DLA MIL-STD-681 F-2012 IDENTIFICATION CODING AND APPLICATION OF HOOKUP AND LEAD WIRE.pdf

1、 MIL-STD-681F 7 March 2012 SUPERSEDING MIL-STD-681E 30 September 2010 DEPARTMENT OF DEFENSE STANDARD PRACTICE IDENTIFICATION CODING AND APPLICATION OF HOOKUP AND LEAD WIRE AMSC N/A FSC 6145 INCH-POUND Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-M

2、IL-STD-681F ii FOREWORD 1. This standard is approved for use by all Departments and Agencies of the Department of Defense. 2. Comments, suggestions, or questions on this document should be addressed to Commander, DLA Land and Maritime, ATTN: VAI, P.O. Box 3990, Columbus, Ohio, 43218-3990 or emailed

3、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 license from IHS-,-,-MIL-STD-681F ii

4、i PARAGRAPH CONTENTS Forward ii 1. 1.1 1.2 2. 2.1 2.2 2.2.1 2.2.2 2.3 3. 3.1 3.1.1 3.1.2 3.1.3 3.1.4 3.1.5 3.1.6 3.1.7 4. 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 5. 5.1 5.1.1 5.1.1.1 5.1.1.2 5.1.1.3 5.1.2 5.1.3 5.1.4 5.2 5.2.1 5.2.2 5.2.3 5.3 5.3.1 5.3.2 5.4 5.4.1 5.4.2 5.4.3 5.4.4 5.5 5.5.1 5.5.2

5、SCOPE Scope Classification APPLICABLE DOCUMENTS General Government documents Specifications, standards, and handbooks Non-Government publications Order of precedence DEFINITIONS Definitions Hookup wire Lead wire Chassis wiring Interconnecting wiring Harness Homogenous cable Jacketed cable GENERAL RE

6、QUIREMENTS Coding of hookup wire Coding of interconnecting wiring Abbreviations Shielded and unshielded wires Color limits Clear and neutral colored insulations Lead wires Hall generator leads DC power wiring for chassis and interconnecting systems AC power wiring in assembled units DETAIL REQUIREME

7、NTS System I Differentiation color coding for chassis wiring (see 1.2) Standard color code for single wires Method of color coding Identification markings Color sequence of helical stripes or circumferential bands Harness wiring Grouping of wires Termination points System II Functional color coding

8、of chassis wiring Standard colors Miscellaneous circuits Direct-coupled circuits System III Differentiation or functional coding of chassis wiring by printed markings Differentiation marking Functional markings System IV Coding of interconnecting wiring Wire insulation color Differentiation markings

9、 Interconnecting wiring on aircraft and guided missles Flat, multiconductor, homogenous cable System V Direct wiring and open wiring Wire insulation color Differentiation markings 1 1 1 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 3 3 3 8 8 8 8 8 8 8 9 9 9 9 9 9 9 9 9 9 9 9 9 10 10 10 10 10 Provided

10、by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-STD-681F iv 5.6 5.6.1 5.6.2 5.6.2.1 5.6.2.2 5.6.3 5.7 5.7.1 5.7.2 5.7.2.1 5.7.2.2 5.7.2.3 5.7.2.4 5.8 6. 6.1 6.2 6.3 6.4 System VI Differential color coding for high density chassis and interconnecting wirin

11、g (see 1.2) Method of color coding Circumferential banding Identification numbers Color sequence of circumferential bands Wire markers Striping or banding Colored helical stripes or circumferential bands Sequence Stripe or band width Stripe or band spacing Length of lay (spacing between groups) Spac

12、ing between groups of bands Braided wire covering NOTES Intended use Subject term (keyword) listing International standardization agreements Changes from previous issue 10 10 10 10 10 11 11 11 11 12 12 12 12 12 12 12 12 12 13 TABLES I. II. III. IV. V. Preferred color sequence for single wires Colors

13、 for chassis and interconnection wiring system by function DC power color coding for chassis and interconnection wiring (optional method) Color coding for ac power wiring (100 V and greater) for single and three phase systems Printing type size of identification marking 4 7 8 8 11 Provided by IHSNot

14、 for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-STD-681F 1 1. SCOPE 1.1 Scope. This standard establishes identification coding systems for all insulated hookup and lead wire used in electrical and electronic equipment by the Departments of the Army, Navy, and Air

15、Force. These coding systems should also be used for identifying lead wires on Hall generators and ac and dc wire coding methods specified (see 4.9 and 4.10). 1.2 Classification. Identification of hookup wiring and lead wire shoud be limited to the following systems: System I Differentiation color co

16、ding for chassis wiring. This system should be employed in complex electronic equipment having numerous wiring points (terminations) and requiring different colored wires for identification. Functional coding (system II) would be inadequate for those complex equipments because of its limited scope o

17、f significant colors. System II Functional color coding of chassis wiring. This system should be employed in simple electronic equipments where it would be advantageous to identify a circuit function or a component part lead by its significant colored wire. System III Differentiation or functional c

18、oding of chassis wiring by printed markings. This system should be employed as an alternate for systems I and II and is preferred for maintaining or repairing equipments. White wires are used for replacement, and will be marked with the designated color or symbol to readily identify it in the equipm

19、ent. Marking may be accomplished through the use of sleeving where the diameter of the wire is so small as to make printing impracticable. System IV Coding of interconnecting wiring. This system should be employed to readily identify wiring between complete units of electronic or electrical systems

20、by means of marking on white insulated wires or applying sleeves, tags, or pressure-sensitive tapes on the insulated wires. System V Direct wiring and open wiring. This system should be employed for direct, open chassis, and cabinet wiring. The hookup wire (see 3.1) need not be color coded; solid wh

21、ite is the preferred color. Permanently numbered sleeves can be used in conjunction with reference designations wherever practical; i.e., terminal boards, bus bars, capacitors, relays, etc. System VI Differential color coding of hookup wire for chassis and interconnection wiring. This system should

22、be employed for identification of wiring in high density wired chassis units and the interconnection between them. Identification may be accomplished by use of solid color insulated wire, circumferential bands or spiral stripes on white insulated wire, or printed sleeve or tape markers. Short hookup

23、 wire, six inches or less between termination points, need not be marked if the path of the short wire can be easily and visually traced. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-STD-681F 2 2. APPLICABLE DOCUMENTS 2.1 General. The document

24、s listed in this section are specified in sections 3, 4, and 5 of this standard. This section does not include documents cited in other sections of this standard or recommended for additional information or as examples. While every effort has been made to ensure the completeness of this list, docume

25、nt users are cautioned that they must meet all specified requirements of documents cited in sections 3, 4, and 5 of this standard 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 pa

26、rt 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 SPECIFICATION MIL-W-5088 Wiring, Aerospace Vehicle. FEDERAL STANDARD MIL-STD-104 Limits for Electrical Insulation Color. (Copies of t

27、hese documents are available online at https:/assist.daps.dla.mil or from the Standardization Document Order Desk, 700 Robbins Avenue, Building 4D, Philadelphia, PA 19111-5094.) 2.2.2 Non-Government publications. The following documents form a part of this document to the extent specified herein. Un

28、less otherwise specified, the issues of these documents are those cited in the solicitation or contract. ASME INTERNATIONAL ASME Y14.38 Abbreviations and Acronyms for Use on Drawings and Related Documents. (Copies of these documents are available online at http:/www.asme.org or from the ASME Interna

29、tional, Three Park Avenue, New York, NY 10016-5990.) 2.3 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,

30、 supersedes applicable laws and regulations unless a specific exemption has been obtained. 3. DEFINITIONS 3.1 Definitions. For the purpose of this standard, the following definitions apply: 3.1.1 Hookup wire. Hookup wire refers to an insulated conductor free at both ends and used for chassis wiring

31、and interconnecting wiring. 3.1.2 Lead wire. Lead wire refers to an insulated conductor forming an integral part of components such as motors, transformers, Hall generators, etc., and used for chassis wiring. 3.1.3 Chassis wiring. Chassis wiring may consist of hookup wire, lead wire, shielded cable,

32、 jacketed multiconductor cable, coaxial cable, or twisted multiconductor groups of wires or cables, or wires and cables, used to connect electrical or electronic elements within the same equipment. 3.1.4 Interconnecting wiring. Interconnecting wiring consists of wires cables, groups or harnesses use

33、d to connect complete units of electrical or electronic systems. 3.1.5 Harness. An assembly of wires or cables, or wires and cables arranged so it may be installed or removed as a unit in the same electronic or electrical equipment. 3.1.6 Homogenous cable. Cable composed of identical insulated condu

34、ctors. 3.1.7 Jacketed cable. A jacketed cable is a bundle of insulated wires encased in a common sheath. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-STD-681F 3 4. GENERAL REQUIREMENTS 4.1 Coding of hookup wire. All hookup wire shall be coded

35、by one or more of the systems listed in 1.2. 4.2 Coding of interconnecting wiring. Coding of interconnecting wiring (system IV) need not apply to jacketed cables. 4.3 Abbreviations. Abbreviations shall be in accordance with ASME Y14.38. 4.4 Shielded and unshielded wires. All requirements for all sys

36、tems shall apply to both shielded and unshielded wires. 4.5 Color limits. Unless otherwise specified, all colors on the finished wire shall conform to class 1 colors of MIL-STD-104. 4.5.1 White, clear, and neutral insulations. The term “white” shall apply only to colors meeting the requirements of “

37、white” in MIL-STD-104. Clear or translucent uncolored (unpigmented) insulation shall be designated “clear”. Natural or neutral colored insulations shall be designated “neutral” (see 4.6). 4.6 Clear and neutral colored insulations. Clear and neutral colored insulations shall be used on wires in lieu

38、of white insulation only when specified by the applicable wire specification. 4.7 Lead wires. Lead wires used for motor leads, transformer leads, and similar applications shall be color coded in accordance with table I, where no conflict would be created with another component color-code standard. 4

39、.8 Hall generator leads. Hall generator lead wires shall be color coded in accordance with table II. 4.9 DC power wiring for chassis and interconnecting systems. DC power wiring for chassis and interconnecting wiring shall be color coded in accordance with table II or table III. 4.10 AC power wiring

40、 in assembled units. AC power wiring in assembled units shall be color coded in accordance with table IV. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-STD-681F 4 TABLE I. Preferred color sequence for single wires. 1/ 2/Base color First stripe

41、or band Second stripe or band Third stripe or band Identification number Black Brown Red Orange Yellow Green Blue Violet Gray White White White White White White White White White White White White White White White White White White White White White White White White White White White White White

42、White White White White White Black Brown Red Orange Yellow Green Blue Violet Gray Black Black Black Black Black Black Black Black Brown Brown Brown Brown Brown Brown Brown Red Red Red Red Red Red Orange Orange Orange Brown Red Orange Yellow Green Blue Violet Gray Red Orange Yellow Green Blue Violet

43、 Gray Orange Yellow Green Blue Violet Gray Yellow Green Blue 0 1 2 3 4 5 6 7 8 9 90 91 92 93 94 95 96 97 98 901 902 903 904 905 906 907 908 912 913 914 915 916 917 918 923 924 925 926 927 928 934 935 936 See footnotes at end of table. Provided by IHSNot for ResaleNo reproduction or networking permit

44、ted without license from IHS-,-,-MIL-STD-681F 5 TABLE I. Preferred color sequence for single wires Continued. 1/ 2/Base color First stripe or band Second stripe or band Third stripe or band Identification number White White White White White White White White White White White White White White Whit

45、e White White White White White White White White White White White White White White White White White White White White White White White White White White White White White White Orange Orange Yellow Yellow Yellow Yellow Green Green Green Blue Blue Violet Black Black Black Black Black Black Black

46、 Black Black Black Black Black Black Black Black Black Black Black Black Black Black Black Black Black Black Black Black Black Black Black Black Black Black Violet Gray Green Blue Violet Gray Blue Violet Gray Violet Gray Gray Brown Brown Brown Brown Brown Brown Brown Red Red Red Red Red Red Orange O

47、range Orange Orange Orange Yellow Yellow Yellow Yellow Green Green Green Blue Blue Violet Red Red Red Red Red Red Orange Yellow Green Blue Violet Gray Orange Yellow Green Blue Violet Gray Yellow Green Blue Violet Gray Green Blue Violet Gray Blue Violet Gray Violet Gray Gray Orange Yellow Green Blue

48、Violet 937 938 945 946 947 948 956 957 958 967 968 978 9012 9013 9014 9015 9016 9017 9018 9023 9024 9025 9026 9027 9028 9034 9035 9036 9037 9038 9045 9046 9047 9048 9056 9057 9058 9067 9068 9078 9123 9124 9125 9126 9127 See footnotes at end of table. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-STD-681F 6 TABLE I. Preferred color sequence for single wires Continued. 1/ 2/ Base color First stripe or band Second stripe