DLA MIL-DTL-3885 G-2010 CABLE ASSEMBLIES AND CORD ASSEMBLIES ELECTRICAL.pdf

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1、Comments, suggestions, or questions on this document should be addressed to Defense Logistics Agency Aviation VEB, 8000 Jefferson Davis Highway, Richmond, VA 23297-5616, or e-mailed to STDZNMGTdla.mil. Since contact information can change, you may want to verify the currency of this address informat

2、ion using the ASSIST database at https:/assist.daps.dla.mil/. AMSC N/A FSC 5995 INCH-POUND MIL-DTL-3885G 29 November 2010 SUPERSEDING MIL-C-3885F 4 December 1985 DETAIL SPECIFICATION CABLE ASSEMBLIES AND CORD ASSEMBLIES, ELECTRICAL Reactivated after 29 November 2010 and may be used for new and exist

3、ing designs and acquisitions. This specification is approved for use by all Departments and Agencies of the Department of Defense. 1. SCOPE 1.1 Scope. This specification covers the minimum requirements, unless otherwise specified, for cable and cord assemblies (referred to as cable assemblies (see 6

4、.5.1), except for radio frequency coaxial cable assemblies. 2. APPLICABLE DOCUMENTS 2.1 General. The documents listed in this section are specified in sections 3 and 4 of this specification. This section does not include documents cited in other sections of this specification or recommended for addi

5、tional 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 the documents cited in sections 3 and 4 of this specification, whether or not they are listed. 2.2 Government do

6、cuments. 2.2.1 Specifications, standards, and handbook. The following specifications, standards, and handbook 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. Provided by IHSNot for

7、 ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-DTL-3885G 2 FEDERAL STANDARDS FED-STD-228 - Cable and Wire, Insulated; Methods of Testing FED-STD-601 - Rubber: Sampling and Testing DEPARTMENT OF DEFENSE SPECIFICATIONS MIL-T-3530 - Thread and Twine, Mildew Resistant or

8、 Water Repellent Treated MIL-DTL-15024 - Plates, Tags, and Bands for Identification of Equipment, General Specification for MIL-M-24041 - Molding and Potting Compound, Chemically Cured, Polyurethane DEPARTMENT OF DEFENSE STANDARDS MIL-STD-202 - Electronic and Electrical Component Parts MIL-STD-252 -

9、 Classification of Visual and Mechanical Defects for Equipment, Electronic, Wired, and Other Devices MIL-STD-13231 - Marking of Electronic Items DEPARTMENT OF DEFENSE HANDBOOK MIL-HDBK-454 - General Guidelines for Electronic Equipment (Copies of these documents are available online at https:/assist.

10、daps.dla.mil/ 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 this document to the extent specified herein. Unless otherwise specified, the issues of these document

11、s are those cited in the solicitation or contract. AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI) ANSI B74.18 - Grading of Certain Abrasive Grain on Coated Abrasive Products (Copies of this document are available online at http:/web.ansi.org/ or from the American National Standards Institute, 25 West

12、43rd Street, 4th floor, New York, NY 20036.) Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-DTL-3885G 3 AMERICAN SOCIETY FOR QUALITY (ASQ) ASQ Z1.4 - Sampling Procedures and Tables for Inspection by Attributes (Copies of this document are availa

13、ble online at http:/www.asq.org/ or from American Society of Quality, 600 North Plankinton Avenue, Milwaukee, WI 53203.) SAE INTERNATIONAL SAE AS5942 - Marking of Electrical Insulating Materials SAE AMS-DTL-23053/5 - Insulation Sleeving, Electrical, Heat Shrinkable, Polyolefin, Flexible, Crosslinked

14、 (Copies of these documents are available online at http:/www.sae.org/ or from SAE International, 400 Commonwealth Drive, Warrendale, PA 15096-0001.) 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 refere

15、nces cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained. 3. REQUIREMENTS 3.1 Detail requirements. The individual cable assemblies shall comply with all the requirements

16、specified herein as well as those cited on the applicable detail specification, specification sheet, or drawing (see 6.2). In the event of a conflict between the requirements of this specification and other requirements of the applicable device specification, the precedence in which requirements sha

17、ll govern, in descending order, is as follows: a. Applicable device specification (detail specification or drawing). b. This specification. c. Specifications, standards, and other documents referenced in section 2. 3.2 First article. When specified (see 6.2), a sample shall be subjected to first art

18、icle inspection in accordance with 4.2. First article inspection shall consist of all tests specified herein, and shall include materials inspection (see 4.2.1). Tests for insulation resistance and dielectric-withstanding voltage shall be performed manually and the insulation resistance readings sha

19、ll be recorded (see 4.4.2 and 4.4.3). 3.3 Material. The material shall be specified in the applicable specification or drawing. However, when a definite material is not specified, a material shall be used which will enable the cable assembly to meet the performance requirements of this specification

20、 and shall be submitted to the contracting officer for approval. Acceptance or approval of any constituent material shall not be construed as a guarantee of the acceptance of the finished product (see 4.2.1). Provided by IHSNot for ResaleNo reproduction or networking permitted without license from I

21、HS-,-,-MIL-DTL-3885G 4 3.3.1 Polyurethane. Molded polyurethane shall conform to MIL-M-24041 or shall meet material reversion test requirements (see 3.9.11). 3.3.2 Solders. MIL-HDBK-454, guideline 5, provides guidance on soldering of electrical connections (see 3.8.2). 3.4 Marking. Marking shall conf

22、orm to MIL-STD-13231. Size of the characters and properties of the marking shall be as specified in SAE AS5942. Unless otherwise specified (see 3.1), the marking shall be on yellow heat-shrinkable tubing, type K2 per MIL-DTL-15024 or class 1 per SAE AMS-DTL-23053/5. All cable assemblies shall have m

23、arkers applied as specified by the applicable drawings, contract, or order. The information to be marked on the cable band shall be as follows: Line 1. Type designation and length, if part of the nomenclature. The length shall be in parentheses. Line 2. Procurement instrument identification number (

24、contract number). Line 3 (if space permits). Manufacturer CAGE. Line 4 (if space permits). National stock number. 3.5 Connectors. Connectors shall meet the requirements of the individual connector specification listed on the drawing or in the contract (see 6.2). 3.6 Design and construction. 3.6.1 Tr

25、eatment of textiles. Staycords, fillers, binders, braids, and other textiles used in the construction of cable assemblies shall be treated in accordance with MIL-T-3530, using type I, class 1 mildew-inhibiting agent, with the following requirements waived: a. First article sample approval. b. Acidit

26、y (pH). c. Mildew-resistance. d. Color. e. Breaking strength. f. Length per pound. g. Sewing finish. The treatment shall be applied only with an alcoholic solution. The methods of treatment shall be as specified in 3.6.1.1 or 3.6.1.2, as applicable. Treatment is not required for nylon, cellulose ace

27、tate, rayon acrylic fibers, polyester, and ends of cable assemblies that terminate in a potted or molded connector (see 6.5.3 and 6.5.4), or a molded crotch. 3.6.1.1 Cut lengths. Prior to attachment of any terminations, such as terminals and connectors, the cut lengths of the cable or cord, prepared

28、 for terminations, shall be immersed in the specified mildew-inhibiting solution as shown in table I. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-DTL-3885G 5 TABLE I. Cable or cord mildew inhibition. Outer covering of cable or cord Degree of

29、immersion Textile, or textile covered by shielding Complete length, uncoiled Jacket of natural or synthetic rubber or of plastic Three inches beyond the edge at which the textile is exposed Immersion shall be for the minimum period of time necessary to obtain complete saturation, but shall not excee

30、d five minutes. As soon as practical after immersion, the treated cable or cord shall be dried so that it may be free of residual solvent. 3.6.1.2 Pretreatment. Textiles may be treated prior to fabrication into cable or cord, provided that the textile is not subsequently covered by insulation or a j

31、acket of natural or synthetic rubber, or plastic, which is applied with the use of heat. 3.6.2 Length of cable assembly. The length of the required cable assembly shall be as specified in the applicable drawing, specification, or contract (see 6.2). The length of the cable assembly as specified shou

32、ld be sufficient to allow for field repairs at each connector or stub end if intended use and storage conditions permit. 3.6.2.1 Cable assembly length tolerance. The tolerance of the overall length of the cable assembly shall be in accordance with table II. Other desired or critical tolerances for s

33、pecific applications shall be as noted on the applicable drawing, specification, or contract (see 6.2). TABLE II. Cable assembly length tolerances. Range of minimum cable lengths1Standard tolerance Less than 12 +0.25 12 to 23.875 +1.0 24 to 35.875 +1.5 36 to 53.875 +2.0 54 to 71.875 +2.5 72 to 150 +

34、3.0 Greater than 150 +2 percent 1 The length of a cable assembly is defined as the overall length, including terminations. 2 Unless otherwise specified, all values are in inches. 3.7 Electrical requirements. 3.7.1 Continuity. Each circuit shall be continuous within the assembly, when tested as speci

35、fied in 4.4.1. 3.7.2 Insulation resistance. The insulation resistance of the cable assembly shall be a minimum of 100 megohms when tested as specified in 4.4.2, except the insulation resistance of a shielded conductor shall be a minimum of 30 megohms. Provided by IHSNot for ResaleNo reproduction or

36、networking permitted without license from IHS-,-,-MIL-DTL-3885G 6 3.7.3 Dielectric withstanding voltage. There shall be no evidence of voltage breakdown when tested as specified in 4.4.3. 3.7.4 Contact resistance variation (applicable only to assemblies using tinsel conductors). The contact resistan

37、ce variation of each terminal and the tinsel conductor shall not exceed 0.06 ohm when tested as specified in 4.4.4. 3.8 Mechanical requirements. 3.8.1 Interchangeability. Connectors shall be tested as specified in 4.5.1. Like units, assemblies, and subassemblies shall be physically and functionally

38、interchangeable, without modification. Individual items shall not be handpicked for fit. 3.8.2 Soldering. MIL-HDBK-454, requirement 5, provides guidance on soldering of electrical connections. All soldered electrical connections shall be tested in accordance with 4.5.2. 3.8.3 Pull. After being subje

39、cted to the test specified in paragraph 4.5.3, the cable assembly shall show no straining of individual conductors (when visible without major disassembly) or physical damage, and shall meet the requirements of 3.7.1, 3.7.2, 3.7.3, and 3.8.5. The pull shall be applied gradually to the required force

40、 and held at that force for 30 seconds. 3.8.4 Pull on connector components. Terminals and taper pins shall not pull off of the conductor ends or out of connectors when subjected to the test specified in 4.5.4. 3.8.5 Immersion (cable assemblies with watertight connectors and splices covered with mold

41、ed rubber or shrinkable tubing). Cable assemblies shall be subjected to the test specified in 4.5.5. There shall be no evidence of moisture penetration into the connector, splice, or molded sections. The tested cable assemblies shall meet the requirements of insulation resistance (see 3.7.2). 3.8.6

42、Durability. Connectors that must be assembled to given dimensions, and that must be potted or molded in accordance with the information contained on the cable assembly drawing, shall be subjected to the durability test specified in 4.5.6. Following the test, and while still mated, the connectors sha

43、ll meet the electrical requirements of 3.7. In addition, there shall be no physical damage, and the force required to unmate the connectors shall be within 10 percent of that measured prior to performing the durability test (see 6.6). 3.9 Service conditions. 3.9.1 Grind test (cables assemblies with

44、molded or potted components only). After grinding as specified in 4.6.1, molded and potted components of the cable assembly shall show no voids or pits when viewed with 3X magnification. 3.9.2 Low-temperature flexibility (cable assemblies with added transition). Each portion of a cable assembly cont

45、aining a splice, crotch, or cable to jacket transition, shall be tested as specified in 4.6.2. Upon examination after test, there shall be no visible cracks, separation of the Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-DTL-3885G 7 bond, or o

46、ther damage in the molded section or adjacent portion of the cable jacket. Following the test, the cable assembly shall meet the requirements of 3.7.1, 3.7.2, and 3.7.3. 3.9.3 Thermal shock. After being subjected to the test specified in 4.6.3, the assembly shall not exhibit any physical damage. Fol

47、lowing the test, the cable assembly shall meet the requirements of 3.7.1, 3.7.2, and 3.7.3. 3.9.4 Moisture resistance (cable assemblies with watertight connectors). After testing as specified in 4.6.4, there shall be no visual evidence of blistering, corrosion, or exposure of the base metal of the c

48、onnector, degradation of elastomers or separation of bonded materials. Following the test, the cable assemblies shall meet the requirements of 3.7.2. 3.9.5 Conductor insulation overcure (molded or heat-cured potted cable assemblies only). The same assembly that has met the requirements of 3.9.3 shal

49、l be tested as specified in 4.6.5. The insulation of each conductor within any portion of the cable jacket encased by a molded crotch, molded termination, or molded section shall be tested for overcure. The percent elongation shall be not less than 90 percent of the minimum unaged elongation requirement of the appropriate Government-approved material specification as tested under method 3031 of FED-STD-228. 3.9.6 Be