1、 INCH-POUND MIL-DTL-32180 17 November 2004 SUPERSEDING MIL-DTL-915/1F 22 August 2002 DETAIL SPECIFICATION CABLE ASSEMBLY, AIRCRAFT ELECTRICAL SERVICE This specification is approved for use by all Departments and Agencies of the Department of Defense. 1. SCOPE 1.1 Scope. This specification establishe
2、s the design for an aircraft electrical service cable assembly used to connect shipboard 400Hz power from Aircraft Electrical Servicing System (AESS) stations to onboard aircraft. 2. APPLICABLE DOCUMENTS 2.1 General. The documents listed in this section are specified in sections 3, 4, or 5 of this s
3、pecification. 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 cautioned that they must meet all specified requi
4、rements 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 document to the extent specified herein. Unles
5、s otherwise specified, the issues of these documents are those cited in the solicitation or contract. COMMERCIAL ITEM DESCRIPTIONS A-A-59551 - Wire, Electrical, Copper (Uninsulated) DEPARTMENT OF DEFENSE SPECIFICATIONS MIL-S-901 - Shock Tests, H.I. (High-Impact) Shipboard Machinery, Equipment, and S
6、ystems, Requirements for DEPARTMENT OF DEFENSE STANDARDS MIL-STD-167-1 - Mechanical Vibrations of Shipboard Equipment (Type 1 - Environmental and Type II - Internally Excited) (Copies of these documents are available online at http:/assist.daps.dla.mil/quicksearch/ or http:/assist.daps.dla.mil or fr
7、om the Standardization Document Order Desk, 700 Robbins Avenue, Building 4D, Philadelphia, PA 19111-5094.) 2.2.2 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. U
8、nless otherwise specified, the issues of these documents are those cited in the solicitation or contract. Comments, suggestions, or questions on this document should be addressed to: Commander, Naval Sea Systems Command, ATTN: SEA 05Q, 1333 Isaac Hull Avenue, SE, Stop 5160, Washington Navy Yard DC 2
9、0376-5160 or emailed to commandstandardsnavsea.navy.mil, with the subject line “Document Comment”. 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 6145 Provided by IHSNot
10、 for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-DTL-32180 DEPARTMENT OF DEFENSE DRAWINGS MS90362 - Connector, Receptacle, External Electric Power, Aircraft, 115/200 Volt, 400 Hertz (Copies of these documents are available online at http:/assist.daps.dla.mil/quicks
11、earch/ or http:/assist.daps.dla.mil or from the Standardization Document Order Desk, 700 Robbins Avenue, Building 4D, Philadelphia, PA 19111-5094.) 2.3 Order of precedence. In the event of a conflict between the text of this document and the references cited herein, the text of this document takes p
12、recedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specification exemption has been obtained. 3. REQUIREMENTS 3.1 First article. When specified (see 6.2), a sample shall be subjected to first article inspection in accordance with 4.2. 3.2 Materials. The
13、 contractor shall select materials capable of meeting all of the operational and environmental requirements specified herein. 3.2.1 Recycled, recovered, or environmentally preferable materials. Recycled, recovered, or environmentally preferable materials should be used to the maximum extent possible
14、, provided that the material meets or exceeds the operational and maintenance requirements, and promotes economically advantageous life cycle costs. 3.3 Cable assembly electrical characteristics. 3.3.1 Rating. The power conductors of the aircraft servicing cable assembly shall be rated at 600 Volts
15、and shall have a minimum current carrying capacity of 175 Amperes. When operating with the minimum current carrying capacity of 175 Amperes, the conductor temperature rise shall not exceed 50 C. The control conductors shall be rated at 300 Volts and shall have a minimum current carrying capacity of
16、5 Amperes. 3.3.2 Voltage drop. The application of a load of 175 Amperes per phase, 0.8 power factor, to the aircraft servicing cable assembly shall result in a maximum voltage drop of 0.04 Volts per foot per phase, when tested at 400Hz, with a 20 C ambient temperature. 3.3.3 Voltage unbalance. The a
17、pplication of a balanced load of 175 Amperes per phase, 0.8 power factor, to the aircraft servicing cable assembly shall result in a maximum voltage unbalance phase-to-phase of 0.5 Volts, when tested at 400Hz, with a 20 C ambient temperature. 3.3.4 Dielectric strength. The dielectric strength betwee
18、n conductors shall not exhibit a leakage current that exceeds 70 micro-amps. 3.3.5 Insulation resistance. The insulation resistance between the conductors shall be a minimum of 100 megohms. 3.4 Cable assembly design. 3.4.1 Cable assembly length. Each aircraft servicing cable assembly shall be 90 1.5
19、 feet in length. Certain applications may call for shorter lengths in which case the same tolerance applies (see 6.2). 3.4.2 Conductor material. The current carrying conductors of the aircraft servicing cable assembly shall be made from annealed copper wire in accordance with A-A-59551, Temper 1 and
20、 coating B or T. 3.4.3 Number and size of conductors. The aircraft servicing cable assembly shall contain six AWG 5 conductors, two per phase, helically laid around one AWG 2 center neutral conductor. There shall be a minimum of six control conductors with a minimum size of AWG 18. 2 Provided by IHS
21、Not for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-DTL-32180 3.4.4 Conductor termination. Each phase conductor (A, B, C, and N) shall be separately lugged to fit 0.375 inch studs. All control conductors shall be lugged to fit #8 size screws. The outer jacket shall
22、 be stripped back to reveal 12 0.5 inches of each conductor except the neutral shall be 14 0.5 inches long. Heat shrink tubing shall be applied to cover the bundle of 12-inch long leads, leaving 2 inches of the neutral uncovered. 3.4.5 Cable jacket. The outer jacket of the aircraft servicing cable s
23、hall be made of reinforced neoprene and shall be capable of withstanding severe abrasion (see 4.5.6). 3.4.6 Cable diameter. The outer diameter of the aircraft servicing cable shall not exceed 1.55 0.05 inches. 3.4.7 Bend radius. The aircraft servicing cable shall have a minimum bend radius of 9 inch
24、es and shall be able to sustain a minimum of 750 consecutive bends without conductor strand breakage in excess of the allowable limits (see 4.5.6) and 2500 consecutive bends without jacket rupture. 3.4.8 Cable impact. The aircraft servicing cable shall be capable of withstanding the impact of a 6 lb
25、. weight dropped repeatedly for 1000 times from a height of 1 foot without experiencing any splits, tears, cracks, or ruptures in the jacketing, short circuits, or loss of continuity in the conductors. 3.4.9 Cable weight. The aircraft servicing cable shall weigh no more than 1.8 + 0.1 lbs. per ft. (
26、excluding the aircraft servicing connector). 3.4.10 Cable marking. The aircraft servicing cable shall be marked along the exterior jacket and shall include: a. Manufacturers name and part number b. “Aircraft Power Cable” 3.4.11 Helical deformation. The aircraft servicing cable shall be capable of wi
27、thstanding up to 2000 deformation cycles (see 4.5.10). These deformation cycles produce severe mechanical stresses, which cause the internal cable elements to move with respect to each other. Failure of cable elements to return to their original positions results in progressive helical deformation o
28、f the cable. 3.4.12 Aircraft servicing connector. 3.4.12.1 Connector. The aircraft servicing connector shall be integrally molded to one end of the cable and shall be watertight. The connector shall provide the interface with shipboard aircraft and shall engage with receptacles conforming to MS90362
29、 and MS90362-1. The aircraft servicing connector shall have six socket contacts marked A, B, C, E, F, and N, arranged as shown on Figure 1. Socket contacts A, B, C, and N shall be connected to phase conductors A, B, C, and Neutral, respectively. 3.4.12.2 Connector flexing. The molded aircraft servic
30、ing cable connector shall be capable of withstanding 10,000 flexing cycles when installed in a mating receptacle without visual evidence of cable and connector damage (see 4.5.11). 3 Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-DTL-32180 FIGUR
31、E 1. Connector socket arrangement (as viewed from the face which mates with the aircraft receptacle). 3.4.12.3 Contact section. The contact section of the molded aircraft servicing connector shall be capable of being repaired in the field by installing a one-piece, molded, replacement contact sectio
32、n. Installation of the contact section shall restore watertight integrity to the molded aircraft servicing connector. Repair shall not include replacement of the entire aircraft servicing connector. 3.4.12.4 Engagement force. The aircraft servicing connector shall be capable of being engaged and dis
33、engaged from the aircraft receptacle 1000 times with a force of 80 20 lbs. throughout the operating temperature range of -30 C to +55 C. 3.4.12.5 Pushbutton switches. The molded aircraft servicing connector shall include an integral ON/OFF pushbutton switch module that is capable of connecting and d
34、isconnecting power to the aircraft receptacle. The ON switch shall be normally OPEN and the OFF switch shall be normally CLOSED. Both switches shall have a minimum continuous AC rating of 115 Volts, 1 Amperes, at 60-400Hz , and a minimum continuous DC rating of 28 Volts, 2 Amperes. The pushbutton sw
35、itches shall be housed in a single, replaceable, watertight module that is keyed to guard against improper installation. Replacement shall not include any wiring. Installation shall restore watertight integrity to the aircraft servicing connector. 3.4.12.6 Insertion interlock. The F-socket of the mo
36、lded aircraft servicing connector shall be constructed of three distinct parts: conductor, insulator, and conductor. The two isolated contacts of the F-socket shall be used as part of a safety interlock circuit to prevent power from being applied to the aircraft servicing connector when not installe
37、d into the aircraft receptacle. Removal of the aircraft servicing connector from the aircraft receptacle shall disconnect power with no amperage level dependency. The F-socket contacts shall be part of the replaceable, molded, contact section (see 3.4.12.3). 3.4.12.7 Insertion interlock controller.
38、The insertion interlock shall include a controller that accepts a 115 Volt, 400Hz, input signal and provides a 24 Volt DC signal that is fully isolated from neutral and ground. This controller module shall also include two isolated sets of normally OPEN relay contacts, rated for 115 Volts, 1 Ampere
39、AC, or 28 Volts, 2 Amperes DC. This controller module shall not exceed 3 inches x 3 inches x 3 inches in size. The controller module shall be watertight. The controller module shall meet Grade A, Class I shock of MIL-S-901 and Type I vibration of MIL-STD-167-1. The controller module shall be supplie
40、d separately. 3.4.12.8 Control wiring. The control wires shall be connected to socket contacts E and F, and the pushbutton switches as shown in Figure 2. 4 Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-DTL-32180 FIGURE 2. Wiring diagram. 4. VER
41、IFICATION 4.1 Classification of inspections. The inspection requirements specified herein are classified as follows: a. First article inspection (see 4.2). b. Conformance inspection (see 4.3). 4.2 First article inspection. First article inspection shall be performed on one complete aircraft servicin
42、g cable assembly when a first article sample is required (see 6.1). First article inspection shall include the examination and inspections in accordance with Table I. 4.3 Conformance inspection. Conformance inspection shall include the examination and inspections in accordance with Table I. 5 Provid
43、ed by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-DTL-32180 TABLE I. Examination and inspections. Test requirement Requirement paragraph Inspection paragraph First article inspection Conformance inspection Rating 3.3.1 4.5.1 XVoltage drop 3.3.2 4.5.2 X V
44、oltage unbalance 3.3.3 4.5.3 X Dielectric strength 3.3.4 4.5.4 X Insulation resistance 3.3.5 4.5.5 X X Cable assembly length 3.4.1 4.4 X X Conductor material 3.4.2 4.4 X Conductor number -30 C, ambient and 55 C. The force required to remove the aircraft servicing connector form the receptacle shall
45、comply with 3.4.12.4. At ambient temperature only, the aircraft servicing connector shall be inserted into, and removed from, the mating receptacle 1000 times. The rate of insertion shall be 2 to 5 cycles per minute. A cycle is defined as one insertion and one removal. A suitable electrical contact
46、lubricant may be used to prevent galling of the contacts. After 1000 cycles, posttest measurements of the engagement force of the aircraft servicing connector shall be made at 30 C, ambient and 55 C. The engagement force shall be within the range of 80 20 lbs. 4.5.13 Insertion interlock. The F-socke
47、t safety interlock circuit of the molded aircraft servicing connector shall be checked to determine that continuity is established upon insertion of the aircraft servicing cable connector into its mating receptacle. Continuity shall be disrupted when the connector is removed from the receptacle. Ope
48、ration other than specified shall constitute failure. 4.5.14 Insertion interlock controller shock. The insertion interlock controller shall be subjected to shock using a light weight shock apparatus in accordance with MIL-S-901. The controller module shall be operated at the conclusion of the shock
49、test to determine that it is fully functional. Less than full operational capability shall constitute failure. 4.5.15 Insertion interlock controller vibration. The insertion interlock controller shall be subjected to vibration in accordance with MIL-STD-167-1. The controller module shall be operated at the conclusion of the vibration test to determine that it is fully functional. Less than full operational capability shall constitute failure. 5. PACKAGIN
