SPECIFICATION:
THIS ISSUE:
DATE:
55A
Issue 4
7 March 2005
Wire and Cable
501 Oakside Avenue, Redwood City, CA 94063-3800
REPLACES:
PAGE:
Amendment 1, Issue 3
1 of 18
WIRE AND CABLE, ELECTRIC, RADIATION-CROSSLINKED,
EXTRUDED, MODIFIED, FLUOROPOLYER-INSULATED
COPPER OR COPPER ALLOY
1.
1.1
SCOPE
SCOPE
This specification covers radiation-crosslinked, extruded, modified, fluoropolymer-insulated
wire and single- and multiple-conductor cables which may be shielded and jacketed. This
insulation may be used alone or in combination with other insulation materials and is intended
for use as a high-temperature, thin-wall insulation system in military, aerospace, and general
purpose hookup wire applications.
1.2
CLASSIFICATION
Products in accordance with this specification shall be of the following types, as specified in
the applicable specification sheet.
Finished Wire
Finished Cable
A single conductor, insulated as specified in the applicable specification
sheet.
Any construction other than finished wire, utilizing a wire or wires with
or without shielding, or with or without an outer jacket.
1.2.1
Temperature Rating
The maximum conductor temperature of the finished wire and cable for continuous use shall
be as specified in the applicable specification sheet.
2.
2.1
APPLICABLE DOCUMENTS
GOVERNMENT-FURNISHED DOCUMENTS
The following documents, of the issue in effect on date of invitation for bids or request for
proposal, form a part of this specification to the extent specified herein.
© 2005 Tyco Electronics Corporation. All rights reserved.
NOTE:
ANY COPY OF THIS DOCUMENT THAT DOES NOT HAVE A
RED "CONTROL" STAMP IS AN UNCONTROLLED COPY.
Page 2 of 18
SPECIFICATION 55A, ISSUE 4
2.1.1
Department of Defense
SPECIFICATIONS
Federal
UU-T-450
Military
MIL-W-22759
MIL-D-26937
STANDARDS
Federal
FED-STD-228
Military
MIL-STD-104
MIL-STD-109
MIL-STD-681
MIL-STD-1916
Limits for Electrical Insulation Color
Quality Assurance Terms and Definitions
Identification Coding and Application of Hook Up and Lead Wire
DOD Preferred Methods for Acceptance of Product
Cable and Wire, Insulated; Methods of Testing
Wire, Electric, Fluoropolymer-Insulated, Copper or Copper Alloy
Detergent, Synthetic, Anionic (Alkyl Benzene Sulfonate)
Tissue, Facial
(Copies of Department of Defense documents may be obtained from the Naval Publications
and Forms Center, 5801 Tabor Avenue, Philadelphia, Pennsylvania 19120.)
2.1.2
Department of Transportation, Federal Aviation Administration
FEDERAL AVIATION REGULATIONS (FAR)
Part 25 Airworthiness Standards: Transport Category Airplanes
(Copies of Department of Transportation, Federal Aviation Administration documents may be
obtained from the Superintendent of Documents, Government Printing Office, Washington,
D.C. 20402.)
2.2
OTHER PUBLICATIONS
The following documents form a part of this specification to the extent specified herein.
Unless otherwise indicated, the issue in effect on date of invitation for bids or request for
proposal shall apply.
NOTE:
ANY COPY OF THIS DOCUMENT THAT DOES NOT HAVE A
RED "CONTROL" STAMP IS AN UNCONTROLLED COPY.
SPECIFICATION 55A, ISSUE 4
Page 3 of 18
2.2.1
American Society for Testing and Materials (ASTM)
E 104
Standard Recommended Practice for Maintaining Constant Relative
Humidity by Means of Aqueous Solutions
(Copies of ASTM publications may be obtained from the American Society for Testing and
Materials, 1916 Race Street, Philadelphia, Pennsylvania 19103.)
2.2.2
National Electrical Manufacturers Association (NEMA)
WC 27500
Standard for Aerospace and Industrial Electrical Cable
(Copies of NEMA publications may be obtained from the National Electrical Manufacturers
Association, 1300 N. 17th Street, Rosslyn, Virginia 22209.)
3.
3.1
REQUIREMENTS
SPECIFICATION SHEETS
The requirements for the individual wires and cables furnished under this specification shall be
as specified herein and in accordance with the applicable specification sheet. Specification
sheet shall mean the Specification Control Drawing (SCD) or the Customer Specification
Report (CSR) when used in conjunction with the SCD, with the SCD taking precedence over
this specification and the CSR taking precedence over the SCD and this specification. An
SCD or CSR may include (but not be limited to) requirements, changes in procedures, or
Quality Assurance Inspection levels which take precedence over this specification.
3.2
QUALIFICATION
The wire and cable furnished under this specification shall be a product which has been tested
and has passed the qualification tests specified herein (see 4.2).
3.3
3.3.1
MATERIALS
Conductor Materials
Conductor materials shall be in accordance with MIL-W-22759 and the applicable
specification sheet.
3.3.2
Shield Materials
Shield strands shall conform to the requirements for conductor materials (3.3.1). When
specified, conforming strands shall be flattened and rectangular in cross section.
3.3.3
Wraps
Wrap tapes, where specified in the applicable specification sheet, shall be applied with an
overlap of 25 percent, minimum, and shall meet the material and construction requirements of
the applicable specification sheet. Overlap is defined as the percentage of tape width covered
by successive turns of tape.
NOTE:
ANY COPY OF THIS DOCUMENT THAT DOES NOT HAVE A
RED "CONTROL" STAMP IS AN UNCONTROLLED COPY.
Page 4 of 18
SPECIFICATION 55A, ISSUE 4
3.3.4
Insulation and Jacket Materials
Insulating materials, used for wire insulation or cable jackets, shall be radiation-crosslinked,
extruded, modified fluoropolymer.
3.4
3.4.1
IN-PROCESS
Conductor Splices
Splices shall be in accordance with MIL-W-22759.
3.4.2
Insulation Flaws
One hundred percent of the wire shall pass the impulse dielectric test or the spark test of MIL-
W-22759 at any designated point or points in the manufacturing process prior to completion of
the finished wire using the voltage specified in the applicable specification sheet.
3.5
FINISHED WIRE AND CABLE
Finished wire and cable shall conform to the following requirements, as applicable, those of
Table 1, and those of the applicable specification sheet (3.1).
3.5.1
3.5.1.1
Crosslinking Tests and Life Cycle
Finished Wire - Accelerated Aging (Crosslinking Proof) and Life Cycle
When finished wire is tested in accordance with 4.6.1, there shall be no cracking of the
insulation and no dielectric breakdown.
3.5.1.2
Finished Cable - Accelerated Aging and Life Cycle
When finished cable is tested in accordance with 4.6.1, there shall be no cracking of the jacket
and, when applicable, no dielectric breakdown of the jacket.
3.5.2
Color
Color shall be in accordance with MIL-STD-104, Class 1. White is preferred for both
insulation and jacket. Colors specified other than white shall be selected in accordance with
MIL-STD-681.
3.5.3
Conductor and Shield Continuity
When finished cable is tested in accordance with WC 27500, there shall be no loss of
continuity in the conductors or shield.
NOTE:
ANY COPY OF THIS DOCUMENT THAT DOES NOT HAVE A
RED "CONTROL" STAMP IS AN UNCONTROLLED COPY.
SPECIFICATION 55A, ISSUE 4
Page 5 of 18
3.5.4
Identification of Product
When specified by the procuring activity, finished wire or cable shall be identified by a
marking applied to the outer surface. The identification shall consist of the appropriate mark
as specified by contract or the applicable specification sheet. The mark color shall be in
accordance with MIL-STD-104, Class 1, and shall be contrasting to that of the marking
surface. Identification shall be applied with the vertical axis of the printed characters parallel
to the longitudinal axis of the wire or cable when the nominal diameter of the marking surface
is 0.050 inch
(1.27 mm)
or smaller. The vertical axis of the printed characters may be either
perpendicular or parallel to the longitudinal axis of the wire or cable when the nominal
diameter of the marking surface exceeds 0.050 inch
(1.27 mm).
3.5.5
Immersion
When finished wire is tested in accordance with MIL-W-22759/32, the diameter increase shall
be not more than 5 percent and there shall be no cracking of the insulation and no dielectric
breakdown.
3.5.6
Insulation Flaws
One hundred percent of finished wire and unshielded, unjacketed cable shall pass the impulse
dielectric test or the spark test of MIL-W-22759 using the voltage specified in the applicable
specification sheet. The test shall be performed during the final winding of the wire or cable
on shipment spools or reels.
3.5.7
Jacket Concentricity
When finished cable is tested in accordance with 4.6.8, the jacket concentricity shall be 70
percent, minimum.
3.5.8
Jacket Flaws
One hundred percent of finished shielded and jacketed cable shall pass the jacket flaws test in
accordance with 4.6.9 using the voltage specified in the applicable specification sheet.
3.5.9
Wrap Test
When tested in accordance with 4.6.14, no cracking of the insulation is allowed. If the
specification sheet does not specify a temperature, the test shall be performed at room
temperature.
NOTE:
ANY COPY OF THIS DOCUMENT THAT DOES NOT HAVE A
RED "CONTROL" STAMP IS AN UNCONTROLLED COPY.
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