DLA MIL-DTL-55446 D-2011 CABLES TELEPHONE SWITCHBOARD PLASTIC INSULATED PLASTIC JACKETED.pdf

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1、AMSC N/A FSC 6145 INCH-POUND MIL-DTL-55446D 9 November 2011 SUPERSEDING MIL-DTL-55446C 21 November 2006 DETAIL SPECIFICATION CABLES, TELEPHONE, SWITCHBOARD: PLASTIC INSULATED, PLASTIC JACKETED Inactive for new design after 16 June 1997. This specification is approved for use by all Departments and A

2、gencies of the Department of Defense. 1. SCOPE 1.1 Scope. This specification covers plastic insulated, plastic jacketed, telephone switchboard cables consisting of number 22 AWG conductors in combinations of pairs and singles ranging from 4 pairs to 201 pairs (see 1.2). 1.2 Classification. The types

3、 of switchboard cables (see 6.2) covered by this specification are listed in table I. TABLE I. Switchboard cable types. Number of pairs and singles Total number of conductors Maximum average overall diameter of finished cables (No.22 AWG) inches (mm) 1/4 pairs 8 .360 (9.14) 5 pairs, 5 singles 15 .44

4、0 (11.18) 6 pairs 12 .390 (9.91) 8 pairs, 8 singles 24 .480 (12.19) 10 pairs, 10 singles 30 .540 (13.72) 11 pairs 22 .470 (11.94) 16 pairs 32 .530 (13.46) 20 pairs 40 .560 (14.22) 20 pairs, 10 singles 50 .610 (15.49) 20 pairs, 20 singles 60 .660 (16.76) 25 pairs 50 .610 (15.49) 26 pairs, 26 singles

5、78 .720 (18.29) 30 pairs 60 .640 (16.26) 40 pairs 80 .720 (18.29) 41 pairs, 41 singles 123 .830 (21.08) 51 pairs 102 .800 (20.32) 76 pairs 152 .910 (23.11) 101 pairs 202 1.030 (26.16) 101 pairs, 100 singles 302 1.250 (31.75) 201 pairs 402 1.410 (35.81) 1/ Dimensions are in inches. Metric equivalents

6、 are given for information only. Comments, suggestions, or questions on this document should be addressed to DLA Land and Maritime, ATTN: VAI, P.O. Box 3990, Columbus, Ohio 43218-3990, or email to WireCabledla.mil. Since contact information can change, you may want to verify the currency of this add

7、ress information using the ASSIST Online database at https:/assist.daps.dla.mil. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-DTL-55446D 2 2. APPLICABLE DOCUMENTS 2.1 General. The documents listed in this section are specified in sections 3, 4

8、, 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, document users are cautioned that they must meet all

9、 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 part of this document to the extent specified h

10、erein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract (see 6.2). FEDERAL STANDARD FED-STD-228 - Cable and Wire, Insulated; Methods of Testing COMMERCIAL ITEM DESCRIPTION A-A-59551 - Wire, Electrical, Copper (Uninsulated) DEPARTMENT OF DEFENS

11、E STANDARD MIL-STD-104 - Limits For Electrical Insulation Colors (Copies of 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.) Provided by IHSNot for ResaleNo

12、reproduction or networking permitted without license from IHS-,-,-MIL-DTL-55446D 3 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 solicitation or co

13、ntract. NCSL International NCSL-Z540.1 - Calibration Laboratories and Measuring and Test Equipment, General Requirements. (Copies of this document are available from http:/www.ncsli.org or from the National Conference of Standards Laboratories (NCSL), 2995 Wilderness Place, Suite 107, Boulder, CO 80

14、381-5404.) 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, however, supersedes applicable laws and regulation

15、s unless a specific exemption has been obtained. 3. REQUIREMENTS 3.1 Description. The cables covered by this specification are switchboard cables, the conductors of which are No. 22 AWG solid copper wire, tinned and individually insulated with an extruded polyvinyl chloride (PVC) covering. The insul

16、ation is color coded for convenient identification of pairs and single wires. The core is made up of pairs and single wires as required and cabled either concentrically in layers or in unit construction, depending on its size. The individual units of unit-constructed cables are bound with color code

17、d spaced servings of yarn or polyethylene tape binders. The core is covered with an overlapped spiral winding of paper or, at the option of the manufacturer, polyester tape. Over this polyester covering and beneath the outer sheath is a nylon ripcord to facilitate stripping. The outer sheath is an e

18、xtruded PVC jacket. 3.2 Recycled, recovered, or environmentally preferable 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 econ

19、omically advantageous life-cycle costs. 3.3 Construction. The cable shall be made up of the number of pairs and single wires as required (see 1.2). The pairs shall be twisted, with the maximum length of pair twist not to exceed 6 inches (152.40 mm). To minimize cross talk, each pair in a concentric

20、type cable or each pair in a unit (for unit construction) shall have a twist with a length of lay different from that of any other pair in the cable or unit, respectively. 3.4. Materials. The materials for the cables covered by this specification shall be as specified herein. When a definite materia

21、l is not specified, the best material commercially available for the purpose intended shall be used. 3.5 Conductors. Each conductor of the cables shall be No. 22 AWG solid, soft, or drawn and annealed tinned copper wire conforming to A-A-59551. 3.5.1 Joints in conductors. If joints are necessary, th

22、e joints shall be made by brazing with silver solder or by welding. The diameter of the wire measured at the joint shall be within the maximum diameter tolerance for the conductors (see 3.7.2). The conductor surface at the joint shall be smooth and free from lumps and sharp projections. The tensile

23、strength of a section of the conductor containing a joint shall be not less than 90 percent of the tensile strength of an adjacent section of the conductor of equal length that is free from joints. The resistance of a section of the conductor not exceeding 6 inches Provided by IHSNot for ResaleNo re

24、production or networking permitted without license from IHS-,-,-MIL-DTL-55446D 4 (152.40 mm) in length, which includes the joint, shall be not more than 105 percent of the resistance of an adjacent section of equal length that is free from joints. 3.6 Insulation. Each conductor of the cable shall be

25、 insulated with an extruded layer of semi-rigid PVC, conforming to a medium-low temperature polyvinylchloride (PVC) and polyvinylchloride acetate type IP compound. 3.6.1 Insulation thickness. The extruded layer of insulating compound applied to each conductor shall be not less than .008 inch (.203 m

26、m) thick. 3.6.2 Diameter of insulated conductor. The diameter of the insulated conductor shall be not more than .048 inch (1.22 mm). 3.6.3 Color code. The insulated conductors shall be color coded to allow identification of pairs and single conductors. The color code shall be specified in table II f

27、or pairs and in table III for singles. 3.6.3.1 Insulation color. The insulation color, including stripe colors, shall be within the limits specified in MIL-STD-104. The base color shall be integral. The color striping shall be either integral or applied to the insulation by any commercially accepted

28、 standard method, provided the colors are readily distinguishable on the insulation after the cable has been subjected to the tests of the specification, except for the flame retardation tests. The colors shall be durable and shall not abrade as a result of cable handling or abrasion. TABLE II. Colo

29、r code for pairs. Pair No. Wire Mate Wide stripe (base color) Narrow stripe Narrow stripe Wide strip (base color) P 1 Blue White Blue White P 2 Orange White Orange White P-3 Green White Green White P 4 Brown White Brown White P 5 Slate White Slate White P 6 Blue Red Blue Red P 7 Orange Red Orange Re

30、d P 8 Green Red Green Red P 9 Brown Red Brown Red P 10 Slate Red Slate Red P 11 Blue Black Blue Black P 12 Orange Black Orange Black P 13 Green Black Green Black P 14 Brown Black Brown Black P 15 Slate Black Slate Black P 16 Blue Yellow Blue Yellow P 17 Orange Yellow Orange Yellow P 18 Green Yellow

31、Green Yellow P 19 Brown Yellow Brown Yellow P 20 Slate Yellow Slate Yellow Spare pair: SP 1 White Red Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-DTL-55446D 5 TABLE III. Color code for singles. Single No. Color coding 1/Base color Stripe (wid

32、e) Stripe (narrow) S 1 Blue - - S 2 Orange - - S 3 Green - - S 4 Brown - - S 5 Slate - - S 6 Blue Red White S 7 Orange Red White S 8 Green Red White S 9 Brown Red White S 10 Slate Red White S 11 Blue Black White S 12 Orange Black White S 13 Green Black White S 14 Brown Black White S 15 Slate Black W

33、hite S 16 Blue Yellow White S 17 Orange Yellow White S 18 Green Yellow White S 19 Brown Yellow White S 20 Slate Yellow White Spare single: SS 1 Red White - 1/ Approximate equal widths for both stripes is an acceptable alternative to wide and narrow stripe specified. 3.6.3.2 Color stripe length of la

34、y. The color stripe length of lay shall not exceed 1 inch (25.4 mm). 3.7 Cabling. The required number of pairs and single conductors shall be cabled in layers as a concentric-type construction or in units as a unit-type construction, as shown on figure 1 through figure 6. 3.7.1 Binders. Each individ

35、ual unit of unit-constructed cables shall be spirally bound with a color coded binder of nylon yarn servings or polypropylene or polyethylene tape. The color code of the binders shall conform to the binder colors specified in the applicable cable configuration on figure 2 through figure 6. 3.7.2 Cor

36、e wrapping. The core shall be wrapped with an overlapping spirally applied Kraft electrical grade paper tape having a .005 inch nominal thickness, or with a polyester tape having a .002 inch (.0508 mm) nominal thickness. If a core binder polyethylene or polypropylene tape is used (similar to unit bi

37、nders in 3.7.1), the core wrapping may be omitted. 3.8 Ripcord. A ripcord of double-ply nylon yarn shall be laid over the wrapped cable core directly beneath the cable jacket. 3.9 Jacket. The outer covering shall be a slate-colored plasticized PVC or its copolymer with polyvinyl acetate type JP. The

38、 jacketing compound shall be a medium-low temperature PVC and polyvinylchloride-acetate (PVCA). The jacket shall be suitably stabilized, compounded, and extruded to provide the cable with a tough, flexible, long-life protective covering. The wall thickness of the plastic jacket shall be .030 inch (.

39、762 mm) minimum for core diameters less than 1 inch (25.4 mm), and .040 inch (1.02 mm) minimum for core diameters 1 inch and over. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-DTL-55446D 6 3.9.1 Diameter of finished cables. The outside diamete

40、r of the finished cable shall be in accordance with the applicable cable and diameter specified in table I. 3.10 Electrical requirements. 3.10.1 Continuity. Each conductor in each cable shall be continuous. 3.10.2 Short circuit. Each conductor shall be free of any contact with any other conductor. 3

41、.10.3 Resistance. The dc resistance of each conductor shall not exceed 94 per mile of cable at 20C. 3.10.4 Dielectric strength. The insulation of each conductor shall be capable of withstanding an ac potential of 1,500 volts for one minute. 3.10.5 Insulation resistance. The insulation resistance bet

42、ween each conductor and the remaining conductors connected together shall be not less than 4,000 megohms per 1,000 feet (305 m) at 20 C. 3.11 Physical requirements for insulation. 3.11.1 Tensile strength. The insulation shall have a tensile strength of 2,500 psi. 3.11.2 Elongation. The insulation sh

43、all have an elongation of 100 percent minimum. 3.11.3 Adhesion. The maximum pull required to remove a 1.250 inch (31.8 mm) length of insulation shall be 3 pounds. 3.11.4 Shrinkage. The maximum allowable insulation shrinkback on the conductor shall not exceed .0625 inch (1.59 mm) when the conductor i

44、s exposed to solder at a temperature of 160 C for 20 seconds. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-DTL-55446D 7 FIGURE 1. Cable configuration-layer type construction. Provided by IHSNot for ResaleNo reproduction or networking permitted

45、 without license from IHS-,-,-MIL-DTL-55446D 8 24 CONDUCTORS (8 pairs, 8 singles). 78 CONDUCTORS (26 pairs, 26 singles) FIGURE 2. Cable configuration-unit type construction.Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-DTL-55446D 9 FIGURE 3. Ca

46、ble configuration- 50, 60 and 80 conductors. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-DTL-55446D 10 FIGURE 4. Cable configuration 102, 123 and 152 conductors. Provided by IHSNot for ResaleNo reproduction or networking permitted without lic

47、ense from IHS-,-,-MIL-DTL-55446D 11 FIGURE 5. Cable construction 202 and 302 conductors.Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-DTL-55446D 12 FIGURE 6. Cable construction 402 conductors. 3.11.5 Cold bend. The insulation shall not develop

48、any cracks visible to the unaided eye after being subjected to -18 C for one hour and immediately bent over a .0625 inch (1.59 mm) diameter mandrel. 3.11.6 Flammability. The insulation on a conductor may burn when exposed to an open flame, but shall be self-extinguishing within 5 seconds after the flame is removed. 3.11.7 Compression strength. The insulation shall withstand a compression load of 1,000 pounds without failure. 3.12 Physical requirements for jacket. 3.12.1 Tensile strength. The jacket shall have a minimum tensile strength of 1,800 psi. 3.12.2 Elo