DLA MIL-DTL-2486 E-2009 CABLE SPECIAL PURPOSE ELECTRICAL WM-46 U.pdf

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1、 AMSC N/A FSC 6145 INCH-POUND MIL-DTL-2486E 12 January 2009 SUPERSEDING MIL-DTL-2486D 7 March 2003 DETAIL SPECIFICATION CABLE, SPECIAL PURPOSE, ELECTRICAL WM-46/U Inactive for new design after 16 June 1997 This specification is approved for use by all Departments and Agencies of the Department of De

2、fense. 1. SCOPE 1.1 Scope. This specification covers one type of ten conductors, Buna S insulated and jacketed cable designated as Cable, Special Purpose, Electrical WM-46/U. Eight of the conductors are equivalent to 20 AWG, four of which are shielded, and two of the conductors are equivalent to 16

3、AWG, one of which is shielded. 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 additional information or as e

4、xamples. 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 documents. 2.2.1 Specificatio

5、ns, 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, suggestions, or questions on this doc

6、ument should be addressed to Defense Supply Center, Columbus, ATTN: DSCC-VAI, P.O. Box 3990, Columbus, OH 43218-3990, or email to WireCabledscc.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:/ass

7、ist.daps.dla.mil. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-DTL-2486E 2 FEDERAL STANDARD FED-STD-228 - Cable and Wire, Insulated; Methods of Testing. COMMERCIAL ITEM DESCRIPTION A-A-59551 - Wire, Electrical, Copper (Uninsulated) DEPARTMENT

8、OF DEFENSE SPECIFICATIONS MIL-DTL-3432 - Cables, (Power and Special Purpose) and Wire, Electrical (300 and 600 volts) MIL-I-631 - Insulation, Electrical, Synthetic-resin Composition, Non-rigid (Copies of these documents are available online at http:/assist.daps.dla.mil/quicksearch/ or from the Stand

9、ardization Document Order Desk, 700 Robbins Ave, 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 solicitat

10、ion or contract. INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO) ISO 17025 - General Requirements for the Competence of Testing and Calibration Laboratories (Copies of these documents are available online at http:/www.iso.ch or from the International Organization for Standardization American Na

11、tional Standards Institute, 11 West 42ndStreet, 13thFloor, New York, NY 10036.) NCSL INTERNATIONAL NCSL-Z540.3 - Laboratories Calibration and Measuring and Test Equipment (Copies of this document are available from http:/www.ncsli.org or from National Conference of Standards Laboratories (NCSL), 299

12、5 Wilderness Place, Suite 107, Boulder, CO 80301-5404.) 2.4 Order of precedence. 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, howev

13、er, supersedes applicable laws and regulations unless a specific exemption has been obtained. 3. REQUIREMENTS 3.1 Recycled, recovered, or environmentally preferable materials. Recycled, recovered or environmentally preferable materials should be used to the maximum extent possible, provided that the

14、 material meets or exceeds the operational and maintenance requirements, and promotes economically advantageous life cycle costs. 3.2 Materials. The materials used for Cable, Special Purposes, Electrical WM-46/U shall be as specified herein. Provided by IHSNot for ResaleNo reproduction or networking

15、 permitted without license from IHS-,-,-MIL-DTL-2486E 3 3.3 Conductors. Cable, Special Purposes, Electrical WM-46/U shall consist of eight 20 AWG conductors and two 16 AWG conductors as specified in A-A-59551 for coated type B, class K wire for ordinary flexing service. 3.4 Conductor separator. A cl

16、ose wind of fine cotton or rayon shall be applied over each conductor. This separator may be omitted if a free stripping insulating compound is used. 3.5 Insulation. 3.5.1 Physical properties. Each conductor shall be insulated with differently colored insulating compounds or the same color compound

17、depending on the method of color coding (see 3.6). The physical properties of the insulation from each conductor shall be as specified in MIL-DTL-3432. 3.5.2 Insulation thickness. The insulation thickness shall be not less than 0.020 inch (.51 mm), or if followed by a braid or serving over the insul

18、ation, the thickness shall not be less than 0.015 inch (.38 mm). 3.6 Insulation color coding. Each insulated conductor shall be differently color coded with colored insulating compounds or a color coded braid. The following colors shall be used on the conductors tabulated below: Conductor AWG Color

19、20 Black 20 White 20 Red 20 Green 16 Orange 16 Blue 20 Brown 20 Yellow 20 Slate 20 Purple 3.7 Shielded conductors. Five of the insulated conductors, colored blue, brown, yellow, slate and purple, shall each have an individual braid of tinned soft or annealed copper wire applied over the insulation o

20、r textile braid if used to a minimum coverage of 85%. Each strand of the braid shall consist of 34 AWG wire in accordance with A-A-59551 for coated type S, soft or drawn-and-annealed wire prior to braiding. 3.8 Cabling. The black and the white conductors shall be twisted together with a lay not exce

21、eding 2 inches (50.80 mm). The remaining conductors shall be cabled around the central conductors with a lay not exceeding 7 inches (177.80 mm). The outer conductors shall be placed in the same order around the cable as the order of the colors of insulation tabulated in 3.6. 3.9 Overall shield. A cl

22、ose braid of tinned, soft, or annealed copper wire shall be applied over the cable conductors to a minimum coverage of 85 percent. Each strand of the braid shall consist of 34 AWG wire in accordance with A-A-59551 for coated type S, soft or drawn-and-annealed wire prior to braiding. 3.10 Jacket sepa

23、rator. A close wind of fine cotton or rayon shall be applied over the shield. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-DTL-2486E 4 3.11 Jacket. The jacket shall be of a jacketing compound type as specified in MIL-DTL-3432. The jacket shall

24、 be applied over the separator to an outside diameter of 0.615 0.015 inch (15.62 mm .38 mm). The wall thickness of the jacket shall be not less than 0.030 inch (.76 mm). The outer jacket shall be uniformly smooth and shall have no ridges, pits, depressions, embossed or engraved markings, or any othe

25、r irregularities which would impair the smoothness of the jacket. 3.12 DC resistance. When tested as specified in 4.5.7, each conductor shall have a DC resistance corresponding to its size at, or corrected to, 25C, as follows: DC resistance, maximum Conductor size (AWG) ohms per 1,000 feet 20 12.1 1

26、6 4.7 3.13 Dielectric strength. The insulated conductor shall withstand for 1 minute without breakdown an alternating current potential of 1,000 volts root-mean-square (rms.), when tested as specified in 4.5.8. 3.14 Insulation resistance. Immediately after the insulated conductors have withstood the

27、 dielectric strength test, the insulation resistance shall be measured as specified in 4.5.9. The insulation resistance of Buna S insulated conductors shall be not less than 500 megohms 1000 feet when measured at or corrected to 15.6C. The insulation resistance of latex insulated conductors shall be

28、 not less than 7,500 megohms 1,000 feet when measured at or corrected to 15.6C. 3.15 Cold bend. The insulation and the jacket shall not crack when tested as specified in 4.5.13 at a temperature of minus 40C 2C. 3.16 Marking of cable. The cable shall be marked on the outside with an inked marking and

29、 on the inside under the overall shield with a marker tape. All letters and numbers in the marking shall be of the same height. 3.16.1 Inked marking. Inked marking shall be clear and legible. The marking shall show no indication of cracking when bent as specified in 3.15. The inked marking shall con

30、sist of the designation WM-46/U, and the number of this specification with three to five letter spaces allowed between them. The marking shall be repeated at intervals along the cable not to exceed one foot. 3.16.2 Marker tape. The marker tape shall consist of a thin synthetic tape as specified in M

31、IL-I-631 or flat woven tape of cotton or synthetic yarn. The designation of WM-46/U, the number of this specification, the year of manufacture, and the manufacturers name or trademark, shall be permanently printed in succession on the tape. Serial number indicating footage may be supplied at the opt

32、ion of the manufacturer. Spacing between cable designation, number of specification, etc., shall be three letters in width. The marking shall be repeated at intervals along the tape not exceeding one foot. The tape shall be applied longitudinally. 3.17 Workmanship. All cables shall be manufactured a

33、nd finished in a thoroughly workmanlike manner specified in with 3.3 through 3.11, and 3.16 through 3.16.2, inclusive. 4. VERIFICATION 4.1 Classification of inspections. The inspection requirements specified herein are classified as follows: Conformance inspection (see 4.4). Provided by IHSNot for R

34、esaleNo reproduction or networking permitted without license from IHS-,-,-MIL-DTL-2486E 5 4.2 Test equipment and inspection facilities. Test and measuring equipment and inspection facilities of sufficient accuracy, quality, and quantity to permit performance of the required inspections shall be used

35、. The establishment and maintenance of a calibration system to control the accuracy of the measuring and test equipment shall be in accordance with NCSL-Z540.3 and ISO 17025 or equivalent. 4.3 Inspection conditions. Unless otherwise specified in the applicable test method, inspections shall be condu

36、cted under the following environmental conditions. a. Temperature: 15C to 35C. b. Pressure: Normal atmospheric. c. Humidity: Prevailing ambient (25 to 90 percent relative). 4.4 Conformance inspection. Conformance inspection shall consist of groups A and B inspections (see 4.4.5 and 4.4.6, respective

37、ly) specified in table I and shall be performed on every lot of cable procured under this specification. Sampling inspection shall be accomplished for each lot as specified in 4.4.2. TABLE I. Group A and B inspections. Inspection Requirement Verification Group A Group B Visual and mechanical - - X -

38、 Color coding 3.6 4.5.1 X - Overall shielding 3.9 4.5.2 X - Conductor shield 3.7 4.5.3 X - Cabling 3.8 4.5.4 X - Conductor separator 3.4 4.5.5 X - Jacket separator 3.10 4.5.6 X - Electrical - - X - DC resistance 3.12 4.5.7 X - Dielectric strength 3.13 4.5.8 X - Insulation resistance 3.14 4.5.9 X - C

39、onductors 3.3 4.5.10 - X Insulation thickness 3.5.2 4.5.11 - X Jacket 3.11 4.5.12 - X Cold bend 3.15 4.5.13 - X Marking of cable 3.16 4.5.14 - X 4.4.1 Lot. A lot shall consist of all cable manufactured under substantially the same conditions and offered for inspection at one time. 4.4.1.1 Lot size.

40、The lot size shall be defined as the number of units of product submitted for inspection. 4.4.1.2 Unit of product. A unit of product shall be defined as the continuous length of cable contained on a single reel, spool, or in a coil. 4.4.1.3 Specimen. A specimen is a single piece of finished cable or

41、 any part removed from the finished cable such as conductors, separators, insulated conductors, shielded conductors, or cabled and shielded conductors, insulations, and jacket, which is taken from a sample unit and subjected to inspection. Provided by IHSNot for ResaleNo reproduction or networking p

42、ermitted without license from IHS-,-,-MIL-DTL-2486E 6 4.4.2 Sampling. A random sample shall be selected from each lot as specified in table II. TABLE II. Inspection sample. Inspection lot size 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 3,2

43、00 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 4.4.3 Rejected lot. Failure of any sample to pass any inspection shall constitute a failure of the lot. If an inspection lot is rejected, the contractor may rework the lot to correct the defects or sc

44、reen out the defective units, and resubmit the lot for re-inspection. Such lots shall be separated from new lots and shall be identified as re-inspected lots (see 4.4.4). 4.4.4 Noncompliance. If a sample fails to pass any inspection, the contractor shall notify the cognizant inspection activity of s

45、uch failure and take corrective action on the materials or processes or both, as warranted 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, the conformance inspection shall be

46、 repeated on replacement articles. (This includes all tests and examinations, or only the test that the original sample failed, at the option of the cognizant inspection activity.) Final acceptance and shipment shall be withheld until inspection has shown that the corrective action was successful. I

47、n the event of failure after re-inspection, information concerning the failure shall be provided to the cognizant inspection activity. 4.4.5 Group A inspection. Group A inspection shall include the applicable inspections specified in table I. 4.4.6 Group B inspection. Group B inspection shall includ

48、e the applicable inspections specified in table I. Unless otherwise specified (see 6.2), group B inspection shall be performed on sample units that have been subjected to and have passed the group A inspection. 4.5 Methods of inspection. 4.5.1 Insulation color coding. Samples of the cable shall be e

49、xamined as specified in 3.6. 4.5.2 Overall shield. Samples of the shielded cable shall be examined as specified in 3.9. 4.5.3 Shielded conductors. Samples of the insulated and shielded conductors shall be examined as specified in 3.7. 4.5.4 Cabling. Sampling of the cabled conductors shall be examined as specified in 3.8. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,