1、 DETAIL SPECIFICATION CABLE ASSEMBLIES, AIRCRAFT AUDIO, GENERAL SPECIFICATION FOR This specification is approved for use by all Departments and Agencies of the Department of Defense. 1. SCOPE 1.1 Scope. This specification covers the general requirements for complete cable assemblies, with molded or
2、attached plugs including any required built-in electronics, used in aircraft intracommunications and intercommunications systems. It covers cord sets for personal gear such as microphones, headsets, earphones, hand sets and similar equipment, and cable assemblies for contact with ground crew personn
3、el. 1.2 Part or identifying numbers (PIN). Part numbers for cable assemblies should be constructed as follows: M22442/X-Y with “X“ being the specification sheet number and “Y“ being any type cable assembly on a specific specification sheet. 2. APPLICABLE DOCUMENTS 2.1 General. The documents listed i
4、n this section are specified in sections 3 and 4 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 u
5、sers are cautioned that they must meet all specified requirements documents cited in sections 3 and 4 of this specification, whether or not they are listed. Comments, suggestions, or questions on this document should be addressed to: Commander, Naval Air Warfare Center Aircraft Division, Code 4L8000
6、B120-3, Highway 547, Lakehurst, NJ, 08733-5100, or emailed to: michael.sikoranavy.mil. Since contact information can change, you may want to verify the currency of this address information using the ASSIST Online database at http:/assist.daps.dla.mil. AMSC N/A FSC 5995 INCH-POUND MIL-DTL-22442G 25 S
7、eptember 2009 SUPERSEDING MIL-DTL-22442F 1 April 2000 Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-DTL-22442G 22.2 Government documents. 2.2.1 Specifications, standards and handbooks. The following specifications, standards and handbooks form
8、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. FEDERAL STANDARDS FED-STD-228 - Cable and Wire, Insulated, Methods of Testing. DEPARTMENT OF DEFENSE SPECIFICATIONS MIL-DTL-641/22 - Jack
9、, Telephone, U-385/U. MIL-DTL-642/14 - Plugs, Telephone (Type U-384/U) 5 Conductor, Single. MIL-DTL-26482 - Connectors, Electrical (Circular, Miniature, Quick Disconnect, Environmental Resisting), Receptacles and Plugs, General Specification for. (See ASSIST database for list of specification sheets
10、.) DEPARTMENT OF DEFENSE STANDARDS MIL-STD-202 - Electronic and Electrical Components Parts. MIL-STD-810 - Environmental Engineering Considerations and Laboratory Tests. MIL-STD-889 - Dissimilar Metals. DEPARTMENT OF DEFENSE HANDBOOKS MIL-HDBK-454 - General Guidelines For Electronic Equipment (Copie
11、s of these documents are available online at http:/assist.daps.dla.mil/quicksearch/ or from the Standardization Document Order Desk, 700 Robbins Avenue, Building 4D, Philadelphia, PA. 19111-5094.) Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-D
12、TL-22442G 32.2.2 Other Government documents, drawings and publications. The following other Government documents, drawings, and publications form 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 c
13、ontract. DEFENSE STANDARDIZATION PROGRAM OFFICE SD-6 - Provisions Governing Qualification (Copies of this document are available online at http:/assist.daps.dla.mil/quicksearch/ or from the Standardization Document Order Desk, 700 Robbins Avenue, Building 4D, Philadelphia, PA 19111-5094.) 2.3 Non-Go
14、vernment publications. The following documents form a part of this specification to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract. AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM) ASTM-D1149 - Standard Test Met
15、hod for Rubber Deterioration -Surface Ozone Cracking in a chamber. (DoD Adopted) (Copies of this document are available from www.astm.org or ASTM International, 100 Barr Harbor Drive, West Conshohocken, PA. 19428-2959.) SAE INTERNATIONAL SAE-AS39029 - Contacts, Electrical Connector, General Specific
16、ation For. (DoD Adopted) (Copies of this document are available from www.sae.org or SAE International, 400 Commonwealth Drive, Warrendale, PA 15096-0001.) UNDERWRITERS LABORATORY (UL) UL-1581 - Wires, Electrical, Cables, and Flexible Cords. (DoD Adopted) (Copies of this document are available from
17、or Underwriters Laboratory, Inc., Publications Stock, 333 Pfingsten Road, North Brook, IL 60062.) Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-DTL-22442G 4AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI) J-STD-001 - Requirements for Soldered Elect
18、rical and Electronic Assemblies. (Copies of this document are available from www.ansi.org or American National Standards Institute, 11 West 42nd Street, New York, NY 10036.) ASSOCIATION CONNECTING ELECTRONICS INDUSTRIES IPC-2221 - Generic Standard for Printed Board Design. IPC-2222 - Sectional Desig
19、n Standard for Rigid Organic Printed Boards. (Copies of these documents are available from www.ipc.org or Association Connecting Electronics Industries, 3000 Lakeside Drive, Bannockburn, IL 60015.) 2.4 Order of precedence. Unless otherwise noted herein or in the contract, in the event of a conflict
20、between the text of this document and the references cited herein (except for related specification sheets, see 3.1), 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. REQUIREMEN
21、TS 3.1 Specification sheets. The individual item requirements shall be as specified herein and in accordance with the applicable specification sheet. A global change has been implemented in regard to cordage jacket materials, to allow the use of polyurethane materials (see 3.4.4). All other cable re
22、quirements as specified in the specification sheets are applicable. In the event of any conflict between requirements of this document and the specification sheets, except as specified above, the latter shall govern. 3.2 Part or identifying numbers (PIN). Part numbers for cable assemblies furnished
23、under this specification shall be constructed as shown in 1.2. 3.3 Qualification. Cable assemblies furnished under this specification shall be products that are authorized by the qualifying activity for listing on the applicable qualified products list before contract award (see 4.3 and 6.3). 3.3.1
24、Qualification of individual components is not required as noted on individual specifications sheets. However the Government reserves the right to require certification of compliance of the same. Production items shall be identical in all respects to those submitted to the Government for approval, un
25、less otherwise approved by the Government in writing. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-DTL-22442G 53.3.2 Qualification by similarity. Cable assemblies furnished under this specification may be qualified by similarity as shown by th
26、e examples in MIL-DTL-22442/6. 3.4 Design and construction. 3.4.1 Connectors. The connectors shall be as specified in the detailed specification sheets. 3.4.1.1 Contacts. Contacts used in MIL-DTL-26482 or equivalent type circular connectors approved by the qualifying activity shall conform to SAE-AS
27、39029. Other contacts shall be as specified in the specification sheet. 3.4.2 Connections. Connections shall be as specified in the specification sheet. 3.4.3 Terminations. Terminations shall be as specified in the specification sheet. 3.4.4 Cable/cord. Cable/cord shall be as specified in the specif
28、ication sheet in regard to cable sizing, configuration, and number of conductors. However, cable/cord jacket and molded section material made of flame retarding polyurethane may be used in lieu of rubber as specified by many specification sheets. In regard to the conductor insulation, alternative ma
29、terials compatible with the outer jacket material may be used. 3.4.4.1 Molded materials. Molded materials shall be made from similar materials as the cordage jacketing materials, and shall provide a bond that will meet the requirements of 3.5.5, 3.5.6, 3.5.8, and 3.5.10 with the cable jacket. 3.4.5
30、Extended length. Extended length of the cable assembly shall be as specified in the specification sheet. 3.4.6 Weight. The maximum weight of the cable assembly shall be as specified in the specification sheet. 3.4.7 Switch assemblies. Each switch assembly housing shall be built in accordance with th
31、e specification sheet and may contain a microphone amplifier, microphone keying switch, earphone impedance matching transformer, and terminal block, or any combination thereof, as specified in the specification sheet. 3.4.8 Switches. Switches shall be as specified in the specification sheet. 3.4.9 T
32、erminal blocks. Terminal blocks shall be as specified in the specification sheet. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-DTL-22442G 63.4.10 Other non-ferrous metals and alloys. The plating or finish used for each individual part shall pr
33、ovide a good appearance, corrosion and deterioration resistance for that part. Various problems such as soldering, fitting, assembly, reaction with adjacent parts and the like, shall be considered in the selection of the plating or finish. 3.4.11 Dissimilar metals. Selection and protection of dissim
34、ilar metal combinations shall be in accordance with MIL-STD-889. The use of dissimilar metals shall be limited to applications where similar metals cannot be used due to peculiar design requirements. 3.4.12 Interchangeability. Interchangeability shall exist between all units and replaceable assembli
35、es, subassemblies, and parts for all equipment delivered on the contract using MIL-HDBK-454, Guideline 7 as guidance. Production items shall be identical in all respects to those submitted to the Government for approval, unless otherwise approved by the Government in writing. 3.4.13 Marking. Cable a
36、ssemblies shall be marked on plastic bands or heat shrinkable tubing, and shall fit snugly around the cable circumference. More than one identification band may be used. Heat shrinkable tubing when used shall not be used as support or as a part of the cable. The cable assemblies shall be marked with
37、 the following information: Information Required Example Contract Number * Military P/N (Type Designator) M22442/XX-X (CX-XXXX) Contractor and Government Entity (CAGE) * NSN NSN 5995-* 3.4.14 Color. The cable shall be black. 3.4.15 Clothing clip. The clothing clip shall be as specified in the specif
38、ication sheet. 3.4.16 Insulating and impregnating compounds. All insulating and impregnating compounds including varnishes and waxes, shall meet the requirements for each application as specified, under all service conditions, including test conditions outlined in section 4 of this specification. Th
39、e compound shall preserve the dielectric strength of the insulation to which it is applied. A compound shall not, either in the state of its original application or as a result of aging under severe service conditions, show any injurious effect upon the insulation it is Provided by IHSNot for Resale
40、No reproduction or networking permitted without license from IHS-,-,-MIL-DTL-22442G 7designed to protect, and shall not cause corrosion or deterioration of adjacent metal or plastic parts. 3.4.17 Cementing compounds. Any cementing compound used in the construction of the cable assembly shall withsta
41、nd all service conditions including test conditions outlined in section 4 of this specification without evidence of loosening or otherwise affecting the performance requirements of the cable assembly. 3.4.18 Soldering. Cable assemblies shall be soldered in accordance with J-STD-001, class 3. 3.4.19
42、Printed wiring boards. Printed wiring boards shall be designed in accordance with IPC-2221 and IPC-2222. 3.5 Performance. The cable assembly shall meet the following performance requirements when applicable. 3.5.1 Continuity. Each conductor shall be continuous in the assembly through the termination
43、s of the conductors, where the design calls for a continuous line. Testing shall be in accordance with 4.5.3. 3.5.2 Dielectric withstanding voltage. Unless otherwise specified in the specification sheet, the cable assemblies shall be capable of withstanding a dielectric withstanding voltage as speci
44、fied in the applicable cordage specification for a minimum of 30 seconds when tested in accordance with 4.5.4. 3.5.3 Gauging. For connector terminated cable assemblies, contacts and interfacial dimensions shall not be changed by the assembly procedure to prevent intermating of connectors. Testing sh
45、all be in accordance with 4.5.5. 3.5.4 Pull and twist. The terminal components including metallic terminals, taper pins, connectors, terminal blocks, and molded bend reliefs shall not part from the conductor at the specified loads in accordance with the applicable drawings or specification sheets. A
46、fter twisting and pulling in accordance with 4.5.6, there shall be no more than 1/32 inch slippage of the cable jacket from the connector, nor separation of the bond on molded terminations, molded bend reliefs, and molded strain reliefs. 3.5.5 Bend relief, “Y” junction/crotch flexibility (see 6.5).
47、For flexible molded cable assemblies with bend reliefs, or “Y” junction/crotchs there shall be no electrical discontinuity, bond separation, or cracking between the insulation or bend relief and the cable jacket after being tested in accordance with 4.5.7 or 4.5.7.1. The test specified in 4.5.7.1 is
48、 required only for cable assemblies that are spliced at the “Y” junction/crotch. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-DTL-22442G 83.5.6 Low temperature flexibility. For cable assemblies with molded or heat-shrunken components, the insu
49、lation of each conductor within a portion of the cable jacket containing a molded or potted splice, crotch, or other molded or potted section or heat-shrunken transition (see 6.5), shall be tested for low temperature flexibility. The condition of the test temperature shall be the lower limit of the cable operating temperature range. If not specified, th
