DLA MIL-DTL-55021 D-2011 CABLE ELECTRICAL SHIELDED SINGLES SHIELDED AND JACKETED SINGLES TWISTED PAIRS AND TRIPLES INTERNAL HOOKUP 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, OH 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-55021D 18 July 2011 SUPERSEDING MIL-DTL-55021C 11 August 2000 DETAIL SPECIFICATION CABLE, ELECTRICAL, SHIELDED SINGLES, SHIELDED AND JACKETED SINGLES, TWISTED PAIRS AND TRIPLES, INTERNAL HOOKUP, GENERAL SPECIFICATION

3、 FOR This specification is approved for use by all Departments and Agencies of the Department of Defense. 1. SCOPE 1.1 Scope. This specification covers electrical cables consisting of unshielded and unjacketed, shielded, jacketed, or shielded and jacketed twisted pairs and triples, and shielded or s

4、hielded and jacketed singles. The cable is intended for internal wiring of electrical equipment for application temperatures of -40 to 105 degrees Centigrade (C), or -65 to 200 C. Cables constructed with polyvinyl chloride (PVC) - insulated wires or jackets are not to be used for aerospace applicati

5、ons. 1.2 Classification. 1.2.1 Type designation. The type designation of cable consists of the following form, and as specified (see 6.2): B 24 C 904 - 903 - 902 P Covering over component Color of Color of Color of wire(s) (see 1.2.1.5) 1st wire 2nd wire 3rd wire (see 1.2.1.4) (see 1.2.1.4) (see 1.2

6、.1.4) Conductor material (see 1.2.1.3) Conductor size (see 1.2.1.2) Wire type (see 1.2.1.1) Type designation example: B24C904-903-902P (MIL-DTL-16878/1 type wire; 24 AWG conductor size; copper material; 1st wire white base color, black first stripe, yellow second stripe; 2nd wire white base color, b

7、lack first stripe, orange second stripe; 3rd wire white base color, black first stripe, red second stripe; covered with polyvinyl chloride jacket). Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-DTL-55021D 2 1.2.1.1 Type of wire. The type of wir

8、e is identified by a one- or two-letter symbol as specified in table I. TABLE I. Type of wire. Symbol type Wire specification 1/B C D E EE BJ CJ DJ MIL-DTL-16878/1 MIL-DTL-16878/2 MIL-DTL-16878/3 NEMA HP 3 NEMA HP 3 MIL-DTL-16878/17 MIL-DTL-16878/18 MIL-DTL-16878/19 1/ MIL-DTL-16878 wire with PVC in

9、sulation should not be used for aerospace applications. 1.2.1.2 Conductor size. The conductor size is identified by a one- or two-digit number that indicates the American Wire Gauge (AWG) size. 1.2.1.3 Conductor material. The conductor material is identified by the letter “C” for copper, the letter

10、“S” for copper clad steel, or the letter “H” for high strength copper alloy. 1.2.1.4 Color code. The color code of each individual wire is identified by a number built up from the digits designating the colors as specified in 3.5.1. For single shielded and single shielded and jacketed constructions,

11、 a dash should not be used. The color code designators for wires 2 and 3 of a twisted pair and triplet are separated by a dash. Two groups of numbers indicate a twisted pair, three groups indicate a twisted triple. Any order of color code designators is acceptable. 1.2.1.5 Construction of covering o

12、ver the finished cable. The covering of the finished cable is identified by a one-, two-, or three-letter symbol as specified in table II. TABLE II. Finished cable covering nomenclature. Symbol 1/Covering over finished cable 2/U Unjacketed and unshielded P Polyvinyl chloride (PVC) jacket FFluorinate

13、d ethylene propylene (FEP) jacket JPolyamide jacket TPolytetrafluoroethylene (PTFE) jacket SShielded and unjacketed SFShielded and covered with FEP jacket SPShielded and covered with PVC jacket SJShielded and covered with Polyamide jacket STWShielded and covered with wrapped PTFE jacket STXShielded

14、and covered with extruded PTFE jacket 1/ All single conductor constructions must include shielding; jacketing is optional. 2/ PVC insulated cable should not be used for aerospace applications. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-DTL-5

15、5021D 3 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 examples. While every ef

16、fort 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 Specifications, standards, and hand

17、books. 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. FEDERAL STANDARD FED-STD-228 - Cable and Wire, Insulated; Methods of T

18、esting DEPARTMENT OF DEFENSE SPECIFICATIONS MIL-C-572 - Cords, Yarns and Monofilaments Organic Synthetic Fiber MIL-DTL-16878 - Wire, Electrical, Insulated, General Specification for MIL-DTL-16878/1 - Wire, Electrical, Polyvinyl Chloride (PVC) Insulated, 105 Deg. C, 600 Volts (Not for Navy Shipboard

19、Use) MIL-DTL-16878/2 - Wire, Electrical, Polyvinyl Chloride (PVC) Insulated, 105 Deb. C, 1000 Volts (Not for Navy Shipboard Use) MIL-DTL-16878/3 - Wire, Electrical, Polyvinyl Chloride (PVC) Insulated, 105 Deg. C, 3000 Volts (Not for Navy Shipboard Use) MIL-DTL-16878/17 - Wire, Electrical, Polyvinyl

20、Chloride (PVC) Insulated, Polyamide Jacket, 105 Deg. C, 600 Volts (Not for Navy Shipboard Use) MIL-DTL-16878/18 - Wire, Electrical, Polyvinyl Chloride (PVC) Insulated, Polyamide Jacket, 105 Deg. C, 1000 Volts, (Not for Navy Shipboard Use) MIL-DTL-16878/19 - Wire, Electrical, Polyvinyl Chloride (PVC)

21、 Insulated, 105 Deg. C, 3000 Volts, Polyamide Covering (Not for Navy Shipboard Use) MIL-DTL-55021/1 - Cable, Electrical, Shielded Singles, Shielded and Jacketed Singles, Twisted Pairs and Triples, Internal Hookup, -40 to 105 C MIL-DTL-55021/2 - Cable, Electrical, Shielded Singles, Shielded and Jacke

22、ted Singles, Twisted Pairs and Triples, Internal Hookup, -65 to 200 C DEPARTMENT OF DEFENSE STANDARD MIL-STD-681 - Identification Coding and Application of Hookup and Lead Wire (Copies of these documents are available online at https:/assist.daps.dla.mil/quicksearch/ or from the Standardization Docu

23、ment Order Desk, 700 Robbins Avenue, Building 4D, Philadelphia, PA 19111-5094.) Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-DTL-55021D 4 2.3 Non-Government publications. The following documents form a part of this document to the extent speci

24、fied herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract. ASTM INTERNATIONAL ASTM D3032 - Standard Test Methods for Hookup Wire Insulation ASTM D4066 - Standard Classification System for Nylon Injection and Extrusion Materials (Copies of

25、these documents are available online from http:/ww w.astm.org or from the ASTM International, P.O. Box C700, 100 Barr Harbor Drive, West Conshohocken, PA 19428-2959.) NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA) NEMA HP 3 - Electrical and Electronic PTFE (Polytetrafluoroethylene) Insulated H

26、igh Temperature Hook-up Wire; Types ET (250 Volts), E (600 Volts), and EE (1000 Volts) (Application for copies should be addressed to the National Electrical Manufacturers Association, 1300 North 17th Street, Suite 1847, Rosslyn, VA 22209.) 2.4 Order of precedence. Unless otherwise noted herein or i

27、n 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 unless a specific exemptio

28、n 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 the specification sheet, the latter

29、shall govern. 3.2 First article. When specified (see 6.2), a sample shall be subjected to first article inspection in accordance with 4.4. 3.3 Recycled, recovered, or environmentally preferable materials. Recycled, recovered, or environmentally preferable materials should be used to the maximum exte

30、nt 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 will enable the cable

31、 to meet the performance requirements of this specification. 3.4.1 Basic wire. All basic wires used in the construction of the cable shall be of the same type (see 1.2.1.1). All basic wires shall conform to either MIL-DTL-16878 or NEMA HP 3. 3.4.2 Shielding. When shielding is specified, the cable sh

32、ield strand size shall be based on the cable core outside diameter and as specified in table III. The cable core outside diameter shall be based on the basic wire diameter multiplied by 1.0 for singles, 1.64 for pairs, and 1.95 for triples. The metallic coating of the copper strands of the shield sh

33、all be the same as the metallic coating of the conductor of the basic wire. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-DTL-55021D 5 TABLE III. Cable shield strand size. Cable core outside diameter Shield strand size .060 inch or smaller 38 A

34、WG .061 to .310 inch 36 AWG .311 to .750 inch 34 AWG .751 inch or larger 32 AWG 3.4.2.1 Braid angle and shield coverage. Braid angle and shield coverage shall be as specified in the applicable specification sheet. 3.4.3 Cable jacket. When jacketing is specified, the cable jacket shall be as specifie

35、d herein or in the applicable specification sheet. 3.5 Design and construction. 3.5.1 Color coding. Unless otherwise specified (see 6.2), color coding of individual wires and jackets shall be in accordance with MIL-STD-681. 3.5.2 Wire twist (twisted pairs and triples). The basic wires shall be group

36、ed together and cabled so that the individual wire is not twisted and a minimum overall diameter is obtained. Unless otherwise specified in the contract or order (see 6.2), fillers shall not be used. 3.5.2.1 Direction of lay. The direction of lay may be left hand or right hand. 3.5.2.2 Length of lay

37、. The length of lay shall be as specified in the applicable specification sheet. 3.5.3 Covering over finished cable. 3.5.3.1 Shield. When a shield is specified in the cable construction (see 1.2.1.5), it shall be applied over the wire(s) as specified herein or in the applicable specification sheet.

38、3.5.3.2 Jacket. When a jacket is specified in the cable construction (see 1.2.1.5), it shall be applied over the shielded or unshielded construction as specified herein or in the applicable specification sheet. 3.5.3.3 Jacket material. 3.5.3.3.1 Polyamide. Polyamide jackets shall be applied concentr

39、ically and shall have a wall thickness as specified in the applicable specification sheet. Polyamide material shall conform to ASTM D4066, type PA 622, grade E 22, or to MIL-C-572. 3.5.3.3.2 Polyvinyl chloride (PVC). PVC jackets shall have a wall thickness as specified in the applicable specificatio

40、n sheet. The tensile strength and elongation of the jacket shall be 1,800 psi minimum and 150 percent minimum, respectively. 3.5.3.3.3 Fluorinated ethylene propylene (FEP). FEP jackets shall have a wall thickness as specified in the applicable specification sheet. The tensile strength and elongation

41、 of the jacket shall be 3,000 psi minimum and 200 percent minimum, respectively. 3.5.3.3.4 Extruded or taped polytetrafluoroethylene (PTFE). Extruded or taped PTFE jackets shall have a wall thickness as specified in the applicable specification sheet. The tensile strength and elongation of the jacke

42、t shall be 3,000 psi minimum and 150 percent minimum, respectively. 3.6 Performance. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-DTL-55021D 6 3.6.1 Dielectric strength. 3.6.1.1 Unshielded cable. The unshielded cable shall withstand the applic

43、able voltage specified in table IV for not less than 1 minute without breakdown. 3.6.1.2 Shielded cable. The shielded cable shall withstand the applicable voltage specified in table IV for not less than 1 minute without breakdown. 3.6.2 Cold bend. 3.6.2.1 Unshielded cable. Unless otherwise specified

44、 in the contract or order (see 6.2), cold bend requirements are not applicable for unshielded cable constructions. TABLE IV. Dielectric strength voltage. Type of wire Basic wire spec Conductor size Volts (rms) B however, final acceptance and shipment shall be withheld until group B inspection has sh

45、own that the corrective action was successful. In the event of failure after re-inspection, information concerning the failure shall be provided to the cognizant inspection activity. 4.6 Methods of inspection. 4.6.1 Visual and mechanical inspection. Cable, components, and wire shall be subjected to

46、a thorough visual and mechanical inspection to ascertain that the materials, construction, workmanship, marking, colors, dimensions, and lengths are in accordance with the applicable requirements. 4.6.2 Dielectric strength. 4.6.2.1 Unshielded cable. The unshielded cable dielectric strength test shal

47、l be conducted in accordance with method 6111 of FED-STD-228 between each conductor and other conductors at the applicable voltage specified in table IV. The minimum immersion period is 4 hours for unshielded/unjacketed cables. Immersion is not required for jacketed cables. 4.6.2.2 Shielded cable. T

48、he shielded cable dielectric strength test shall be conducted in accordance with method 6111 of FED-STD-228. The applicable test voltage (see table IV) shall be applied between the conductor and shield for singles and between each conductor and the other conductors and shield in common for pairs and

49、 triples. Immersion is not required. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-DTL-55021D 10 4.6.3 Cold bend. Specimens of the finished cable shall have each conductor stripped, approximately 1 inch at each end, to the bare conductor and shall have one end attached to a mandrel and the other end weighted. After conditioning for 4 hours at a temperature o