DLA MIL-DTL-38359 E-2011 CABLE POWER ELECTRICAL AIRPORT LIGHTING CROSS-LINKED POLYETHYLENE (XLP).pdf

1、AMSC N/A FSC 6145 INCH-POUND MIL-DTL-38359E 27 September 2011 SUPERSEDING MIL-DTL-38359D 24 January 2011 DETAIL SPECIFICATION CABLE, POWER, ELECTRICAL, AIRPORT LIGHTING, CROSS-LINKED, POLYETHYLENE (XLP) This specification is approved for use by all Departments and Agencies of the Department of Defen

2、se. 1. SCOPE 1.1 Scope. This specification covers 8 AWG single conductor electric power cable of two voltage ranges intended primarily for use in airport lighting series circuits. 1.2 Classification. Cables are of the following classes, as specified: Class 1 3,000 V rms Class 2 5,000 V rms 1.2.1 Par

3、t or Identifying Number (PIN). PINs are of the following form, as specified: Class 1 M38359-3K Class 2 M38359-5K 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

4、 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 of documents cited in sections 3, 4 or 5 of this specificati

5、on, whether or not they are listed. 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

6、address 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-38359E 2 2.2 Government documents. 2.2.1 Specifications, standards and handbooks. The following specifications

7、, standards and handbooks form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those listed in cited in the solicitation or contract. DEPARTMENT OF DEFENSE STANDARDS MIL-STD-810 - Environmental Engineering Considerations and Labor

8、atory Tests (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.) 2.3 Non-Government publications. The following documents form a part of this document

9、 to the extent specified herein. Unless otherwise specified, the documents are the issues of the documents cited in the solicitation or contract. INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO) ISO 10012-1 - Equipment, Quality Assurance Requirements for Measuring - Part 1 Metrological Confirmat

10、ion System for Measuring Equipment (Copies of these documents are available online at http:/www.iso.ch or from the International Organization for Standardization American National Standards Institute, 11 West 42ndStreet, 13thFloor, New York, NY 10036.) NCSL INTERNATIONAL NCSL Z540.3 - General Requir

11、ements for Calibration of Measuring and Test Equipment (Copies of these documents are available online at http:/www.ncsli.org or from NCSL International, 2995 Wilderness Place, Suite 107 Boulder, Colorado 80301-5404) NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION, (NEMA) NEMA WC 71 Standard for Non-S

12、hielded Power Cables Rated 2001 5000 Volts for Use in the Distribution of Electrical Energy Copies of these documents are available online at http:/www.nema.org or from the National Electrical Manufacturers Association, 1300 North 17th Street, Suite 1847, Rosslyn, VA 22209.) 2.4 Order of precedence.

13、 In 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 regulations unless a specific exemption has been obtained. Provided by IHSNot for ResaleNo reproduc

14、tion or networking permitted without license from IHS-,-,-MIL-DTL-38359E 3 3. REQUIREMENTS 3.1 First article. Cables specified under this specification shall be subjected to a first article inspection (see 6.6). First article inspection shall be performed at laboratory acceptable to the procuring ac

15、tivity on sample units produced with equipment and procedures used in production. 3.2 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 is

16、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 manu

17、facture of cables furnished to comply with this specification shall be of such quality and form that the finished product conforms to the requirements of this specification. 3.3 Design and construction. The cable shall be designed and constructed for use in airport lighting systems. It shall be cons

18、tructed for continuous outdoor service under all weather conditions while on the surface of the ground, buried directly in the ground, installed in conduit, or submerged in fresh or salt water. The voltage rating, high potential withstanding voltage, wire size, and average thickness of the insulatio

19、n for the cables specified herein shall be as specified in table I. TABLE I. Combined cable characteristics. Characteristic Class 1 Class 2 Voltage rating 3,000 V rms 5,000 V rms High potential withstanding voltage 7,500 V rms (5 minutes) 11,000 V rms (5 minutes) Insulation thickness (average) .075

20、inch (1.91 mm) .11 inch (2.79 mm) Diameter: Minimum .31 inch (7.87 mm) .38 inch (9.65 mm) Nominal .32 inch (8.13 mm) .39 inch (9.91 mm) Maximum .34 inch (8.64 mm) .41 inch (10.41 mm) 3.3.1 Conductors. The conductor shall conform to type C, number 8 AWG, class B, tin coated. 3.3.1.1 Splices. Splices

21、in the conductor shall be such that each splice will not increase the diameter of the conductor. No splice shall be made in the conductor as a whole. Not more than one strand shall be spliced in any one foot of conductor. 3.3.1.2 Resistance. The resistance of the conductor of 1,000 feet of completed

22、 cable at +20 C shall not be greater than .65 ohm. 3.3.1.3 Conductor shield. A semiconducting layer or tape shall be applied directly over the stranded conductor, over which the cable insulation shall be applied. The conductor shield shall have a minimum thickness of .005 inch (0.13 mm). 3.3.1.4 Mar

23、ker threads. Nonhygroscopic-type marker threads shall be provided in the conductor strands or directly along the conductor for identification purposes. The color and number of threads used shall be identical with those used by the manufacturer on his other products. Provided by IHSNot for ResaleNo r

24、eproduction or networking permitted without license from IHS-,-,-MIL-DTL-38359E 4 3.3.2 Insulation. The insulation shall consist of a black cross-linked thermoplastic polyethylene (XLP) compound which meets the requirements for the insulation specified in NEMA WC 71 and all the requirements specifie

25、d herein. The insulation shall be applied tightly and concentrically about the conductor over the conductor shield and shall be free from pores, splinters, and other such defects. 3.3.2.1 Insulation thickness. The average thickness of the insulation shall be not less than that specified in table I.

26、The minimum thickness at any point shall be not less than 90 percent of the thickness specified in table I. If the insulation is applied in more than one layer, the adjacent layers shall be molded into a homogeneous mass and the mass considered as a whole for all measurements and tests. 3.3.2.2 Insu

27、lation resistance. The measured insulation resistance (see 4.6.4 ) at 15.6 C shall be not less than that calculated from the following formula: R = K log10dDWhere R = Megohms - 1000 feet D = Outside diameter of insulation in inches d = Diameter of uninsulated conductor in inches K = Constant 25,000

28、for insulation specified herein NOTE: If the temperature differs from 15.6 C during the resistance measurement, correction shall be made by multiplying the calculated value of R by the coefficient corresponding to the temperatures during measurement. The coefficient for the insulation shall be that

29、specified by the manufacturer. The temperature coefficient shall be determined in accordance with NEMA WC 71. 3.3.2.3 Joints. All joints made in the insulation shall be such that all parts affected in the process will be electrically and physically equal to the remainder of the insulation and shall

30、conform to the thickness requirements specified herein. 3.3.2.4 Physical properties. The physical properties of the insulation shall be as follows: a. Original physical requirements: (1) Tensile strength, initial, 1,800 lbf/in2minimum. (2) Elongation at rupture, 350 percent minimum. (3) Modulus at 2

31、00 percent elongation, 1,000 lbf/in2minimum. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-DTL-38359E 5 b. Aging requirements: (1) After air oven test at a minimum of 150 C for 168 hours: (a) Tensile strength in percent of unaged value, 75 perc

32、ent minimum. (b) Elongation at rupture in percent of unaged value, 65 percent minimum. (2) After air pressure heat test for 42 hours at 80 lbs/in2and 127 C: (a) Tensile strength in percent of unaged value, 75 percent minimum. (b) Elongation at rupture in percent of unaged value, 75 percent minimum.

33、3.3.2.5 Ozone resistance. The cable insulation shall be resistant to ozone attack. 3.3.2.6 Moisture absorption. The moisture absorption properties of the cable insulation shall be as follows: Increase in capacitance: 1 to 14 days: 3 percent maximum 7 to 14 days: 1.5 percent maximum 3.3.2.7 Cold bend

34、. The cable insulation shall not crack as a result of bending at a radius of 2.5 times the cable diameter when in an ambient temperature of -40 C or less. 3.4 Performance. 3.4.1 High temperature. The cable shall be resistant to high temperatures encountered while in storage and under service conditi

35、ons. When in an ambient temperature of 71 C, a full reel of cable shall not suffer permanent set to any portion of the cable or show evidence of insulation deterioration. 3.5 Surface marking on cable. The manufacturers name and contract number shall be legibly marked on the surface of all cable. The

36、 markings shall be of paint or ink applied at intervals not exceeding 10 feet. The markings shall be durable and not readily smeared during handling of the cable. 3.6 Workmanship. Workmanship shall be of the quality necessary to produce cable free from all defects which affect proper functioning in

37、service. The exterior surface of the cable shall be smooth, uniform, and free from splinters, ridges, grooves, indentations, and protuberances visible to the naked eye. 3.7 Cable lengths. Except as specified in, cable shall be of one continuous 3,000-foot length, +10, -3 percent (see 6.2). Provided

38、by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-DTL-38359E 6 3.7.1 Allowable short lengths. Unless otherwise specified by the acquiring activity (see 6.2), short lengths may be supplied in accordance with the following schedule on orders of 100,000 feet a

39、nd over: a. 85 percent or more of the order: 3,000-foot lengths. b. 10 percent or less of the order: 1,500-foot minimum lengths. c. 5 percent or less of the order: 1,000-foot minimum lengths. For orders of less than 100,000 feet, all lengths shall be 3,000 feet +10, -3 percent. 3.8 Recycled, recover

40、ed 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 economically advantageous life cycle costs. 3

41、.9 Pure tin. The use of pure tin is prohibited (see 6.7). The maximum amount of pure tin is 97 percent and the alloy material shall inhibit the growth of tin whiskers. 4. VERIFICATION 4.1 Classification of inspections. The inspection requirements specified herein are classified as follows: a. First

42、article inspection (see 4.3). b. Conformance inspection (see 4.4). 4.2 Inspection conditions. Unless otherwise specified (see 6.2), all inspections shall be conducted at a temperature of 2510 C. 4.3 First article inspection. The first article inspection shall consist of all the tests specified in 4.

43、5. 4.3.1 Sample size. The sample shall consist of a reel of cable or a 50 foot or longer coil. The sample shall be appropriately identified with the manufacturers part number and other information as required by the acquiring activity. 4.3.2 Requirements cross-reference matrix. Table II provides a c

44、ross-reference matrix of section 3 requirements tested or verified below. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-DTL-38359E 7 TABLE II. Requirements cross-reference matrix. Requirement Verification Requirement Verification 3.1 4.3 3.3.2.

45、3 4.6.2, 4.6.4 , 4.6.4.1 3.3 4.6.2, 4.6.3 3.3.2.4 4.6.10 3.3.1 4.6.2 3.3.2.5 4.6.7 3.3.1.1 4.6.2 3.3.2.6 4.6.6 3.3.1.2 4.6.9 3.3.2.7 4.6.8 3.3.1.3 4.6.2 3.4.1 4.6.11 3.3.1.4 4.6.2 3.5 4.6.2 3.3.2 4.6.2 3.6 4.6.2 3.3.2.1 4.6.4.1 3.7 4.6.2 3.3.2.2 4.6.4 3.7.1 4.6.2 4.4 Conformance inspection. Conforma

46、nce inspection shall consist of group A and B inspections. 4.4.1 Inspection of product for delivery. Inspection of product for delivery shall consist of groups A and B. 4.4.1.1 Selection of sample units. The inspection sample shall be product selected at random from the lot without regard to quality

47、 and shall be of the size specified in table V. A sample unit is defined as a length of cable drawn from a unit of product. 4.4.1.2 Test specimen. A test specimen may be the entire sample unit (length of finished cable) or any portion of the sample unit that is to be tested. 4.4.2 Group A inspection

48、. Each cable shall be subjected to the individual tests shown in table III. TABLE III. Group A inspection. Inspection Requirement Test method Visual inspection 3.3 4.6.2 Inspection of product 3.6 4.4.1, 4.4.1.1, 4.5.1 High potential withstanding voltage test 3.3 4.6.3 Insulation resistance test 3.3.

49、2.2 4.6.4 Continuity test 3.3 4.6.5 4.4.3 Group A acceptance. Each sample selected in accordance with 4.4.1.1 shall be examined to determine conformance with the requirements in table III. If one or more defects are found in the inspection sample, the production lot shall be rejected and not supplied to this specification. 4.4.4 Group B inspection. Group B inspection shall consist of the tests