DLA MIL-DTL-49055 F-2012 CABLES POWER ELECTRICAL (FLEXIBLE FLAT UNSHIELDED) (ROUND CONDUCTOR) GENERAL SPECIFICATION FOR.pdf

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1、AMSC N/A FSC 6145 INCH-POUND MIL-DTL-49055F 14 November 2012 SUPERSEDING MIL-DTL-49055E 9 January 2008 DETAIL SPECIFICATION CABLES, POWER, ELECTRICAL, (FLEXIBLE, FLAT, UNSHIELDED), (ROUND CONDUCTOR), GENERAL SPECIFICATION FOR This specification is approved for use by all Departments and Agencies of

2、the Department of Defense. 1. SCOPE 1.1 Scope. This specification covers flexible, flat, unshielded electrical cables with either solid or stranded inner round conductors. 2. APPLICABLE DOCUMENTS 2.1 General. The documents listed in this section are specified in sections 3, 4, or 5 of this specifica

3、tion. 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 specified requirements

4、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 Specifications, standards, and handbooks. The following specifications, standards and handbooks form a part of this document to the extent specified herein. Unless otherwi

5、se specified, the issues of these documents are those cited in the solicitation or contract. Comments, suggestions, or questions on this document should be addressed to Defense Supply Center Columbus, ATTN: DSCC-VAI, P.O. Box 3990, Columbus, Ohio 43218-3990, or email to WireCabledscc.dla.mil. Since

6、contact information can change, you may want to verify the currency of this address information using the ASSIST Online database at https:/assist.dla.mil. Reactivated after 2 August 2006 and may be used for new and existing designs and acquisitions. Provided by IHSNot for ResaleNo reproduction or ne

7、tworking permitted without license from IHS-,-,-MIL-DTL-49055F 2 FEDERAL SPECIFICATION TT-I-735 - Isopropyl Alcohol FEDERAL STANDARD FED-STD-228 - Cable and Wire, Insulated; Method of Testing. DEPARTMENT OF DEFENSE SPECIFICATIONS MIL-DTL-5624 - Turbine Fuel, Aviation, Grades JP-4, JP-5 and JP5/JP-8S

8、T MIL-PRF-23699 - Lubricating Oil, Aircraft Turbine Engines, Synthetic Base, NATO Code Number 0-156 DEPARTMENT OF DEFENSE STANDARDS MIL-STD-104 - Limits for Electrical Insulation Color. MIL-STD-202 - Test Methods for Electronic and Electrical Component Parts. MIL-STD-681 - Identification Coding and

9、Application of Hook Up and Lead Wire. MIL-STD-1285 - Marking of Electrical and Electronic Parts. (Copies of these documents are available online at https:/assist.dla.mil/quicksearch/ or from the Standardization Document Order Desk, 700 Robbins Avenue, Building 4D, Philadelphia, PA 19111-5094.) 2.3 N

10、on-Government publications. The following documents form a part of this document to the extent specified herein. Unless otherwise specified, the documents are the issues of the documents cited in the solicitation or contract (see 6.2). Provided by IHSNot for ResaleNo reproduction or networking permi

11、tted without license from IHS-,-,-MIL-DTL-49055F 3 ASTM INTERNATIONAL ASTM-B3 - Soft or Annealed Copper Wire ASTM-B33 - Tinned Soft or Annealed Copper Wire for Electrical Purposes ASTM-B286 - Copper Conductors for Use in Hookup Wire for Electronic Equipment ASTM-B298 - Silver-Coated Soft or Annealed

12、 Copper Wire ASTM-B355 - Nickel-Coated Soft or Annealed Copper Wire ASTM-D740 - Methyl Ethyl Ketone ASTM-D3032 - Hookup Wire Insulation ASTM-G21 - Determining Resistance of Synthetic Polymeric Materials to Fungi (Copies of these documents are available online at http:/www.astm.org or from the Americ

13、an Society for Testing and Materials, P.O. Box C700, 100 Barr Harbor Drive, Conshohocken, PA 19428-2959). NCSL INTERNATIONAL NCSL-Z540.3 - Requirements for the Calibration of Measuring and Test Equipment (Copies of this document are available from http:/www.ncsli.org or from NCSL International, 2995

14、 Wilderness Place, Suite 107, Boulder, CO 80301.) UNDERWRITERS 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, Inc., Publication Stock, 333 Pfingsten Road,

15、 Northbrook, IL 60002-2096.) 2.4 Order of precedence. In 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 regu

16、lations unless 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 sheet. In the event of any conflict between the requirements of this specification and th

17、e specification sheet, the latter shall govern. 3.2 Qualification. Cables furnished under this specification shall be products that are authorized by the qualifying activity for listing on the applicable qualified products list before contract award (see 4.6 and 6.3). Provided by IHSNot for ResaleNo

18、 reproduction or networking permitted without license from IHS-,-,-MIL-DTL-49055F 4 3.3 Materials. The materials for the principal components of the cable shall be as specified herein. Prior approval to use substitute material must be obtained from the qualifying activity. When a definite material i

19、s not specified, a material shall be used that will enable the finished products to meet the performance requirements of this specification. Acceptance or approval of any constituent material shall not be construed as a guaranty of the acceptance of the finished product. All materials used in the ma

20、nufacture of cables furnished hereunder shall be of such quality and form that the finished product conforms to the requirements of this specification. All materials used shall conform to the requirements specified herein. 3.3.1 Insulation material. Insulation materials are listed in table I. These

21、materials shall have temperature ratings and aging temperatures as specified herein. 3.3.2 Conductors. Conductors shall be stranded, bare or coated, as specified (see 3.1). All conductors shall conform to ASTM-B286 requirements. 3.3.2.1 Conductor strands. a. Bare copper conductor. Bare copper conduc

22、tors shall conform to soft or annealed copper conductor in accordance with ASTM-B3. b. Tin-coated copper conductor. Tin-coated copper conductor shall conform to the continuity and adherence coating requirements for tinned, soft or annealed copper conductor in accordance with ASTM-B33. c. Silver-coat

23、ed copper conductor. Silver-coated copper conductor shall have a thickness of not less than 40 microinches of silver and meet the continuity of coating requirements of ASTM-B298. d. Nickel-coated copper conductor. Nickel-coated copper conductor shall have a thickness of not less than 50 microinches

24、of nickel and meet the continuity of coating requirements of ASTM-B355. TABLE I. Insulation materials, ratings, and aging temperatures. Material 1/Temperature rating (max) 1/Aging temperature Polyvinylchloride (PVC) 2/105C 136C Polyethyleneterephthalate (PET) 105C 136C Polyvinylidene fluoride (PVDF)

25、 135C 150C Polyalkene, crosslinked 150C 225C Ethylene tetrafluoroethylene (ETFE) 150C 200C Ethylene tetrafluoroethylene modified, crosslinked 150C 200C Ethylene-chlorotrifluoroethylene (ECTFE) 150C 200C Fluorinated ethylene propylene (FEP) 200C 230C FEP-polyimide tape 200C 230C Polytetrafluoroethyle

26、ne (PTFE) 260C 300C Perfluoroalkoxy (PFA) 260C 285C 1/ For information only. 2/ Not for aerospace application. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-DTL-49055F 5 3.3.2.2 Stranded conductors. Stranded conductors shall be concentrically-u

27、nilay or concentrically stranded in accordance with ASTM-B286. Conductors shall not be coated after stranding (no overcoating). Individual strands shall be coated before stranding and meet all the requirements of the basic wires specified in 3.3.2.1. 3.3.3 Recycled, recovered, or environmentally pre

28、ferable materials. Recycled, 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. 3.4 Design and constructio

29、n. Design and construction of the cable shall be as specified herein and in the applicable specification sheet (see 3.1). 3.4.1 Conductors. The size and number of the conductors shall be as specified in the applicable specification sheet. 3.4.2 Wire spacing. The acceptable spacing of the wires in th

30、e cable shall be as specified in the applicable specification sheet. 3.4.3 Finished cable. Finished cable shall conform to the configuration as specified in the applicable specification sheet. 3.4.3.1 Lengths and splices. All delivered cable shall be free of conductor splices. There shall be no spli

31、ces of the cable as a whole unit. Unless otherwise specified (see 4.4.1, 6.2 and table II), minimum lengths required are 10 feet with a minimum average of 25 feet per shipment. 3.4.3.2 Cable weight. The maximum cable weight per thousand feet shall be in accordance with the applicable specification s

32、heet (see 3.1 and 4.6.1.1). TABLE II. Finished cable lengths. Cable width Minimum percentage of footage in shipment with lengths greater than: Inches 100 ft 50 ft 25 ft 10 ft .5 50 80 - 100 1.0 - 50 80 100 2.0 - 50 80 100 3.4.3.3 Color. The color shall be in accordance with the applicable specificat

33、ion sheet (see 3.1) and shall be in accordance with MIL-STD-104, class 1. 3.5 Insulation flaws. One hundred percent of the finished cable shall be subjected to the insulation flaws test specified in 4.6.3. Test voltages shall be as specified in the applicable specification sheet (see 3.1). 3.6 Diele

34、ctric withstanding voltage. Cables shall withstand the voltage specified in the applicable specification sheet (see 3.1), and there shall be no evidence of breakdown or flashover. 3.7 Insulation resistance. Cable insulation resistance shall be not less than 500 megohms1,000 feet when subjected to th

35、e test specified in 4.6.5. 3.8 Conductor continuity. One hundred percent of the finished cable shall be subjected to the conductor continuity test specified in 4.6.8. There shall be no indication of discontinuity in any conductor. Provided by IHSNot for ResaleNo reproduction or networking permitted

36、without license from IHS-,-,-MIL-DTL-49055F 6 3.9 Conductor resistance. Cable conductor direct current (dc) resistance shall not exceed the value specified in the applicable specification sheet (see 3.1). 3.10 Thermal shock. Cables shall withstand the temperature cycles specified (see 3.1), without

37、cracking of the insulation and with no evidence of delamination or visible change. The insulation shrinkage shall not be greater than that specified in the applicable specification sheet (see 3.1). 3.11 Flammability. Cables shall not convey flame along their length and shall not convey flame to comb

38、ustible materials in the vicinity when subjected to the flammability test specified in 4.6.9. 3.12 Folding. Cables shall withstand 180 transverse folding and unfolding without indicating loss of continuity. There shall be no evidence of cracking, delamination, or fracturing, and the cables shall sub

39、sequently meet the dielectric withstanding voltage requirement. 3.13 High-temperature aging. Cables shall withstand high-temperature aging. There shall be no cracking or separation of the insulation, and the cables shall subsequently meet the dielectric withstanding voltage requirement. 3.14 Flexing

40、 endurance. Cables shall exhibit no discontinuity or evidence of cracking, fracturing, delamination, or rupturing when subjected to the flexing endurance test specified in 4.6.12. 3.15 Moisture resistance. The insulation resistance of the cables shall be not less than the value specified in the spec

41、ification sheet (see 3.1), and the insulation shall not exhibit any evidence of delamination, when the cables are subjected to the test specified in 4.6.13. 3.16 Low pressure (maximum rated temperature). The cable insulation shall show no evidence of shrinkage greater than .0625 inch (1.6 mm) at eit

42、her end of the cable specimen, ballooning, bubbling, voids, or insulation weight loss greater than 1 percent, when subjected to the test specified in 4.6.14. 3.17 Fungus resistance. The cables shall be fungus resistant. 3.18 Fluid immersion. The cables shall show no change in weight greater than 5 p

43、ercent and no cracking or separation of the insulation when subjected to the immersion tests specified in 4.6.16. 3.19 Marking. Unless otherwise specified (see 3.1 and 6.2), cables shall be marked in accordance with the following: a. Part or Identifying Number (PIN) (see 3.1). b. Manufacturers name

44、or symbol, CAGE code, and the date shall be in accordance with MIL-STD-1285. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-DTL-49055F 7 The printing shall be legible and in a contrasting color. Color used for identification coding shall be in a

45、ccordance with MIL-STD-681. All number 1 conductors shall be identified. The printed marking shall be located along the reference edge of the cable at 12 inch (305 mm) maximum repeat. Marking is required on cables with 0.050 inch (1.3 mm) (or wider spacing of conductors (see figure 1). .1250.10 .050

46、 MIN TYPICAL FLAT CABLE NOTES: 1. Dimensions are in inches. 2. Metric equivalents are for information only. FIGURE 1. Identification marking. IDENTIFICATION MARKING Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-DTL-49055F 8 3.20 Durability of i

47、dentification. The identification marking shall withstand a minimum of 125 cycles (250 strokes) when tested as specified in 4.6.17. 3.21 Shrinkage. The cable shall have no separation of the insulation and the insulation shrinkage shall be not greater than that specified in the applicable specificati

48、on sheet (see 3.1) when tested as specified in 4.6.18. 3.22 Workmanship. The cable shall be free of kinks, abrasions, and cracked or peeled surfaces. The cable shall be a uniform and consistent product and shall be free from defects that adversely affect the serviceability of the product. 4. VERIFICATION 4.1 Classification of inspections. The inspection requirements specified herein are classified as follows: a. Qualification inspection (see 4.4). b. Conformance inspection (see 4.5). 4.2 Requirements cross-reference matrix. Table III provides a cross-reference matrix