DLA MIL-DTL-16878 H-2012 WIRE ELECTRICAL INSULATED GENERAL SPECIFICATION FOR.pdf

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1、Comments, suggestions, or questions on this document should be addressed to DLA Land and Maritime, ATTN: VAI, P.O. Box 3990, Columbus, Ohio 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

2、 Online database at https:/assist.daps.dla.mil. AMSC N/A FSC 6145 INCH-POUND MIL-DTL-16878H 11 March 2012 SUPERSEDING MIL-DTL-16878G 11 August 2000 DETAIL SPECIFICATION WIRE, ELECTRICAL, INSULATED, GENERAL SPECIFICATION FOR This specification is approved for use by all Departments and Agencies of th

3、e Department of Defense. 1. SCOPE 1.1 Scope. This specification covers unshielded wire for hookup and lead wiring of electrical and electronic components and equipment. The temperature rating of wire under this specification ranges from -65 to 260 degrees Celsius (C), with potential rating from 250

4、to 5,000 volts root mean square (Vrms). 1.2 Classification. Wire is classified as to conductor material, size, stranding, and insulation color code (see 3.1 and 6.2). 1.2.1 Part or Identifying Number (PIN). The PIN consists of the following form: M16878/03 B C B * Specification Conductor Conductor C

5、onductor Insulation sheet number material size stranding color code (see 1.2.2) (see 1.2.3) (see 1.2.4) (see 1.2.5) (see 1.2.6) 1.2.2 Specification sheet number. The specification sheet number designation consists of the prefix M (which indicates a military specification item), the specification num

6、ber, a slash, and the specification sheet number. 1.2.3 Conductor material. Conductor material is designated by a single letter as follows: B - Coated copper C - Coated copper-clad steel (C.C. Steel) D - Coated high-strength copper alloy (H.S.C.A.) Provided by IHSNot for ResaleNo reproduction or net

7、working permitted without license from IHS-,-,-MIL-DTL-16878H 2 1.2.4 Conductor size. The conductor American Wire Gage (AWG) size is designated by a single letter as follows (see 6.1.2): AWG Letter AWG Letter AWG Letter AWG Letter 32 A 20 G 8 N 00 W 30 B 18 H 6 P 000 Y 28 C 16 J 4 R 0000 Z 26 D 14 K

8、 2 S 24 E 12 L 1 T 22 F 10 M 0 U 1.2.5 Conductor stranding. The number of strands making up the conductor is designated by a single letter as follows: Number of strands Letter Number of strands Letter 1 A 133 L 7 B 168 M 10 C 259 N 16 D 665 P 19 E 817 R 26 F 1045 S 37 G 1330 T 41 H 1672 V 65 J 2109

9、W 105 K 1.2.6 Insulation color code. The insulation color code is in accordance with the identification coding system of MIL-STD-681, and may be one, two, or three digits depending on the number or absence of stripes or bands. The first number is the color of the insulation; the second number is the

10、 color of the first stripe or band; and the third number is the color of the second stripe or band. Designation of the color code need not be imprinted on the wire. The colors and their corresponding numbers are as follows: Color Number designator Color Number designator Black 0 Green 5 Brown 1 Blue

11、 6 Red 2 Violet (purple) 7 Orange 3 Gray (slate) 8 Yellow 4 White 9 The colors listed are the preferred colors in accordance with FED-STD-595 unless the contracting activity specifies alternates (see 6.2). 2. APPLICABLE DOCUMENTS 2.1 General. The documents listed in this section are specified in sec

12、tions 3, 4, or 5 of this specification. This section does not include documents cited in other sections of this specification or recommended for additional information or as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they mus

13、t meet all specified requirements documents cited in sections 3, 4, or 5 of this specification, whether or not they are listed. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-DTL-16878H 3 2.2 Government documents. 2.2.1 Specifications, standards

14、 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 (see 6.2). FEDERAL STANDARD FED-STD-228 - Cable and Wire, Insu

15、lated; Methods of Testing DEPARTMENT OF DEFENSE SPECIFICATIONS MIL-C-572 - Cords, Yarns, and Monofilaments, Organic Synthetic Fiber MIL-Y-1140 - Yarn, Cord, Sleeving, Cloth, and Tape-Glass (See Supplement 1 for list of specification sheets.) DEPARTMENT OF DEFENSE STANDARD MIL-STD-104 - Limits for El

16、ectrical Insulation Color (Copies of these documents are available online at https:/assist.daps.dla.mil/quicksearch/ or from the Standardization Document Order Desk, 700 Robbins Avenue, Building 4D, Philadelphia, PA 19111-5094.) 2.3 Non-Government publications. The following documents form a part of

17、 this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract. ASME INTERNATIONAL ASME B46.1 - Surface Texture (Surface Roughness, Waviness, and Lay) (Copies of these documents are available online at http:/ww

18、w.asme.org or from the ASME International, Three Park Avenue, New York, NY 10016-5990.) ASTM INTERNATIONAL ASTM B33 - Standard Specification for Tinned Soft or Annealed Copper Wire for Electrical Purposes ASTM B173 - Standard Specification for Rope-Lay-Stranded Copper Conductors Having Concentric-St

19、randed Members, for Electrical Conductors ASTM B286 - Standard Specification for Copper Conductors for Use in Hookup Wire for Electronic Equipment ASTM B298 - Standard Specification for Silver-Coated Soft or Annealed Copper Wire ASTM B355 - Standard Specification for Nickel-Coated Soft or Annealed C

20、opper Wire ASTM B501 - Standard Specification for Silver-Coated, Copper-Clad Steel Wire for Electronic Application ASTM B520 - Wire, Steel, for Electronic Applications, Tin-Coated, Copper-Clad ASTM B559 - Standard Specification for Nickel-Coated, Copper-Clad Steel Wire for Electronic Application AST

21、M B624 - Standard Specification for High-Strength, High-Conductivity Copper-Alloy Wire for Electronic Application ASTM D1248 - Standard Specification for Polyethylene Plastics Molding and Extrusion Materials Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IH

22、S-,-,-MIL-DTL-16878H 4 ASTM D2802 - Standard Specification for Ozone-Resistant Ethylene-Propylene Rubber Insulation for Wire and Cable ASTM D4066 - Standard Classification System for Nylon Injection and Extrusion Materials (PA) ASTM G21 - Standard Practice for Determining Resistance of Synthetic Pol

23、ymeric Materials to Fungi (Copies of these documents are available online at http:/www.astm.org or from the ASTM International, P.O. Box C700, 100 Barr Harbor Drive, West Conshohocken, PA 19428-2959.) IPC ASSOCIATION CONNECTING ELECTRONICS INDUSTRIES J-STD-006 - Requirements for Electronic Grade Sol

24、der Alloys and Fluxed and Non-Fluxed Solid Solders for Electronic Soldering Applications (Copies of this document are available online at http:/www.ipc.org or from the IPC Association Connecting Electronics Industries, 2000 Lakeside Drive, 309S, Bannockburn, IL 60015.) INSULATED CABLE ENGINEERS ASSO

25、CIATION (ICEA) ICEA T-24.380 - Partial Discharge Test Procedure (Copies of this document are available online at http:/ or from the ICEA, P.O. Box 1658, Carrollton, Georgia 30112.) NCSL INTERNATIONAL NCSL-Z540.1 - Laboratories, Calibration and Measuring and Test Equipment (Copies of these documents

26、are available online at http:/www.ncsli.org or from NCSL International, 2995 Wilderness Place, Suite 107 Boulder, Colorado 80301-5404.) NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA) NEMA WC 52 - High Temperature and Electronic Insulated Wire-Impulse Dielectric Testing NEMA WC 56 - 3.0 kHz Ins

27、ulation Continuity Proof Testing of Hook-up Wire (Copies of this document are available from http:/www.nema.org or from the National Electrical Manufacturers Association, 1300 North 17th Street, Suite 1847, Rosslyn, VA 22209.) Provided by IHSNot for ResaleNo reproduction or networking permitted with

28、out license from IHS-,-,-MIL-DTL-16878H 5 SAE INTERNATIONAL SAE AMS 3249 - Ethylene Propylene (EPDM) Rubber Hydrazine-Base-Fluid Resistant (Copies of these documents are available online at http:/www.sae.org or from the SAE International, 400 Commonwealth Drive, Warrendale, PA 15096-0001.) UNDERWRIT

29、ERS LABORATORIES (UL) UL 1581 - Reference Standard for Electrical Wires, Cables, and Flexible Cords (Copies of these documents are available online at http:/ or from the Underwriters Laboratories, Publication Stock, 333 Pfingsten Road, Northbrook, IL 60062-2096.) 2.4 Order of precedence. Unless othe

30、rwise noted herein or in the contract, in the event of a conflict between the text of this document and the references cited herein (except for related specification sheets), the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unl

31、ess a specific exemption has been obtained. 3. REQUIREMENTS 3.1. Specification sheets. The individual item requirements shall be as specified herein and in accordance with the applicable specification sheets. In the event of any conflict between requirements of this specification and the specificati

32、on sheet, the latter shall govern. 3.2 First article. When specified (see 6.2), a sample shall be subjected to first article inspection in accordance with 4.2. 3.3 Recycled, recovered, or environmentally preferable materials. Recycled, recovered, or environmentally preferable materials should be use

33、d to the maximum extent possible, provided that the material meets or exceeds the operational and maintenance requirements, and promotes economically advantageous life-cycle costs. 3.4 Materials. Materials shall be as specified herein. When a material is not specified, a material shall be used that

34、will enable the insulated wire to meet the performance requirements of this specification. 3.4.1 Conductors. Conductors shall be solid (see 6.1.3) or stranded as specified in table I, or as approved by the contracting activity (see 6.2), for the specific wire. Each strand of the conductor shall be o

35、f the same composition. When coated wires are used, individual strands shall be coated before stranding. Each strand shall have the same coating. Conductors shall meet the requirements specified in 3.4.1.1 through 3.4.1.7 before application of insulation. 3.4.1.1 Tin-coated copper conductors. Tin-co

36、ated copper conductors shall conform to ASTM B33 for soft or annealed copper. 3.4.1.2 Silver-coated copper conductors. Silver-coated soft or annealed copper conductors shall conform to ASTM B298 with a 40 microinches (minimum) thickness of silver. 3.4.1.3 Nickel-coated copper conductors. Nickel-coat

37、ed soft or annealed copper conductors shall conform to ASTM B355 with a 50 microinches (minimum) thickness of commercially pure nickel. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-DTL-16878H 6 TABLE I. Details of conductors. Size desig- natio

38、n (see 1.2.4) Nominal conductor area (circular mils) 1/Stranding (number of strands x AWG of strands) Allowable number of missing strands (max) Nominal diameter of individual strands (inch) 1/ Diameter of conductor Maximum dc resistance of finished wire (ohms/1000 feet at 20 C) Soft or annealed copp

39、er High-strength copper alloy 3/Copper- clad steel Min (inch) Max (inch) Silver- coated Nickel- coated Tin- coated Silver- coated Nickel- coated 32 64 1 X 32 2/0 .0080 .0075 .009 169.0 175.00 178.00 200.0 205.0 451.0 32 67 7 X 40 0 .0031 .0088 .011 173.0 185.00 189.00 204.0 232.0 483.0 30 100 1 X 30

40、 2/0 .0100 .0095 .011 108.0 112.00 116.00 127.0 132.0 283.0 30 112 7 X 38 2/0 .0040 .0110 .013 100.7 110.70 114.10 117.4 129.6 285.0 28 159 1 X 28 0 .0126 .0120 .013 68.0 70.00 71.60 80.0 82.0 184.0 28 175 7 X 36 2/0 .0050 .0140 .016 63.8 67.90 68.60 74.4 79.0 178.0 26 253 1 X 26 0 .0159 .0150 .017

41、42.7 43.80 45.30 50.2 51.5 116.0 26 278 7X 34 0 .0063 .0180 .020 40.5 43.10 43.40 47.6 50.7 110.0 26 304 19 X 38 2/0 .0040 .0180 .022 38.4 42.20 41.30 44.8 49.4 107.0 24 404 1 X 24 0 .0201 .0190 .022 26.8 27.40 27.80 31.4 31.9 71.4 24 448 7 X 32 0 .0080 .0230 .025 25.2 26.50 27.00 29.4 30.8 67.6 24

42、475 19 X 36 2/0 .0050 .0230 .027 24.3 25.90 26.20 28.4 30.1 65.6 22 640 1X 22 0 .0253 .0247 .026 17.0 18.10 17.70 19.6 19.9 44.4 22 700 7X 30 0 .0100 .0280 .031 15.9 16.60 17.10 18.7 19.5 42.1 22 754 19 X 34 2/0 .0063 .0290 .033 15.1 16.00 16.20 17.5 18.6 40.8 20 1020 1X 20 0 .0320 .0310 .033 10.5 1

43、0.70 10.90 12.2 12.6 - 20 1111 7 X 28 0 .0126 .0360 .039 10.0 10.40 10.70 11.8 12.2 - 20 1000 10 X 30 0 .0100 .0380 .040 11.3 11.80 12.10 - - - 20 1216 19 X 32 2/0 .0080 .0370 .041 9.19 9.77 9.88 10.8 11.4 - 18 1620 1 X 18 0 .0403 .0390 .041 6.60 6.70 6.90 - - - 18 1770 7 X 26 0 .0159 .0470 .050 6.2

44、8 6.50 6.70 - - - 18 1608 16 X 30 0 .0100 .0480 .051 6.30 6.60 6.80 - - - 18 1900 19 X 30 2/0 .0100 .0460 .052 5.79 6.10 6.23 - - - 16 2580 1 X 16 0 .0508 .0500 .052 4.20 4.35 4.36 - - - 16 2426 19 X29 2/0 .0113 .0520 .059 4.52 4.76 4.81 - - - 16 2600 26 X 30 0 .0100 .0570 .062 4.31 4.55 4.69 - - -

45、14 4110 1 X 14 0 .0641 .0630 .065 2.58 2.67 2.68 - - - 14 3831 19 X 27 2/0 .0142 .0650 .073 2.88 3.00 3.06 - - - 14 4100 41 X 30 0 .0100 .0720 .081 2.74 2.85 2.94 - - - Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-DTL-16878H 7 TABLE I. Details

46、 of conductors - Continued. Size desig-nation (see 1.2.4) Nominal conductor area (circular mils) 1/Stranding (number of strands x AWG of strands) Allowable number of missing strands (max) Nominal diameter of individual strands (inch) 1/Diameter of conductor Maximum dc resistance of finished wire (oh

47、ms/1000 feet at 20 C) Soft or annealed copper High-strength copper alloy 3/Copper- clad steel Min (inch) Max (inch) Silver- coated Nickel- coated Tin- coated Silver- coated Nickel- coated 12 6530 1 X 12 0 .0808 .0790 .082 1.620 1.680 1.690 - - - 12 6088 19 X 25 0 .0179 .0820 .093 1.810 1.880 1.920 -

48、 - - 12 5874 37 X 28 2/0 .0126 .0840 .091 1.900 1.980 2.020 - - - 12 6500 65 X 30 0 .0100 .0930 .099 1.730 1.800 1.850 - - - 10 10380 1 X 10 0 .1019 .1000 .103 1.020 1.050 1.060 - - - 10 9354 37 X 26 2/0 .0159 .1060 .115 1.190 1.240 1.260 - - - 10 10500 105 X 30 0 .0100 .1180 .130 1.070 1.110 1.150

49、- - - 8 16800 168 X 30 0 .0100 .1600 .175 - - .708 - - - 8 16983 133 X 29 2/ 0 .0113 .1580 .173 .658 .694 .701 - - - 6 26818 133 X 27 0 .0142 .1980 .217 .418 .436 .445 - - - 4 42615 133 X 25 0 .0179 .2500 .274 .264 .275 .280 - - - 2 66140 133 X 23 0 .0223 .3300 .355 .167 .171 .176 - - - 2 66304 259 X 26 0 .0159 .3250 .350 .174 .180 .186 - - - 2 66500 665 X 30 2/2 .0100