DLA MIL-DTL-55425 E-2011 CABLE TELEPHONE WF-16( ) U.pdf

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1、 AMSC N/A FSC 6145 INCH-POUND MIL-DTL-55425E 15 February 2011 SUPERSEDING MIL-DTL-55425D 19 August 2005 DETAIL SPECIFICATION CABLE, TELEPHONE WF-16( )/U This specification is approved for use by all Departments and Agencies of the Department of Defense. 1. SCOPE 1.1 Scope. This specification covers

2、two (2) pairs of parallel stranded conductors, each pair commonly insulated with high density polyethylene; the pairs twisted together to form a four (4) wire voice/frequency telephone cable designated as Telephone Cable WF-16( )/U (see 6.5 ). 2. APPLICABLE DOCUMENTS 2.1 General. The documents liste

3、d 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 effort has been made to ensure the completeness of this list, docu

4、ment users are cautioned that they must meet all 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

5、part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are cited in the solicitation or contract. FEDERAL SPECIFICATIONS L-P-390 - Plastic Molding and Extrusion Material, Polyethelyene and Copolymers (Low, Medium and High Density). FEDERAL STA

6、NDARDS FED-STD-228 - Cable and Wire, Insulated, Methods of Testing. FED-STD-595/30117 - Colors Used in Government Procurement. Inactive for new design after 14 September 1999. Comments, suggestions, or questions on this document should be addressed to DLA Land and Maritime, ATTN: VAI, P.O. Box 3990,

7、 Columbus, Ohio 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 Online database at https:/assist.daps.dla.mil. Provided by IHSNot for ResaleNo reproduction or networking permitted without

8、 license from IHS-,-,-MIL-DTL-55425E 2 DEPARTMENT OF DEFENSE SPECIFICATIONS MIL-C-572 - Cords, Yarns, and Monofilaments Organic Synthetic Fiber. MIL-Y-1140 - Yarn, Cord, Sleeving, Cloth, and Tape Glass. MIL-DTL-3241 - Reels, Cable (Reels DR-5( ), DR-7( ), DR-8( ), RC 453( )/G, RL-159( )/U) (Copies o

9、f these documents are available online at https:/assist.daps.dla.mil/quicksearch/ 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 specif

10、ied herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract. ASTM INTERNATIONAL ASTM B105 - Hard-Drawn Copper Alloy Wires for Electrical Conductors. ASTM D470 - Methods of Testing Rubber and Thermoplastic Insulated Wire and Cable. ASTM D573 -

11、 Method of Test for Accelerated Aging of Vulcanized Rubber by the Oven Method. ASTM D3953 - Standard Specification for Steel, Seals, Flat, Strapping. ASTM-D4727/D4727M -Standard Specification for Fiberboard Sheet Stock (Container grade) and Cut Shapes Corrugated and Solid. (Copies of these documents

12、 are available online from http:/www.astm.org or from ASTM International, 100 Barr Harbor Drive, P.O. Box C700, West Conshohocken, PA 19428-2959.) 2.4 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 pr

13、ecedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained. 3. REQUIREMENTS 3.1 First article. When specified in the contract, a sample shall be subjected to first article inspection in accordance with 4.2. 3.2 Materials. 3.2

14、.1 Strands. The conductor strands shall be bare, hard-drawn wire, copper alloy #85, in accordance with ASTM B105. Each strand shall be 0.0085 in 0.0001 in (.216 mm .003 mm) in diameter. 3.2.2 Insulating compound. The insulating compound shall be a high density (linear) polyethylene, in accordance wi

15、th L-P-390, type II, class H, grade 1. The insulating compound used on one pair of conductors shall be brown, in accordance with FED-STD-595/30117. Both colors of the insulating compound shall contain 1 +2%,-0% of titanium dioxide ultraviolet inhibitor 3.2.3 Code markers. One conductor of a pair sha

16、ll contain the manufacturers code marker and the other conductor of the same pair the marker for the year of manufacture. The yarn used for marker threads shall be one of the following: a. Glass yarn, form 1, class C, yarn numbers ECE450-1/0, ECE450-1/2 or ECD900-1/2, in accordance with MIL-Y-1140.

17、b. One end of 30 dernier, 40 filament type SAR, for Y yarn in accordance with MIL-C-572. 3.3 Construction. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-DTL-55425E 3 3.3.1 Conductors. Each conductor shall be composed of 7 copper alloy strands a

18、s specified in 3.2.1 3.3.1.1 Stranding. The maximum length of lay of the concentric stranded conductor shall be 0.5 inch (12.7 mm), and the direction of lay shall be left hand. The outside strands shall lie evenly and smoothly around the central strand without crowding. 3.3.2 Insulation. Each pair s

19、hall be insulated with a tight, well centered compound as specified in 3.2.2, with a minimum wall thickness at any point of .014 inch (.356 mm) when measured as specified in method 1018 of FED-STD-228. The insulation shall strip cleanly and readily with the use of pliers. 3.3.2.1 Configuration. Each

20、 conductor pair shall consist of two conductors in parallel mutually insulated in an approximate figure eight cross section. The pair colored olive shall have two “V” shaped tracer ridges. They shall be located and dimensioned as shown on figure1. 3.3.2.2 Separation. Separation of the conductors of

21、each pair is accomplished by snipping the insulation at the end of the pair midway between the conductors and tearing them apart. The tensile force necessary to separate the two wires after snipping shall be not less than one pound and not more than three pounds. 3.3.2.3 Overall diameter. The overal

22、l diameter of each pair shall be as follows: Major axis 0.125.007 in (3.17.18 mm) Minor axis 0.083.005 in (2.11.13 mm) Conductor separation 0.038 005 in (.97.127 mm) between inside surfaces of the conductors. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from I

23、HS-,-,-MIL-DTL-55425E 4 NOTE: This pictorial presentation is for reference purposed only and does not necessarily represent the actual configuration of the finished cable. However, all dimensions and requirements of this specification apply. FIGURE 1. 4-Wire field wire. Provided by IHSNot for Resale

24、No reproduction or networking permitted without license from IHS-,-,-MIL-DTL-55425E 5 3.3.3 Finished cable. Two finished single pairs (one of each color) shall be twisted closely together, with a right hand lay which shall not exceed six inches when averaged over a 10 foot length, to form a twisted

25、two pair assembly. Uniform tension shall be maintained on both pairs during the twisting operation to prevent looping or bunching of the pairs and to assure that each pair supports half the tensile load. 3.3.4 Recycled, recovered, or environmentally preferable materials. Recycled, recovered, or envi

26、ronmentally 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 Performance characteristics. 3.4.1 Tubing (heat shock). The insulated

27、 pair shall show no visible strains or cracking of the insulation when tested as specified in 4.6.1. 3.4.2 Thermal stress cracking. The insulated pair shall show no visible strains or cracking of the insulation when tested as specified in 4.6.2. 3.4.3 Cold bend. The insulated pair shall not crack ei

28、ther before or after aging when tested as specified in 4.6.3 and 4.6.3.1. 3.4.4 Elongation. Insulation elongation shall be not less than 400% when tested as specified in 4.6.4. 3.4.4.1 Elongation after aging. Insulation elongation after aging, when tested as specified in 4.6.4.1, shall have not less

29、 than 80% of elongation as measured in 4.6.4. 3.4.5 Cutting. The average cutting load shall be not less than 70 pounds and the cutting load for any one specimen shall be not less than 60 pounds (see 4.6.5). 3.4.6 Breaking load. The breaking load shall be not less than 77 pounds for each insulated pa

30、ir (see 4.6.6). 3.5 Electrical requirements. 3.5.1 Dielectric strength, separated conductors. The individually insulated conductors shall withstand a potential of 1,000V rms for one minute when tested as specified in 4.7.1. 3.5.2 Attenuation. The attenuation of each pair shall be no greater than sho

31、wn on figure 2 when measured both wet and dry and as specified in 4.7.6. 3.5.3 DC resistance. The direct current (dc) resistance of each pair, at or corrected to 20 C, shall not exceed 282.5 per loop-mile (see 4.7.2). Provided by IHSNot for ResaleNo reproduction or networking permitted without licen

32、se from IHS-,-,-MIL-DTL-55425E 6 FIGURE 2. Attenuation.Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-DTL-55425E 7 3.5.4 Dielectric strength cable. The cable shall withstand a potential of 1,000V rms for one minute when tested as specified in 4.

33、7.3. 3.5.5 Insulation resistance. Insulation resistance of the cable at or corrected to 15.6 C, shall be not less than 5,000 megohms per single conductor mile (see 4.7.4). 3.5.6 Mutual capacitance. The mutual capacitance shall not exceed 0.11 F per pair mile when tested in accordance with 4.7.5. 3.6

34、 Insulation repairs and splices. No insulation repairs or splices shall be allowed. 3.7 Workmanship. The cable shall be manufactured in such a manner as to be of uniform quality and free from defects that will affect life, serviceability, or appearance and shall be in accordance with the applicable

35、portions of 3.2 and 3.3 (see 4.8). 3.8 Recycled, recovered, or environmentally referable 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, an

36、d promotes economically advantageous life cycle costs. 3.9 Prepackaging. Each length of cable shall be fully and evenly wound on a reel conforming to MIL-DTL-3241, type DR-5. Both ends of cable shall be brought out and secured in a position that will permit a continuity check (DC resistance, see 3.5

37、.3). Each reel with cable shall be overwrapped with one thickness of fiberboard conforming to ASTM-D4727/D4727M, Type CF, class weather resistant, variety SW, grade V3C, of sufficient length to extend the full distance between the reel flanges and of sufficient length to overlap the ends by at least

38、 6 inches (152 mm). The overwrap shall be secured with two bands of flat steel strapping conforming to ASTM D3953, type 1, .5 inch wide by 0.020 inch (12.7 mm by 0.508 mm) thick. 4. VERIFICATION 4.1 Classification of inspections. The inspection requirements specified herein are classified as follows

39、: a. First article inspection (see 4.2). b. Conformance inspection (see 4.3). 4.2 First article inspection. Unless otherwise specified in the contract, the first article inspection shall be performed by the contractor. 4.2.1 Units. The contractor shall furnish five (5) one mile lengths of finished c

40、able WD-16( ) each mile wound on reel DR-5 as a sample for approval, if required by the invitation for bids or contracts. 4.2.2 Inspection. The first article inspection shall consist of the inspections specified in subsidiary documents covering the items in 4.4 and the inspections specified in table

41、s I, III and V. 4.3 Conformance inspection. The contractor shall perform the inspections specified in 4.4 and 4.3.1 through 4.3.3. This does not relieve the contractor of his responsibility for performing any additional inspection which is necessary to control the quality of the product and to assur

42、e compliance with all specification requirements. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-DTL-55425D 8 4.3.1 Group A inspection. Each unit on contract shall be inspected for conformance to the inspections specified in table I. Discrete lo

43、ts shall be formed from units that pass this inspection. Factors of lot composition shall be defined herein or in the contract. 4.3.1.1 Order of inspection within group A. Group A inspection shall be performed in an order satisfactory to the Government. 4.3.1.2 Sampling plan. Samples shall be random

44、ly selected in accordance with table II. If one or more defects are found, the lot shall be rescreened and defects removed. After screening and removal of defects, a new sample shall be randomly selected in accordance with table II. If one or more defects are found in the second sample, the lot shal

45、l be rejected and shall not be supplied to this specification. TABLE I. Group A inspection. Inspection Requirement paragraph Test method paragraph Sampling procedure Visual and dimensional Conductors Stranding Insulation Configuration Separation Overall diameter Finished cable Code markers Workmansh

46、ip Electrical DC resistance Dielectric strength, cable Insulation resistance Mutual capacitance 3.3.1 3.3.1.1 3.3.2 3.3.2.1 3.3.2.2 3.3.2.3 3.3.3 3.2.3 3.7 3.5.3 3.5.4 3.5.5 3.5.6 4.8 4.8 4.8 4.8 4.8 4.8 4.8 4.8 4.8 4.7.2 4.7.3 4.7.4 4.7.5 See table II TABLE II. Sample sizes for group A inspection.

47、Lot size Sample size visual and dimensional Sample size electrical 2 to 8 ALL ALL 9 to 150 13 13 151 to 280 20 20 281 to 500 29 29 501 to 1,200 34 34 1,201 to 3,200 42 42 3,201 to 10,000 50 50 10001 to 35,000 60 60 35,001 to 150,000 74 74 150,001 to 500,000 90 90 500,001 and over 102 102 4.3.2 Group

48、 B inspection. Group B inspection shall normally be performed in inspection lots that have passed group A inspection and on samples selected from units that have been subjected to and met the group A inspection. This specification shall conform to table III. Provided by IHSNot for ResaleNo reproduct

49、ion or networking permitted without license from IHS-,-,-MIL-DTL-55425E 9 4.3.2.1 Group B sampling plans. A sample of parts shall be randomly selected in accordance with table IV. If one or more defects are found, the lot shall be rescreened and defects removed. After screening and removal of defects, a new sample of parts shall be