1、 AMSC N/A FSC 6145 MIL-DTL-8777F 9 November 2011 SUPERSEDING MIL-DTL-8777E 21 May 2007 DETAIL SPECIFICATION WIRE, ELECTRICAL, SILICONE-INSULATED, COPPER, 600-VOLT, 200C This specification is approved for use by all Departments and Agencies of the Department of Defense. 1. SCOPE 1.1 Scope. This speci
2、fication covers single conductor wire with a silicone primary insulation capable of continuous operation at 600 volts and a maximum conductor temperature of 200C (392F). These wires are suitable for use in aircraft and missiles using any combination of electrical loading and ambient temperature, pro
3、vided the maximum conductor temperature is not exceeded. The wires covered by this specification are not intended as fire-resistant wires. 1.2 Classification. Single conductor insulated wire as specified in the applicable MS sheet (see 6.2). 2. APPLICABLE DOCUMENTS 2.1 General. The documents listed
4、in this section are 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, docume
5、nt users are cautioned 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, and standards and handbooks. The following specifications, standards and handbooks fo
6、rm 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 contract. INCH-POUND Comments, suggestions, or questions on this document should be addressed to DLA Land and Maritime, ATTN: VAI, P.O. Box 3990
7、, 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:/assist.daps.dla.mil. Inactive for new design after 01 June 1998. Provided by IHSNot for ResaleNo r
8、eproduction or networking permitted without license from IHS-,-,-MIL-DTL-8777F 2 COMMERCIAL ITEM DESCRIPTION A-A-59551 - Wire, Electrical, Copper. FEDERAL SPECIFICATION TT-I-735 - Isopropyl Alcohol. FEDERAL STANDARD FED-STD-228 - Cable and Wire, Insulated; Methods of Testing. DEPARTMENT OF DEFENSE S
9、PECIFICATIONS MIL-W-5088 - Wiring, Aerospace Vehicle. MIL-PRF-5606 - Hydraulic Fluid, Petroleum Base, Aircraft, Missile, and Ordnance. MIL-DTL-5624 - Turbine Fuel, Aviation Grades JP-4, JP-5, and JP-5/JP-8 ST. MIL-PRF-7808 - Lubricating Oil, Aircraft Turbine Engine, Synthetic Base. DEPARTMENT OF DEF
10、ENSE STANDARDS MIL-STD-104 - Limits for Electrical Insulation Color. MS25471 - Wire, Electrical Silicone-Insulated, Copper, 600 Volt, 200C, Polyester Jacket. MS27110 - Wire, Electrical Silicone-Insulated, Copper, 600 Volt, 200C, FEP Jacket. (Copies of these documents are available online at https:/a
11、ssist.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 to the extent specified herein. Unless otherwise specified, the docume
12、nts are the issues of the documents cited in the solicitation or contract (see 6.2). ASTM INTERNATIONAL ASTM B298 - Wire, Copper, Silver-Coated Soft or Annealed. (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
13、, West Conshohocken, PA 19428-2959.) X-RITE, INCORPORATED Munsell Book of Color (Copies of this document are available online at www.x- or requested from X-rite Corporate Headquarters, USA, 4300 44thStreet, SE, Grand Rapids, MI 49512.) Provided by IHSNot for ResaleNo reproduction or networking permi
14、tted without license from IHS-,-,-MIL-DTL-8777F 3 NCSL INTERNATIONAL NCSL-Z540.1 Calibration Laboratories and Measuring and Test Equipment, General Requirements (Copies of these documents are available online at http:/www.ncsli.org or from NCSL International 2995 Wilderness Place, Suite 107 Boulder,
15、 Colorado 80301-5404.) SAE INTERNATIONAL SAE AS1241 - Fire Resistant Phosphate Ester Hydraulic Fluid for Aircraft (Copies of these documents are available online at http:/www.sae.org or from the SAE World Headquarters, 400 Commonwealth Drive, Warrendale, PA 15096-0001.) 2.4 Order of precedence. In e
16、vent of a conflict between the text of this document and the references cited herein (except for related specification sheets), 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.
17、REQUIREMENTS 3.1 Specification sheets. The individual item requirements shall be as specified herein and as specifed in the applicable specification sheet. In the event of any conflict between the requirements of this specification and the specification sheet, the latter shall govern. 3.2 Qualificat
18、ion. Wires furnished under this specification shall be products that are authorized by the qualifying activity for listing on the applicable qualified products list (QPL) before contract award (see 4.6 and 6.3). 3.3 Materials. The materials for the principal components of the wire shall be as specif
19、ied herein. Prior approval to use substitute material must be obtained from the qualifying activity. When a definite material is 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 co
20、nstituent material shall not be construed as a guaranty of the acceptance of the finished product. All materials used in the manufacture of wires furnished hereunder shall be of such quality and form that the finished product conforms to the requirements of this specification. All materials used sha
21、ll conform to the requirements specified herein. 3.3.1 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
22、 requirements, and promotes economically advantageous life-cycle costs. 3.3.2 Conductor material. Strands used in the manufacture of conductors shall be annealed or soft drawn copper wire from the best obtainable, commercially pure wire bars, and as specified in A-A-59551. Provided by IHSNot for Res
23、aleNo reproduction or networking permitted without license from IHS-,-,-MIL-DTL-8777F 4 3.3.3 Insulating materials. 3.3.3.1 Primary insulation. The primary insulation shall be of silicone rubber, applied by extrusion or taping. If a silicone rubber tape is used, it shall be fused into a homogeneous
24、mass. 3.3.3.2 Inner braid. The inner braid shall consist of glass fibers or a combination of glass fibers and polyester fibers covering the primary insulation. The inner braid shall be treated with a heat-resistant finisher. 3.3.3.3 Outer jacket. The outer jacket shall be as specified in the applica
25、ble MS sheet. 3.4 Design and construction. 3.4.1 Conductors. 3.4.1.1 Conductor coating. Individual strands shall be uniformly coated with a smooth continuous layer of commercially pure silver having a minimum thickness of 40 micro inches when tested as specified in 4.6.2.2. Following the continuity
26、of coating test in 4.6.2.1, there shall be no evidence of exposed copper. 3.4.1.2 Stranding. 3.4.1.2.1 Concentric-lay. Wire sizes 22 through 12 shall be constructed with concentric-lay conductors and as specified in table I. Concentric-lay shall be interpreted to be a central core surrounded by one
27、or more layers of helically wound strands. It is optional for the direction of lay for successive layers to be alternately reversed (true concentric-lay) or to be in the same direction (unidirectional lay). When unidirectional lay is used, the strands shall be assembled in a geometric arrangement of
28、 concentric layers, so as to produce a smooth and uniform conductor, circular in cross-section and free of any crossovers, high strands or other irregularities. The direction of lay of individual strands in the outer layer of the concentrically stranded conductors of finished wire shall be left hand
29、. The length of lay in the outer layer shall be not less than 8 nor more than 16 times the maximum conductor diameter specified in the applicable MS sheet. 3.4.1.2.2 Rope lay. Wire sizes 10 through 00 shall be rope lay and as specified in table I and as follows: a. Rope lay stranded conductors shall
30、 be laid up concentrically with a center core surrounded by one of more helically wound members. It is optional for the direction of lay for successive layers to be alternately reversed (true concentric-lay) or to be in the same direction (unidirectional lay). The length of lay of the outer layer of
31、 rope lay stranded members forming the conductor shall be not less than 10 nor more than 14 times the outside diameter of the completed conductor. The direction of lay of the outside layer may be either left or right hand. b. Members of rope lay stranded conductors: The length of lay of the conducto
32、rs composing the stranded members shall be not greater than 16 times the outside diameter of the member. Stranding of the individual members may be concentric or bunch. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-DTL-8777F 5 TABLE I. Wire con
33、struction details. Wire size Nominal CMA 1/of conductor (circular mils) Number of strands Allowable number of missing strands Nominal diameter of individual strands inch/(mm) Maximum diameter of stranded conductor inch/(mm) Maximum resistance at 20C (68F) (/1,000 ft.) 22 755 19 0 0.0063 (.16) 0.033
34、(.84) 15.2 20 1,200 19 0 .0079 (.20) .041 (1.04) 9.42 18 1,909 19 0 .0100 (.25) .052 (1.32) 6.03 16 2,409 19 0 .0113 (.29) .060 (1.52) 4.72 14 3,830 19 0 .0142 (.36) .074 (1.88) 2.99 12 6,088 19 0 .0179 (.45) .093 (2.36) 1.88 10 9,880 49 0 .0142 (.36) .128 (3.25) 1.16 8 16,864 133 0 .0113 (.29) .176
35、 (4.47) 0.70 6 26,813 133 0 .0142 (.36) .218 (5.54) 0.436 4 42,613 133 0 .0179 (.45) .272 (6.91) 0.274 2 66,832 665 2 .0100 (.25) .345 (8.76) 0.179 1 82,108 817 2 .0100 (.25) .384 (9.75) 0.144 0 105,022 1,045 3 .0100 (.25) .432 (10.97) 0.114 00 133,665 1,330 3 .0100 (.25) .490 (12.45) 0.090 1/ Circu
36、lar Mil Area (CMA) 3.4.1.3 Splices. Splices in individual strands shall be butt-brazed. Individual brazed splices in any section of the conductor shall not occur closer together than 10 feet. Splices in any individual stranded member, in rope-lay construction, shall be so finished off that the condu
37、ctor diameter is not increased at the point of brazing. In no case shall the whole conductor be spliced at one point. 3.4.1.4 Elongation. When tested as specified in 4.6.2.3, the individual strands from the conductor of the finished wire shall withstand an elongation of 10 percent before breaking. 3
38、.4.1.5 Conductor diameter. The diameter of the conductor of the finished wire shall be as specified in table I. 3.4.2 Insulation. 3.4.2.1 Concentricity. The primary insulation shall be formed concentrically around the conductor. When measured as specified in 4.6.3.1, the concentricity shall be not l
39、ess than 70%. 3.4.2.2 Physical properties. When tested separately as specified in 4.6.3.2.1, the physical properties of extruded primary insulation shall be not less than specified in the applicable MS sheet. 3.4.2.2.1 Physical properties after aging. When tested as specified in 4.6.3.2.2, extruded
40、primary insulation removed from finished wire shall have physical properties not less than the values specified for aged samples in the applicable MS sheet. 3.4.2.3 Primary insulation flaws. After application of the primary insulation, and prior to the application of any other material, all of the w
41、ire shall pass the test specified in 4.6.3.3 without failure. 3.4.3 Finished wire. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-DTL-8777F 6 3.4.3.1 Finished wire diameter. The diameter of the finished wire shall be as specified in the applicab
42、le MS sheet. 3.4.3.2 Finished wire weight. When tested as specified in 4.6.4.14, the weight of the finished wire shall be not greater than the values specified in the applicable MS sheet. 3.4.3.3 Wire outer surface. The outer surface of the wire shall be non-corrosive and flexible, and shall be fini
43、shed smooth. The multiple layers of braided material, used as the outer covering, shall be bonded together by the heat-resistant finisher to prevent fraying. Adjacent layers of wire, when wound on a reel, shall not stick to one another at any temperature under 200C. 3.4.3.4 Color. The color shall be
44、 black or white as specified in MIL-STD-104, or tan as specified in the following limits as defined by the Munsell Book of Color: Hue - Red limit 10R Hue - Green limit 5Y Value - Not less than 6.0 (dark limit) Chroma - Not greater than 8.0 (saturation limit) The above color requirements shall also a
45、pply after the test specified in 4.6.4.3.1. 3.4.4 Performance. 3.4.4.1 Conductor resistance. When tested as specified in 4.6.4.1, the conductor resistance of the finished wire shall be as specified in table I. 3.4.4.2 Finished wire flaw test. All of the finished wire shall conform to the test specif
46、ied in 4.6.4.2 without electrical breakdown. 3.4.4.3 Life cycle. Following the tests specified in 4.6.4.3.1 and 4.6.4.3.2, there should be no cracking of the outer surface or of the primary insulation as viewed visually without magnification. The test specimen shall then conform to the test specifie
47、d in 4.6.4.3.3 without electrical breakdown or flashover. The insulation shall not cause pitting of the conductor during the test specified in 4.6.4.3.4. 3.4.4.4 Cold bend. The wire shall withstand the test in 4.6.4.4 without cracking the outer surface or primary insulation when viewed visually with
48、out magnification. The test specimen shall then pass the test specified in 4.6.4.3.3 without breakdown or flashover. 3.4.4.5 Oil absorption. After having been subjected to the test specified in 4.6.4.5, the increase in diameter shall not exceed 5 percent. The insulation shall show no evidence of com
49、ing through the outer cover. The test specimen shall then withstand the tests specified in 4.6.4.3.2 and 4.6.4.3.3 without electrical breakdown or flashover. 3.4.4.6 Immersion. Following the test specified in 4.6.4.6, the increase in diameter shall not exceed 5 percent. The insulation shall show no evidence of coming through the outer cover. The test specimen shall then withstand the test specified in 4.6.4.3.3 with
