NEMA WC 27500-2015 Aerospace and Industrial Electrical Cable.pdf

1、NEMA Standards PublicationNational Electrical Manufacturers AssociationANSI/NEMA WC 27500-2015Aerospace and IndustrialElectrical CableANSI/NEMA WC 27500-2015 American National Standard for Aerospace and Industrial Electrical Cable Secretariat: National Electrical Manufacturers Association Approved:

2、January 7, 2015 Published: June 1, 2015 American National Standards Institute, Inc. 2015 National Electrical Manufacturers Association. All rights, including translation into other languages, reserved under Universal Copyright Convention, the Berne Convention for the protection of Literary and Artis

3、tic Works, and the International and Pan American copyright conventions. 2015 National Electrical Manufacturers Association NOTICE AND DISCLAIMER The information in this publication was considered technically sound by the consensus of persons engaged in the development and approval of the document a

4、t the time it was developed. Consensus does not necessarily mean that there is unanimous agreement among every person participating in the development of this document. American National Standards Institute, Inc. (ANSI) standards and guideline publications, of which the document contained herein is

5、one, are developed through a voluntary consensus standards development process. This process brings together volunteers and/or seeks out the views of persons who have an interest in the topic covered by this publication. While NEMA administers the process and establishes rules to promote fairness in

6、 the development of consensus, it does not write the document and it does not independently test, evaluate, or verify the accuracy or completeness of any information or the soundness of any judgments contained in its standards and guideline publications. NEMA disclaims liability for any personal inj

7、ury, property, or other damages of any nature whatsoever, whether special, indirect, consequential, or compensatory, directly or indirectly resulting from the publication, use of, application, or reliance on this document. NEMA disclaims and makes no guaranty or warranty, expressed or implied, as to

8、 the accuracy or completeness of any information published herein, and disclaims and makes no warranty that the information in this document will fulfill any of your particular purposes or needs. NEMA does not undertake to guarantee the performance of any individual manufacturer or sellers products

9、or services by virtue of this standard or guide. In publishing and making this document available, NEMA is not undertaking to render professional or other services for or on behalf of any person or entity, nor is NEMA undertaking to perform any duty owed by any person or entity to someone else. Anyo

10、ne using this document should rely on his or her own independent judgment or, as appropriate, seek the advice of a competent professional in determining the exercise of reasonable care in any given circumstances. Information and other standards on the topic covered by this publication may be availab

11、le from other sources, which the user may wish to consult for additional views or information not covered by this publication. NEMA has no power, nor does it undertake to police or enforce compliance with the contents of this document. NEMA does not certify, test, or inspect products, designs, or in

12、stallations for safety or health purposes. Any certification or other statement of compliance with any health- or safety-related information in this document shall not be attributable to NEMA and is solely the responsibility of the certifier or maker of the statement. ANSI/NEMA WC 27500-2015 Page i

13、2015 National Electrical Manufacturers Association Foreword This standard was developed by the High Performance Wire and Cable section of NEMA as a non-governmental standard replacement for MIL-DTL-27500 electrical cable, which is widely used in aerospace and other industries. It contains: a) Refere

14、nce standards (section 1) b) Identification methods (section 2) and requirements (Section 3.10) c) Construction details (sections 2, 3) d) Material requirements (section 2) e) Conductors f) Primary wire g) Shields h) Jackets i) Electrical requirements (section 3.8) j) Physical requirements (section

15、3.8) 1) Other requirements (sections 3.11-3.14) k) Color/size/weight/lengths/markings l) Test methods for above requirements (section 4) m) Inspection/QC/process control procedures (section 4) n) Packaging (section 5) o) Notes/cross-reference/other data (section 6) p) Ordering data q) Qualification

16、and retention of qualification requirements The requirements contained herein are consensus requirements that have been developed over the past three decades by knowledgeable engineers in the aerospace industry. Members of the NEMA High Performance Wire and Cable Section that participated in develop

17、ment of the current edition of this standard: AFC Cable Systems New Bedford, MA AmerCable El Dorado, AR Belden Inc. St. Louis, MO Berk-Tek, a Nexans Company Elm City, NC Cable USA LLC. Naples, FL Coleman Cable Inc. Waukegan, IL General Cable Highland Heights, KY Harbour Industries LLC. Shelburne, VT

18、 IWG High Performance Conductors Inman, SC Kaneka North America Pasadena, TX Leviton Manufacturing Co., Inc. Gardena, CA Quirk Wire Company, Inc. West Brookfield, MA Radix Wire Company Euclid, OH RSCC Aerospace and Defense East Granby, CT Southwire Company Carrollton, GA The Monroe Cable Company, In

19、c. Middletown, NY The Okonite Company Ramsey, NJ TE Connectivity Menlo Park, CA ANSI/NEMA WC 27500-2015 Page ii 2015 National Electrical Manufacturers Association Contents Foreword i SECTION 1 GENERAL . 1 1.1 SCOPE 1 1.2 REFERENCED STANDARDS 1 1.3 ORDER OF PRECEDENCE . 3 SECTION 2 CLASSIFICATION 4 2

20、.1 GENERAL . 4 2.2 CABLE DESIGNATION . 4 2.2.1 Identification Method of Cable Wire (with Shield Coverage) 4 2.2.2 Conductor Size . 5 2.2.3 Basic Wire Specification 5 2.2.4 Number of Wires Per Cable . 8 2.2.5 Shield Style and Material 8 2.2.6 Jacket Material, Color, and Temperature Rating . 9 SECTION

21、 3 REQUIREMENTS . 11 3.1 CONSTRUCTION . 11 3.2 BASIC WIRE . 11 3.3 FINISHED CABLE . 11 3.4 IDENTIFICATION OF CABLE WIRE 11 3.4.1 Preferred Identification Method 11 3.4.2 Optional Identification Method A 11 3.4.3 Optional Identification Method B 14 3.4.4 Optional Identification Method C 14 3.4.5 Opti

22、onal Identification Method D 15 3.4.6 Optional Identification Method E 15 3.4.7 Optional Identification Method F 15 3.5 CABLE LAY-UP AND DIRECTION . 15 3.6 FILLERS AND BINDER TAPES 16 3.7 SHIELD . 16 3.7.1 Round Shield 16 3.7.2 Flat Shield 18 3.7.3 Braid Angle . 18 3.7.4 Shield Coverage . 18 3.7.5 S

23、hield Splices . 18 3.8 JACKET 18 3.8.1 Jacket Requirements . 18 3.8.2 Jacket Material . 19 3.9 FUNCTIONAL CHARACTERISTICS 23 3.9.1 Dielectric Withstand . 23 3.9.2 Jacket Flaws (Shielded-and-jacketed Cables Only). 23 3.9.3 Conductor Continuity 23 3.9.4 Cold Bend (Jacketed and Shielded-and-jacketed Ca

24、bles Only) 23 3.9.5 Thermal Shock . 23 3.9.6 Blocking 23 3.9.7 Flammability . 24 3.9.8 Lamination Sealing . 24 3.9.9 Crosslinked Verification 24 3.9.10 Shield Solderability . 24 3.9.11 Temperature Rating . 24 3.9.12 Component Tensile and Elongation . 24 3.9.13 Low-fluoride Jackets 24 ANSI/NEMA WC 27

25、500-2015 Page iii 2015 National Electrical Manufacturers Association 3.9.14 Stripe and Band Durability 24 3.9.15 Smooth Surface Verification. 24 3.10 IDENTIFICATION OF PRODUCT . 24 3.10.1 Wire Product Identification . 24 3.10.2 Cable Product Identification . 24 3.10.3 Identification Marker Tape 26 3

26、.11 CABLE DIAMETER . 26 3.12 CABLE WEIGHT . 26 3.13 CONTINUOUS LENGTHS 26 3.14 WORKMANSHIP. 26 SECTION 4 VERIFICATION . 27 4.1 CLASSIFICATION OF INSPECTION 27 4.2 CONDITIONS OF INSPECTION 27 4.2.1 Quality Conformance Inspection 27 4.2.2 Process Control Tests 28 4.2.3 Disposition of Rejections 29 4.2

27、.4 Qualification Inspection 29 4.2.5 Certified Test Reports 34 4.3 METHODS OF INSPECTION . 34 4.3.1 Inspection of Product . 34 4.3.2 Shield Strands 34 4.3.3 Dielectric Withstand . 35 4.3.4 Jacket Flaws 35 4.3.5 Braid Angle and Shield Coverage 35 4.3.6 Cold Bend. 35 4.3.7 Voltage Withstand, Jacket .

28、36 4.3.8 Conductor Continuity 36 4.3.9 Thermal Shock . 36 4.3.10 Crosslinked Verification 36 4.3.11 Bend Test . 36 4.3.12 Jacket Wall Thickness . 37 4.3.13 Jacket Tensile Strength and Elongation . 37 4.3.14 Lamination Sealing (Tape-wrapped Jacket, Materials 11, 12, 22, 24, 25, 61, 62, 72, 74, 75) 37

29、 4.3.15 Jacket Blocking 37 4.3.16 Concentricity . 38 4.3.17 PTFE Tapewrapped Jacket Delamination . 38 4.3.18 Shield Solderability . 38 4.3.19 Flammability . 38 4.3.20 Smooth Surface Verification. 38 4.3.21 Low-fluoride Test 38 4.3.22 Stripe, Band, or Print Durability 38 4.4 CABLE DIAMETER . 38 4.5 C

30、ABLE WEIGHT . 39 4.5.1 Measured . 39 4.5.2 Calculated 39 4.6 Continuous Lengths 40 SECTION 5 PACKAGING. 41 5.1 General 41 SECTION 6 NOTES 42 6.1 APPENDICES . 42 6.2 ORDERING DATA 42 6.2.1 Acquisition Requirements 42 ANSI/NEMA WC 27500-2015 Page iv 2015 National Electrical Manufacturers Association A

31、PPENDIX A (INFORMATIVE) CABLE DESIGN GUIDELINES . 43 A.1 INTRODUCTION. 43 A.2 ELEMENTS OF PRIMARY WIRE SELECTION . 43 A.2.1 Conductor Size . 43 A.2.2 Conductor Type 43 A.2.3 Insulation Type . 43 A.3 ELEMENTS OF SHIELD SELECTION . 43 A.3.1 Material. 43 A.3.2 Flat vs Round Strands 43 A.3.3 Shield Cove

32、rage . 43 A.4 ELEMENTS OF JACKET SELECTION. 44 A.5 CABLE IDENTIFICATION AND COLOR CODES 44 A.6 CONSULTATION 44 APPENDIX B (INFORMATIVE) SUPERSESSIONS AND REPLACEMENTS . 45 B.1 SUPERSEDED SYMBOLS . 45 B.2 MANNED AEROSPACE REPLACEMENTS . 47 Tables Table 2-1 Identification Methods Cross-reference 5 Tab

33、le 2-2.1 Basic Wire Specification . 5 Table 2-2.2 Basic Wire Specification . 7 Table 2-3 Shield Material 9 Table 2-4 Jacket Material and Color . 10 Table 3-1 Circuit Identification Colors for Basic Wires . 12 Table 3-2 Circuit Identification Colors for Basic Wires . 13 Table 3-3 Color of Insulation

34、for Identification of Wire Sizes in Accordance with MIL-STD-686 14 Table 3-4 Circumferential Band Configuration for Wire Number Identification 15 Table 3-5 Round Shield Strand Size. 17 Table 3-6 Cable and Geometry Factors . 17 Table 3-7 Jacket Wall Thickness 22 Table 3-8 Thermal Shock . 23 Table 3-9

35、 Cable Product Identification 25 Table 4-1 Quality Conformance Inspection 27 Table 4-2 Process Control Test 28 Table 4-3 NAVAIR Qualification Inspection 31 Table 4-4 Sample for Qualification by Construction . 32 Table 4-5 Test Mandrel Diameters (inches) . 37 Table 4-6 Specific Gravity for Jacketing

36、Materials . 40 Table B-1 Cross-reference of Canceled Wire Symbols and Specifications 45 ANSI/NEMA WC 27500-2015 Page 1 2015 National Electrical Manufacturers Association Section 1 GENERAL 1.1 SCOPE This standard contains requirements for finished cables. Component wires are covered by other referenc

37、ed standards. These cables are intended for signal and low-voltage power applications with defined environment or temperature conditions found in commercial aircraft, military aircraft, and high-performance vehicles. Naval Air Systems Command (NAVAIR) approval is required to manufacture these cables

38、. 1.2 REFERENCED STANDARDS American National Standards Institute (ANSI) 11 West 42nd Street New York, NY 10036 American Society for Quality Control (ASQC) 611 East Wisconsin Avenue Milwaukee, Wisconsin 53202 ANSI/ASQ Z 1.4 Sampling Procedures and Tables for Inspection by Attributes American Society

39、for Testing and Materials (ASTM) 100 Barr Harbor Drive West Conshohocken, PA 19428 ASTM A 313/A313M Standard Specification for Stainless Steel Spring Wire ASTM B 272 Copper Flat Copper Products with Finished (Rolled or Drawn) Edges (Flat Wire and Strip) ASTM B 298 Silver-Coated Soft or Annealed Copp

40、er Wire ASTM B 3 Soft or Annealed Copper Wire ASTM B 33 Standard Specification for Tinned Soft or Annealed Copper Wire for Electrical Purposes ASTM B 355 Nickel-Coated Soft or Annealed Copper Wire ASTM B 624 Standard Specification for High-strength, High-conductivity Copper Alloy Wire for Electronic

41、 Application ASTM B971 Standard Specification for Silver-Coated Braid and Ribbon Flat Copper Wire Intended for Use in Electronic Application ASTM B972 Standard Specification for Nickel-Coated Braid and Ribbon Flat Copper Wire Intended for Use in Electronic Application ASTM B973 Standard Specificatio

42、n for Tin-Coated Braid and Ribbon Flat Copper Wire Intended for Use in Electronic Application ASTM D 3032 Hookup Wire Insulation, Standard Methods of Testing ASTM D 4066 Polyamide Injection and Extrusion Materials (PA) Nylon Injection and Extrusion Materials (PA) ANSI/NEMA WC 27500-2015 Page 2 2015

43、National Electrical Manufacturers Association Department of Defense Standardization Document Order Desk 700 Robbins Avenue, Bldg 4D Philadelphia, PA 19111-5094 MIL-DTL-12000 Packaging of Cable, Cord, and Wire, Electric MIL-DTL-25038 Wire, Electrical, High Temperature and Fire Resistant MIL-DTL-81381

44、 Wire, Electric, Polyimide-insulated, Copper or Copper Alloy MIL-DTL-8777 Wire, Electrical, Silicone-Insulated, Copper, 600 Volt, 200C MIL-STD-104 Limits for Electrical Insulation Color MIL-STD-202 Test Methods Standard for Electronic and Electrical Component Parts MIL-STD-2223 Test Methods for Insu

45、lated Electric Wire MIL-STD-681 Identification Coding and Application of Hookup and Lead Wire MIL-STD-686 Cable and Cord, Electrical; Identification Marking and Color Coding of MS25471 Wire, Electrical-Silicone, Copper, 600 Volt, 200 Deg. C, Polyester Jacket MS27110 Wire, Electrical-Silicone, Copper

46、, 600 Volt, 200 Deg. C, FEP Jacket (ASG) National Electrical Manufacturers Association (NEMA) 1300 North 17th Street, Suite 900 Rosslyn, Virginia 22209 NEMA WC 52 High-Temperature and Electronic Insulated WireImpulse Dielectric Testing NEMA WC 56 3.0 kHz Insulation Continuity Proof Testing of Hook U

47、p Wire NEMA WC 65 A Reasoned Approach to Solving Solderability Problems with Tin-Coated and Nickel-Coated Stranded Conductors in High Performance Wire and Cable Applications NEMA WC 67 Standard for Uninsulated Conductors Used in Electrical and Electronic Applications NEMA WC 72 Continuity of Coating

48、 Testing for Electrical Conductors National Institute for Standards and Technology (NIST) Publications Office Bldg 101 Gaithersburg, MD 20879 NBS HDBK 100 International Annealed Copper Standard (IACS) SAE International 400 Commonwealth Drive Warrendale, PA 15096-0001 USA AS22759 Wire, Electric, Fluo

49、ropolymer-insulated, Copper or Copper Alloy AS4373 Test Methods for Insulated Electric Wire AS50861 Wire, Electrical, Polyvinyl Chloride Insulated, Copper or Copper Alloy AS50881 Wiring, Aerospace Vehicle AS81044 Wire, Electric, Crosslinked Polyalkene, Crosslinked Alkaneimide Polymer, or Polyarylene Insulated Copper or Copper Alloy ANSI/NEMA WC 27500-2015 Page 3 2015 National Electrical Manufacturers Association Superintendent of Documents US Government Printing Office Washington, DC 20402 H4-1 Federal Supply Code for Manufacturers, United States and Canada, Name to Cod