1、AMSC N/A FSC 6145 INCH-POUND MIL-DTL-49104C 9 November 2011 SUPERSEDING MIL-DTL-49104B 16 July 2007 DETAIL SPECIFICATION CABLE, TELEPHONE WD-1A/TT (FIELD WIRE, PARALLEL PAIR) Inactive for new design after 16 June 1997. This specification is approved for use by all Departments and Agencies of the Dep
2、artment of Defense. 1. SCOPE 1.1 Scope. This specification covers stranded conductor, polyethylene insulated, parallel lay field telephone cable. Each conductor consists of seven strands: four of copper and three of steel. 2. APPLICABLE DOCUMENTS 2.1 General. The documents listed in this section are
3、 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, document users are cautio
4、ned that they must meet all specified requirements of 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 doc
5、ument to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract. FEDERAL SPECIFICATION L-P-390 - Plastic, Molding and Extrusion Material, Polyethylene and Copolymers (Low, Medium and High Density) Comments, suggestions,
6、or questions on this document should be addressed to DLA Land and Maritime, ATTN: VAI, P.O. Box 3990, Columbus, OH 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
7、:/assist.daps.dla.mil. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-DTL-49104C 2 FEDERAL STANDARD FED-STD-228 - Cable and Wire, Insulated; Methods of Testing COMMERCIAL ITEM DESCRIPTION A-A-59551 - Wire, Electrical, Copper (Uninsulated) DEPART
8、MENT OF DEFENSE SPECIFICATION MIL-DTL-3241 - Reels, Cable (Reels DR-5( ), DR-7( ), DR-8( ), RC-453( )/G, RL-159( )/U) (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, Philadelp
9、hia, PA 19111-5094.) 2.3 Non-Government publications. The following documents form a part of this document to the extent specified herein. Unless otherwise specified, the documents are the issues of the documents cited in the solicitation or contract (see 6.2). ASTM INTERNATIONAL ASTM A641/A641M - S
10、tandard Specification for Steel Wire, Zinc-coated (Galvanized) Carbon (Copies of these documents are available online at http:/www.astm.org or from the ASTM International, P.O. Box C700, 100 Barr Harbor Drive, West Conshohocken, PA 19428-2959.) NCSL International NCSL-Z540.1 - Laboratories, Calibrat
11、ion and 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.) 2.4 Order of precedence. Unless otherwise noted herein or in the contract, in the event of a conflic
12、t 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. 3. REQUIREMENTS 3.1 First article. When specified (see 6.2), a
13、 sample shall be subjected to first article inspection in accordance with 4.3. 3.2 Materials. 3.2.1 Copper strands. Copper strands shall be tinned, soft or annealed copper wire in accordance with A-A-59551. Each strand shall be .011 inch 0.05 in (.28 1.27 mm) diameter. Provided by IHSNot for ResaleN
14、o reproduction or networking permitted without license from IHS-,-,-MIL-DTL-49104C 3 3.2.2 Steel strands. Steel strands shall be round steel wire .011 in 0.05 in (.28 mm 1.27 mm) diameter. The wire shall be coated with a smooth, continuous, uniform and adherent zinc coating of commercially pure zinc
15、 (galvanized) in accordance with ASTM A641/A641M. The weight of zinc shall not be less than 25 grams of zinc per kilogram of coated strand. 3.2.3 Insulation compound. The insulation compound shall be black high-density polyethylene or copolymer, type III, class H, grade 1, in accordance with L-P-390
16、, except that the carbon black content shall be no greater than 2.5%. 3.2.4 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 operati
17、onal and maintenance requirements, and promotes economically advantageous life-cycle costs. 3.3 Construction. 3.3.1 Conductors. Each conductor shall be composed of four coated copper strands and three coated steel strands. 3.3.1.1 Stranding. The maximum length of lay of the strand conductor shall be
18、 one inch and the direction of lay shall be left hand. The outside strands shall lie evenly and smoothly around the central strand without crowding. An antioxidant, such as Liquid Antox manufactured by E.I. duPont deNemours and Co., Inc.; Bayol 35, manufactured by Humble Oil and Refining Co.; MX-910
19、 lube-oil manufactured by Mohawk Refining Co.; or an equally satisfactory light oil, may be used as a lubricant in the stranding operation, in which case there shall be no excess oil on the finished stranded conductor. 3.3.2 Finished cable characteristics. The finished cable shall consist of a pair
20、of conductors in parallel, commonly insulated in an approximate figure-8 cross section (see figure 1). The finished cable shall be twisted right-hand-lay (such as in a bunch strander) to make one twist per 12 inches (304.80 mm) when averaged over a 100-foot length. Separation of the conductors of th
21、e pair shall be by snipping the insulation at the end of the pair midway between the conductors and then tearing them apart. The tensile force necessary to separate the two conductors shall be not less than 1 pound or more than 3 pounds. After the conductors are separated, the insulation shall not p
22、ull away from either conductor. No insulation repairs or wire splices shall be permitted in finished cable. The dimensions of the cable shall be as follows (see figure 1): A Major axis .135 .005 inch (3.43 .13 mm) B Minor axis .070 .003 inch (1.78 .08 mm) C Conductor separation .033 .003 inch (0.84.
23、08 mm) (between inside surface of the conductors) D Conductor diameter .033 .003 inch (.84 . 08 mm) Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-DTL-49104C 4 FIGURE 1. Dimension characteristics. 3.3.2.1 Insulation. The pair of conductors shall
24、 be insulated with a tight well-centered compound as specified in 3.2.3 with a minimum wall thickness of .014 inch (.36 mm). The insulation on the separated conductors shall strip cleanly and readily with the use of pliers. 3.4 Physical characteristics. 3.4.1 Cable. 3.4.1.1 Tubing. The finished cabl
25、e shall be capable of being looped back and wound tightly on itself for five loose turns without showing any visible strains or cracking of the insulation. 3.4.1.2 Deformation. The decrease in diameter of an insulated conductor shall not exceed 15 percent after being exposed to a temperature of 951
26、C for 1 hour +5, -0 minutes. 3.4.1.3 Cold bend and aging. The finished cable shall be capable of withstanding cold bending and aged cold bending at -40 C. 3.4.1.4 Insulation cutting load. The insulation of the finished cable shall withstand a cutting load of not less than 55 pounds. 3.4.1.5 Insulati
27、on breaking load. The insulation of the finished cable shall withstand a breaking tension load of not less than 170 pounds. 3.5 Performance. 3.5.1 DC resistance. The direct current (dc) resistance of the cable, at or corrected to 20 C, shall not exceed 46 ohms per 1,000 loop-feet. 3.5.2 Dielectric s
28、trength. The cable shall withstand a potential of 1,000 Vrms. 3.5.3 Insulation resistance. Insulation resistance of cable, at or corrected to 15.6 C, shall not be less than 10,000 meg per 1,000 feet. D C A B Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IH
29、S-,-,-MIL-DTL-49104C 5 3.5.4 Attenuation. The attenuation of each pair of conductors shall not exceed the range of values shown on figure 2 under both wet and dry conditions. The dry readings shall be not more than 30% below the wet readings. 3.5.5 Crosstalk. The crosstalk to an adjacent similar cab
30、le shall be at least 55 dB down. 3.6 Flatness. The cable shall lie flat and straight when uncoiled from a reel or a spool or dispenser onto a level surface. 3.7 Workmanship. The conductors, insulation and cable shall be uniform in quality and free from defects that affect performance, serviceability
31、, or appearance, such as lumps, kinks, splits, abrasions, scrapes, corroded surfaces, skin impurities, and faulty extruded surfaces. 01.441234562.80.3 0.5 1.0 2.0 4.0Attenuation indB/mileFrequency in kHzFIGURE 2. Attenuation. Provided by IHSNot for ResaleNo reproduction or networking permitted witho
32、ut license from IHS-,-,-MIL-DTL-49104C 6 4. VERIFICATION 4.1 Classification of inspections. The inspection requirements specified herein are classified as follows: a. First article inspection (see 4.3). b. Conformance inspection (see 4.4). 4.2 Test equipment and inspection facilities. Test and measu
33、ring equipment and inspection facilities of sufficient accuracy, quality, and quantity to permit performance of the required inspection shall be established and maintained by the contractor. The establishment and maintenance of a calibration system to control the accuracy of the measuring and test e
34、quipment (i.e., non-Government standard NGS or federal or military standard) shall be done in accordance with NCSL-Z540.1, or equivalent requirement. 4.3 First article inspection. When required (see 6.2), first article inspection shall be performed on a representative sample of cable fabricated unde
35、r the manufacturers normal production methods. The sample shall consist of two 1-mile lengths of finished cable with each mile wound on reel DR-5( ) conforming to MIL-DTL-3241. The first article inspection shall consist of the group A and group B inspections and tests specified in table I and table
36、II, respectively. TABLE I. Group A inspection. Inspection Requirement Verification Visual and dimensional 3.3 4.5.1 DC resistance 3.5.1 4.5.10 Dielectric strength 3.5.2 4.5.8 Insulation resistance 3.5.3 4.5.9 Workmanship 3.7 4.5.1 TABLE II. Group B inspection. Inspection Requirement Verification Coa
37、ting 3.2.2 4.5.2 Conductor separation 3.3.2 4.5.14 Tubing 3.4.1.1 4.5.3 Deformation 3.4.1.2 4.5.4 Cold bend and aging 3.4.1.3 4.5.5, 4.5.5.1 Insulation cutting load 3.4.1.4 4.5.6 Insulation breaking load 3.4.1.5 4.5.7 Attenuation 3.5.4 4.5.11 Crosstalk 3.5.5 4.5.12 Flatness 3.6 4.5.13 4.4 Conformanc
38、e inspection. Conformance inspection shall consist of the inspections listed for component inspection and group A and B inspections as specified in table I and table II. Conformance inspection shall be performed on every lot of cable procured under this specification. 4.4.1 Inspection lot. Unless ot
39、herwise specified (see 6.2), an inspection lot shall consist of all cable of the same Part or Identifying Number (PIN), produced under essentially the same conditions on the same machine, that is presented for inspection and shipment at one time. Provided by IHSNot for ResaleNo reproduction or netwo
40、rking permitted without license from IHS-,-,-MIL-DTL-49104C 7 4.4.2 Unit of product. The unit of product for determining lot size for sampling shall be the quantity of cable offered for inspection on one coil, one reel, or one spool, as applicable. 4.4.3 Component inspection. The components of the c
41、able listed in table III shall be inspected using the applicable documents (see 4.5.1) for each lot. 4.4.4 Group A inspection. Group A inspection shall consist of the inspections specified in table I and shall be performed on each lot of cable acquired under the specification. Group A inspections ma
42、y be performed at an appropriate stage of the manufacturing operation rather than on the finished cable. 4.4.5 Group B inspection. Group B inspection shall consist of the inspections specified in table II. Group B inspection shall be performed on sample units that have been subjected to and have pas
43、sed the group A inspection. Group B inspection shall be performed in any order on randomly selected samples from an inspection lot. 4.4.5.1 Sampling. A random sample shall first be selected from each lot. The sample size shall be based on the inspection lot size from which the sample was selected fo
44、r group A inspection. Sampling for inspection shall be specified in table IV. 4.4.5.2 Specimen lengths. The specimen shall be of the length specified in the applicable test method. TABLE III. Visual and dimensional examination. Examination Requirements Verification Construction: Conductors 3.3.1 4.5
45、.1 Stranding 3.3.1.1 FED-STD-228, method 1531 Insulation thickness 3.3.2.1 FED-STD-228, method 1018 1/ 2/ Finished cable characteristics 3.3.2 4.5.1 1/ An average diameter shall be the average of the readings obtained by making two measurements at right angles to each other at three different points
46、 along the length of a 12 inch (304.80 mm) specimen. 2/ The average wall thickness shall be considered equal to one-half the difference between the average diameter of the insulated conductor and the non-insulated conductor for the same specimen. Provided by IHSNot for ResaleNo reproduction or netwo
47、rking permitted without license from IHS-,-,-MIL-DTL-49104C 8 TABLE IV. Inspection sample. Inspection lot size 1/ Sample size 1 1 2 to 8 2 9 to 90 3 91 to 150 12 151 to 280 19 281 to 500 21 501 to 1,200 27 1,201 to 3,200 36 3,201 to 10,000 38 10,001 to 35,000 46 1/ Lot size is based on number of ree
48、ls, spools, or coils. 4.4.6 Rejected lot. Failure to pass any of the tests and inspections shall constitute failure of the lot and the lot shall be rejected. If an inspection lot is rejected, the lot may be reworked to correct the defects or screen out the defective units, and the lot submitted for
49、re-inspection. Such lots shall be separated from new lots and shall be identified as re-inspected lots. 4.4.7 Noncompliance. If a sample fails to pass group B inspection (see 4.4.5), the contractor shall notify the cognizant inspection activity of such failure and take corrective action on the materials, processes, or both, as warranted, on all units of the
