DLA MIL-DTL-18266B-2006 CORD ASSEMBLY ELECTRICAL P O H-87B U.pdf

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1、 INCH-POUND MIL-DTL-18266B 17 February 2006 SUPERSEDING MIL-C-18266A(AS) 30 June 1976 DETAIL SPECIFICATION CORD ASSEMBLY, ELECTRICAL: P/O H-87B/U Inactive for new design after 22 September 1999. This specification is approved for use by all Departments and Agencies of the Department of Defense. 1. S

2、COPE 1.1 Scope. This specification covers requirements and tests for Cord: P/O H-87B/U. 1.2 Classification. The cords covered by this specification are of one type, designated, Cord: P/O H-87B/U. 2. APPLICABLE DOCUMENTS 2.1 General. The documents listed in this section are specified in sections 3, 4

3、, 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 must meet all

4、 specified requirements documents cited in sections 3, 4, or 5 of this specification, whether or not they are listed. 2.2 Government documents. 2.2.1 Specifications, standards, and handbooks. The following specifications, standards, and handbooks form a part of this document to the extent specified

5、herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract. FEDERAL STANDARDS FED-STD-228 - Cable and Wire, Insulated; Methods of Testing DEPARTMENT OF DEFENSE SPECIFICATIONS MIL-P-642/3 - Plug, Telephone (Types PJ-054B and PJ-054R) and Accessor

6、y Screws MIL-C-10392 - Cord, Electrical (Audio, Miniature) MIL-N-18307 - Nomenclature and Identification for Electronic, Aeronautical, and Aeronautical Support Equipment Including Ground Support Equipment Comments, suggestions, or questions on this document should be addressed to: Commander, Defense

7、 Supply Center Columbus, Attn: VAI, P. O. Box 3990, Columbus, Ohio, 43218-3990 or emailed to mailto:Sounddscc.dla.mil. Since contact information can change, you may want to verify the currency of this address information using the ASSIST Online database at http:/assist.daps.dla.mil. AMSC N/A FSC 596

8、5 Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-DTL-18266B 2(Copies of these documents are available online at http:/assist.daps.dla.mil/quicksearch/ or http:/assist.daps.dla.mil from the Standardization Document Order Desk, 700 Robbins Avenue,

9、 Building 4D, Philadelphia, PA 19111-5094.) 2.3 Order of precedence. 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 specif

10、ic exemption has been obtained. 3. REQUIREMENTS 3.1 Qualification. Cords furnished under this specification shall be products that are authorized by qualifying activity for listing on the applicable qualified products list before contract award (see 4.2 and 6.4). 3.2 Parts, materials and processes.

11、Parts, materials and processes shall be as specified herein. However, when definite parts, materials, and processes are not specified, parts, materials and processes shall be used, which will enable the cord to meet all the requirements of this specification. Acceptance or approval of any constituen

12、t parts, materials, and processes shall not be construed as a guarantee of the acceptance of the finished product. 3.2.1 Fungus and moisture resistant materials. Materials which are not nutrients for fungi and moisture resistant shall be used. 3.2.1.1 Central cords, fillers, binders, etc. All cotton

13、 or other textiles used as a central core, filler, binder, etc. shall be fungus treated prior to their use. The impregnating material shall not affect the electrical or physical characteristics of the cordage. 3.2.2 Cordage. The insulation and jacket compounds shall be in accordance with MIL-C-10392

14、 homogenous in character, tough and elastic. The resultant cordage shall be free from blisters, cracks and other imperfections which would affect the serviceability. 3.2.2.1 Pure tin. The use of pure tin, as an underplate or final finish, is prohibited both internally and externally. Tin content of

15、cord assembly components and solder shall not exceed 97 percent, by mass. Tin shall be alloyed with a minimum of 3 percent lead, by mass (see 6.5.1). 3.3 Design and construction. 3.3.1 Jacket. The jacket shall provide long life under severe service conditions. The jacket shall have a minimum thickne

16、ss of 0.020 inch and shall not adhere or stick to the conductor insulation. The finished cordage shall have a reasonably smooth surface. 3.3.1.1 Stripping. Irregularities in the jacket edge due to stripping shall not exceed 0.1875 inch overall. 3.3.2 Conductor. Each stranded conductor shall be equiv

17、alent to 404 circular mils (# 24 AWG) and shall consist of 41 strands of # 40 AWG bunched stranded with a lay of no more than 0.6 inch. 3.3.2.1 Conductor resistance. The resistance of the individual conductor of the finished cordage shall not exceed 0.04 ohm per foot at a temperature of 20C. 3.3.2.2

18、 Conductor strands. The conductor strands shall be 9.8 circular mils (#40 AWG). Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-DTL-18266B 33.3.2.3 Conductor insulation. The conductor insulation shall be “free-stripping” and shall not have any de

19、trimental properties which would make soldering of the conductors difficult. The conductor insulation shall be in accordance with MIL-C-10392. 3.3.3 Cordage assembly. The single conductor cordage shall be composed of a conductor in accordance with 3.3.2 and conductor insulation in accordance with 3.

20、3.2.3. The multi-conductor cordage shall be Type WM-59A/U in accordance with MIL-C-10392. 3.3.3.1 Outside diameter. The cordage shall have a maximum outside diameter of 0.059 inch (1.5 mm) for single conductor and 0.212 0.010 inch (5.4 mm) for multi-conductor. 3.3.3.2 Electrical continuity (see 4.6.

21、2). The electrical continuity shall be as shown schematically on figure 1. 3.3.4 Tensile strength and elongation (see 4.5.5). The tensile strength and elongation of the conductor strands shall exhibit the following performance. Tensile strength 45,000 pound per square inch (psi) minimum Elongation (

22、in 10 inches) 13% minimum 3.3.5 Dielectric strength (see 4.5.2). The finished cordage shall withstand, without breakdown, the specified voltage. 3.3.6 Insulation resistance (see 4.5.3). The insulation resistance of the finished cordage shall be not less than 500 megohms per 1,000 feet at a temperatu

23、re of 20C. 3.3.7 Transformer dc insulation resistance (see 4.6.3). The dc insulation resistance between the primary and secondary windings within the transformer-plug shall be not less than 100 megohms at a temperature of 20C. 3.3.8 Stay cord. Where more than one conductor is required, a central cor

24、e or interstice filler shall extend through the length of the cordage and shall be suitable for use as a strain-relief cord. The central core or filler shall be a low stretch material with a 25 pound minimum breaking strength. Where a single conductor is used, a stay cord will not be required; howev

25、er, the conductor insulation shall be secured to the terminal by a suitable bonder. 3.3.9 Flexing (see 4.5.6). The cordage shall be capable of withstanding at least 30,000 flexing cycles without showing evidence of electrical discontinuity or change in specified characteristics of the insulation. 3.

26、3.10 Transformer-plug. 3.3.10.1 Transformer. The transformer shall be of the isolating impedance matching type capable of transferring audio frequency energy from a 600 ohm source (radio receiver output) to a 7.5 ohm load (two 15 ohm impedance earphones connected in parallel). The transformer shall

27、provide a maximum power transfer of one-half watt with a power insertion loss not to exceed 2.5 dB and with no direct current (dc) flowing in either primary or secondary winding. 3.3.10.2 Size. The size of the transformer shall be governed by the dimensions of the transformer-plug shell. 3.3.10.3 Pl

28、ug. The plug shall be in accordance with MIL-P-642/3 for type PJ-054 except that the shell and terminals may be modified to accommodate the transformer. The shell shall be an integral part of the plug sleeve and shall provide means for anchoring the cordage. Provided by IHSNot for ResaleNo reproduct

29、ion or networking permitted without license from IHS-,-,-MIL-DTL-18266B 43.3.10.4 Terminals. The terminals shall be of the “slim type” made of half-hard brass and finished with white nickel plate to 0.0004 inch minimum depth. The finished dimensions shall be as presented on figure 1. FIGURE 1. Cord

30、assembly, P/O H-87B/U. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-DTL-18266B 5Inches mm Inches mm Inches mm Inches mm .003 0.1 .110 2.8 .250 6.4 .550 14.0 .010 0.25 .125 3.2 .281 7.1 .625 15.9.012 0.3 .141 3.6 .344 8.7 .671 17.0 .015 0.4 .15

31、6 4.0 .438 11.1 .688 17.5.052 1.3 .175 4.4 .448 11.4 .776 19.7 .058 1.47 .180 4.6 .500 12.7 2.00 50.8.059 1.5 .187 4.7 .523 13.3 5.00 127.0 .085 2.2 .212 5.4 .531 13.5 9.25 235.0.090 2.3 .219 5.6 .546 13.9 27.0 685.8 NOTES: 1. Unless otherwise specified, tolerance shall be 0.015 inch. 2. Metric equi

32、valents are given for general information only. FIGURE 1. Cord assembly, P/O H-87B/U - Continued. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-DTL-18266B 63.3.11 Cord assembly. Cord: P/O H-87B/U shall be assembled as shown pictorially and sche

33、matically on figure 1. After assembling the transformer within the transformer-plug shell, the remaining space within the shell shall be filled with a suitable epoxy resin. The assembled transformer-plug shall be protected by rubber molding to a depth of not less than 0.025 inch. The junction of the

34、 single and multi-conductor cordage shall be protected and reinforced by a rubber molding. In addition, the junction molding shall include an eyelet for attaching the cord to the helmet. The dimensions of the finished cord shall be in accordance with figure 1. 3.3.12 Total weight. The total weight o

35、f each cord shall be no greater than six ounces. 3.4 Performance. 3.4.1 Frequency response (see 4.6.4). The frequency response characteristics of the transformer shall be smooth and free from abnormal irregularities over the frequency range of 200 to 6,000 Hz. The output response over this frequency

36、 range shall be within 2dB of the 1000 Hz output. 3.4.2 Distortion (see 4.6.5). The distortion introduced by the transformer shall not exceed 2 percent for frequencies between 1,000 and 6,000 Hz. The distortion may increase for frequencies below 1,000 Hz, but, shall not exceed 15 percent at 200 Hz.

37、3.4.3 Impedance (see 4.6.6). The impedance of the primary and secondary windings over the frequency range of 200 to 6,000 Hz shall not deviate from the 1,000 Hz values by more than 15 percent. 3.4.4 Overload (see 4.6.7). The cord (transformer) shall be able to withstand an overload of 500 milliwatts

38、 rms at 1,000 Hz for a period of 8 hours without signs of failure. After meeting this requirement, the cord (transformer) shall meet the requirements of 3.4.1 and 3.4.2. 3.5 Environmental. 3.5.1 Flame-retardant cord (see 4.5.4). Self-sustained combustion of the finished cord insulation shall not pro

39、gress at a rate in excess of 1 inch per minute. 3.5.2 Temperature requirements. 3.5.2.1 Operating range. The cordage shall be flexible and resilient throughout the temperature range of 55 to +85C (-67 F to +185 F). 3.5.3 Humidity (see 4.6.8). The cord shall be able to withstand an ambient humidity c

40、ondition of 95 percent, relative at 50 C (122 F). After meeting this requirement, the cord shall meet the requirements of 3.4.1. 3.5.4 Cold bend (see 4.5.7). Specimens of the cordage shall show no evidence of cracking or other damage to the jacket or conductor insulation after being subjected to a c

41、old bend test. Immediately following the cold bend test, the specimens shall withstand without breakdown a modified version of the dielectric withstanding voltage test of MIL-C-10392. 3.5.5 Ambient temperature cycling (see 4.6.9). The cord shall be able to withstand ambient temperature cycling witho

42、ut degradation of performance. After meeting this requirement, the cord shall meet the frequency response requirements of 3.4.1. 3.6 Identification. 3.6.1 Nomenclature. The nomenclature shall be in accordance with MIL-N-18307. Provided by IHSNot for ResaleNo reproduction or networking permitted with

43、out license from IHS-,-,-MIL-DTL-18266B 73.6.1.1 Cord. The complete cord shall have a metal band or other suitable means of marking to show the designation P/O H-87B/U, contract number, and contractors code designation in conformance with MIL-N-18307 and as shown on figure 1. 4. VERIFICATION 4.1 Cla

44、ssification of inspections. The inspection requirements specified herein are classified as follows: a. Qualification inspection (see 4.2) b. Conformance inspection (see 4.3) 4.2 Qualification inspection. Qualification inspection shall consist of all the requirements and tests of table ll and of this

45、 specification performed at a laboratory approved by the qualifying activity. 4.2.1 Qualification samples. Qualification samples shall consist of 10 (ten) complete cords of each manufacturers part number, for which approval is requested. In lieu of ten completed cords, the manufacturer may, with the

46、 approval of the qualifying activity, submit 5 (five) complete cords and 5 (five) cords complete, except for the transformer-plug. The samples submitted for qualification approval shall be representative of normal production. 4.2.1.1 Scope. The qualification inspection shall consist of tests in the

47、following categories. a. Tests to determine the suitability of the cordage. b. Tests to determine the suitability of the finished product (cord). 4.2.2 Retention of qualification. Retention of qualification shall be made by means of certification (DD Form 1718, Certification of Qualified Products, s

48、hall be used for obtaining certification). Failure to provide certification shall be cause for removal from QPL. 4.3 Conformance inspection. The contractor shall furnish all samples and shall be responsible for performing the required tests. All inspection and testing shall be under the supervision

49、of the government inspector. The contractor shall furnish test reports, in duplicate, showing quantitative results for all acceptance tests. Such reports shall be signed by an authorized representative of the contractor or laboratory. Conformance shall consist of the following tests: a. Individual tests (see 4.3.1) b. Sampling tests (see 4.3.2) 4.3.1 Individual inspections. Each cord (100 percent) sh