sample units that have been subjected to and have passed group A and B inspections. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-DTL-13169E 6 4.2.8 Rejected lot. Failure to pass any o

37、f the tests and inspections constitutes failure of the lot and the lot shall be rejected. If an inspection lot is rejected, the contractor may rework the lot to correct the defects or screen out the defective units, and resubmit the lot for re-inspection. Such lots shall be separated from new lots a

38、nd shall be identified as re-inspected lots. 4.2.9 Non-compliance. If a sample fails to pass group B or C inspections (see 4.2.5 and 4.2.7), the contractor shall notify the cognizant inspection activity of such failure and take corrective action on the materials or processes, or both, as warranted,

39、on all units of the product. Acceptance and shipment of the product shall be discontinued until corrective action has been taken. After the corrective action has been taken, group B or C inspection shall be repeated on the replacement articles. (This includes all tests and examinations, or only the

40、test that the original sample failed, at the option of the cognizant inspection activity). Group A inspection may be re-instituted; however, final acceptance and shipment shall be withheld until group B or C inspection has shown that the corrective was successful. In the event of failure after re-in

41、spection, information concerning the failure shall be provided to the cognizant inspection activity. 4.2.10 Test equipment and inspection facilities. Test and measuring equipment and inspection facilities of sufficient accuracy, quality, and quantity to permit performance of the required inspection

42、shall be established and maintained by the contractor. The establishment and maintenance of a calibration system to control the accuracy of the measuring and test equipment (e.g., non-Government standard (NGS) or federal or defense standard) shall be in accordance with NCSL Z540.3 or equivalent. 4.3

43、 Methods of inspection. 4.3.1 Visual and dimensional inspection. The finished wire shall be inspected to verify that the materials, construction, and workmanship are in accordance with the applicable requirements. 4.3.1.1 Insulation thickness. The insulation thickness shall be measured using method

44、1018 of FED-STD-228. 4.3.1.2 Outside diameter. The outside diameter of the finished wire shall be measured by using method 1011 of FED-STD-228. 4.3.2 Physical properties of insulation. 4.3.2.1. Condition and age. Specimens shall not be heat treated, immersed in water or subjected to any mechanical o

45、r chemical treatment not specified herein. No tests shall be made within 24 hours after manufacture unless agreed to by the manufacturer. 4.3.2.1.1 Tensile strength. Tensile strength shall be determined in accordance with method 3021 of FED-STD-228, except that flat, smooth, steel grips of the self-

46、aligning type may be used. 4.3.2.1.2 Elongation. Elongation shall be determined in accordance with method 3031 of FED-STD-228, except that bench marks shall be 2 inches (50.8mm) apart, and flat, smooth, steel grips of the self-aligning type may be used. The elongation after aging shall be based on t

47、he bench marks applied before aging. 4.3.2.1.3 Set. Set shall be determined in accordance with method 3161 of FED-STD-228, except that the bench marks shall be 2 inches (50.8 mm) apart. The test specimens shall be stretched so that the distance between bench marks is 6 inches (152 mm); they shall be

48、 released within 5 seconds. The set shall be determined 1 minute after the beginning of release. Flat, smooth, steel, grips of the self-aligning type may be used. 4.3.2.1.4 Tensile stress. Apparatus and procedure shall be as specified in method 3041 of FED-STD-228. Provided by IHSNot for ResaleNo re

49、production or networking permitted without license from IHS-,-,-MIL-DTL-13169E 7 4.3.2.1.5 Tear resistance. Apparatus and procedure shall be as specified in method 3111 of FED-STD-228. The specimens shall be cut and buffed from a section of the jacket under test except as indicated in 4.3.2.1. 4.3.2.1.6 Thin-walled jackets. For tear resistance tests of jackets having an allowed minimum t