55FB1511-20-7L-0 (871895-000) - Tyco Electronics

Raychem Wire and Cable

501 Oakside Avenue, Redwood City, CA 94063-3800

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SPECIFICATION: 55F

THIS ISSUE: Issue 4

DATE: 1 October 2008

REPLACES: Issue 3

PAGE: 1 of 16

CABLE, ELECTRIC, FILTER LINE

1. SCOPE

1.1 SCOPE

This specification covers finished cable and cable components for use as low pass filters to

replace standard airframe interconnect wiring for aerospace vehicles and other applications.

1.2 CLASSIFICATION

Products in accordance with this specification shall be of the following types, as specified in

the applicable specification sheet.

Component Wire: A single conductor, insulated as specified in the applicable specification

sheet.

Finished Cable: Any construction other than component wire, utilizing a wire or wires

with or without shielding, and with or without an outer jacket.

1.2.1 Temperature Rating

The maximum conductor temperature of the component wire or finished cable for continuous

use shall be as specified in the applicable specification sheet.

2. APPLICABLE DOCUMENTS

2.1 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.

Page 2 of 16 SPECIFICATION 55F, ISSUE 4

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2.1.1 Department of Defense

SPECIFICATIONS

Military

MIL-C-85485 Cable, Electric, Filter Line, Radio Frequency Absorptive

STANDARDS

Military

MIL-STD-104 Limits for Electrical Insulation Color

(Copies of Department of Defense documents may be obtained from the Naval Publications

and Forms Center, Standardization Documents Order Desk, Bldg. 4D, 700 Robbins Ave.,

Philadelphia, PA 19111-5094; or at http://assist.daps.dla.mil/quicksearch/.)

2.2 OTHER PUBLICATIONS

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.

2.2.1 American National Standards Institute (ANSI)

ANSI/ASQ Z1.4 Sampling Procedures and Tables for Inspection by Attributes

(Copies of ASQ documents may be obtained from the ASQ Distribution Center,

5131 S. Third Street, Milwaukee, WI 53207-6028; or at www.asq.org.)

2.2.2 International Organization for Standardization (ISO)

8402 Quality Management and Quality Assurance - Vocabulary

(Copies of ISO documents may be obtained from the International Organization for

Standardization; or at www.iso.org.)

3. REQUIREMENTS

3.1 SPECIFICATION SHEETS

The requirements for the component wire and finished cable furnished under this specification

shall be as specified herein and in accordance with the applicable specification sheet. In the

event of a conflict, the requirements of the specification sheet shall govern.

3.2 QUALIFICATION

The component wire and finished cable furnished under this specification shall be a product

which has been tested and has passed the qualification tests specified herein (see 4.2).

SPECIFICATION 55F, ISSUE 4 Page 3 of 16

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3.3 CONSTRUCTION AND MATERIALS

Materials not specifically designated herein shall be of the quality and form best suited for the

purpose intended. Unless otherwise specified, the materials shall meet the following

requirements:

3.3.1 Conductors

Conductor material and construction shall be in accordance with MIL-C-85485 and the

applicable specification sheet.

3.3.2 Shields

Shield material and construction shall be in accordance with MIL-C-85485 and the applicable

specification sheet. Round braided shields shall have an angle 18 to 40 degrees relative to the

axis of the cable.

3.3.3 Insulating Materials

Insulating materials, used for wire insulation or cable jackets, shall be in accordance with

MIL-C-85485 and the applicable specification sheet.

3.3.4 Wraps

Tape wraps, 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.

3.4 IN-PROCESS

3.4.1 Insulation Flaws

One hundred percent of the wire shall pass the impulse dielectric test or the spark test of

MIL-C-85485 at any designated point or points in the manufacturing process prior to

completion of the component wire using the voltage specified in the applicable specification

sheet.

3.5 COMPONENT WIRE AND FINISHED CABLE

3.5.1 Component Wire

Component wire shall conform to the requirements of Table 1 and to those of the applicable

specification sheet.

3.5.2 Finished Cable

Finished cable shall conform to the requirements of Table 2 and to those of the applicable

specification sheet. Component wires used in the cable shall conform to the requirements of

3.5.1, prior to cabling.

Page 4 of 16 SPECIFICATION 55F, ISSUE 4

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3.5.3 Cabling

The required number of components as specified in the applicable specification sheet shall be

cabled together with a left-hand lay. For cables having multiple layers, the outer layer shall be

left-hand and the inner layer or layers may be either right-hand or left-hand lay. The lay

length of the components in the outer layer shall be not less than eight nor more than sixteen

times the outside diameter of the cable bundle.

3.5.4 Crosslinking Proof Test and Life Cycle

When finished cable is tested in accordance with 4.5.2, there shall be no cracking of the jacket

and, when applicable, no dielectric breakdown of the jacket.

3.5.5 Identification and Color Striping Durability

When required by the specification sheet, identification printing and color striping of the

finished cable jacket shall be capable of withstanding the identification and color striping

durability test of MIL-C-85485 for the number of cycles and with the weight specified in the

applicable specification sheet.

3.5.6 Identification of Product

When specified by the procuring activity, component wire or finished cable shall be identified

by a marking applied to the outer surface. The identification shall consist of the appropriate

mark as specified by the 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 (1.3 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 (1.3 mm).

3.5.7 Immersion

When finished cable is tested in accordance with 4.5.5, the diameter increase shall be not more

than 5 percent, there shall be no cracking of the jacket and, when applicable, there shall be no

dielectric breakdown of the jacket.

3.5.8 Insulation Flaws

One hundred percent of component wire and unshielded, unjacketed cable shall pass the

impulse dielectric test or the spark test of MIL-C-85485 using the voltage specified in the

applicable specification sheet. Testing shall be performed during the final winding of the wire

or cable on shipment spools or reels.

SPECIFICATION 55F, ISSUE 4 Page 5 of 16

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3.5.9 Jacket Concentricity

When finished cable is tested in accordance with MIL-C-85485, the jacket concentricity shall

be not less than 70 percent.

3.5.10 Jacket Flaws

When required by the applicable specification sheet, one hundred percent of finished shielded

and jacketed cable shall pass the jacket flaws test of MIL-C-85485 using the voltage specified

in the applicable specification sheet. Testing shall be performed during the final winding of

the cable on shipment spools or reels.

3.5.11 Jacket Flexure Endurance

When required by the specification sheet and tested in accordance with 4.5.7, there shall be no

cracking of the jacket.

3.5.12 Jacket Resistivity

When finished cable is tested in accordance with MIL-C-85485, the jacket resistivity for

conductive jackets shall be 150 ohm-cm, maximum.

3.5.13 Low Temperature-Cold Bend

When finished cable is tested in accordance with 4.5.8, there shall be no cracking of the jacket

and, when applicable, no dielectric breakdown of the jacket.

3.5.14 Thermal Stability

When component wire is tested in accordance with 4.5.9, there shall be no dielectric

breakdown during the voltage withstand (dielectric) test and the stop band attenuation

requirements for the applicable component wire size shall be met. There shall be no cracking

of the insulation after the bend test and no dielectric breakdown during the voltage withstand

(post environmental) test.

3.5.15 Weight Loss

When required by the specification sheet and tested in accordance with 4.5.10, specimens of

cable with woven or spiral, round or flat, shielding shall not exceed a weight loss of 0.45

percent.

3.5.16 Wrap Test

When component wire is tested in accordance with 4.5.11, there shall be no cracking of the

insulation.

Page 6 of 16 SPECIFICATION 55F, ISSUE 4

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TABLE 1. PROPERTIES OF COMPONENT WIRE

Examination or Test Requirement Test Method *Test Type

Attenuation (Insertion Loss) Specification Sheet MIL-C-85485 2

Blocking Specification Sheet and MIL-C-85485 MIL-C-85485 Q

Color Specification Sheet and MIL-C-85485 4.5.3 1

Component Wire Diameter Specification Sheet 4.5.3 1

Concentricity Specification Sheet 4.5.1 2

Conductor Diameter Specification Sheet 4.5.3 1

Conductor Elongation and Breaking Strength Specification Sheet or MIL-C-85485 MIL-C-85485 1

Conductor Resistance Specification Sheet MIL-C-85485 1

Conductor Splices MIL-C-85485 4.5.3 1

Conductor Stranding Specification Sheet and MIL-C-85485 4.5.3 1

Construction and Materials Specification Sheet and 3.3 4.5.3 1

Crosslinking Proof Test Specification Sheet and MIL-C-85485 MIL-C-85485 2

Flammability Specification Sheet MIL-C-85485 2

Fluoride Extraction Specification Sheet 4.5.4 Q

Humidity Resistance Specification Sheet MIL-C-85485 Q

Identification and Color Striping Durability Specification Sheet MIL-C-85485 1

Identification of Product Specification Sheet and 3.5.6 4.5.3 1

Immersion Specification Sheet MIL-C-85485 Q

Insulation Elongation and Tensile Strength Specification Sheet MIL-C-85485 1

Insulation Flaws Specification Sheet and 3.5.8 MIL-C-85485 3

Insulation Resistance Specification Sheet 4.5.6 1

Insulation Thickness Specification Sheet 4.5.3 2

Life Cycle Specification Sheet and MIL-C-85485 MIL-C-85485 Q

Low Temperature-Cold Bend Specification Sheet and MIL-C-85485 MIL-C-85485 2

Removability of Insulation MIL-C-85485 MIL-C-85485 1

Shrinkage Specification Sheet MIL-C-85485 2

Smoke Specification Sheet MIL-C-85485 Q

Surface Resistance Specification Sheet MIL-C-85485 Q

Thermal Shock Resistance Specification Sheet MIL-C-85485 2

Thermal Stability Specification Sheet and 3 .5.14 4.5.9 Q

Vacuum Stability Specification Sheet MIL-C-85485 Q

Weight Specification Sheet MIL-C-85485 1

Workmanship MIL-C-85485 MIL-C-85485 1

Wrap Test Specification Sheet and 3.5.16 4.5.11 2

*Test Type:

1 = Quality Conformance Test, Group 1 (see 4.3)

2 = Quality Conformance Test, Group 2 (see 4.3)

3 = Quality Conformance Test, Group 3 (see 4.3)

Q = Qualification Test (see 4.2)

SPECIFICATION 55F, ISSUE 4 Page 7 of 16

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TABLE 2. PROPERTIES OF FINISHED CABLE

Examination or Test Requirement Test Method *Test Type

Blocking Specification Sheet and MIL-C-85485 MIL-C-85485 Q

Cabling Specification Sheet and 3.5.3 4.5.3 1

Conductor and Shield Continuity MIL-C-85485 MIL-C-85485 3

Construction and Materials Specification Sheet and 3.3 4.5.3 1

Crosslinking Proof Test Specification Sheet and 3.5.4 4.5.2 2

Dimensions Specification Sheet 4.5.3 1

Flammability Specification Sheet MIL-C-85485 2

Fluoride Extraction Specification Sheet 4.5.4 Q

Identification and Color Striping Durability Specification Sheet and 3.5.5 MIL-C-85485 1

Identification of Product Specification Sheet and 3.5.6 4.5.3 1

Immersion 3.5.7 4.5.5 Q

Insulation Flaws Specification Sheet and 3.5.8 MIL-C-85485 3

Jacket Color Specification Sheet and MIL-C-85485 4.5.3 1

Jacket Concentricity 3.5.9 MIL-C-85485 2

Jacket Elongation and Tensile Strength Specification Sheet MIL-C-85485 1

Jacket Flaws Specification Sheet and 3.5.10 MIL-C-85485 3

Jacket Flexure Endurance Specification Sheet and 3.5.11 4.5.7 2

Jacket Resistivity 3.5.12 MIL-C-85485 2

Jacket Thickness Specification Sheet 4.5.3 2

Life Cycle Specification Sheet and 3.5.4 4.5.2 Q

Low Temperature-Cold Bend Specification Sheet and 3.5.13 4.5.8 2

Shield Coverage and Angle Specification Sheet and 3.3.2 MIL-C-85485 1

Thermal Shock Resistance Specification Sheet MIL-C-85485 2

Vacuum Stability Specification Sheet MIL-C-85485 Q

Voltage Withstand (Dielectric) Specification Sheet MIL-C-85485 3

Weight Specification Sheet MIL-C-85485 1

Weight Loss Specification Sheet and 3.5.15 4.5.10 2

Workmanship MIL-C-85485 MIL-C-85485 1

*Test Type:

1 = Quality Conformance Test, Group 1 (see 4.3)

2 = Quality Conformance Test, Group 2 (see 4.3)

3 = Quality Conformance Test, Group 3 (see 4.3)

Q = Qualification Test (see 4.2)

Page 8 of 16 SPECIFICATION 55F, ISSUE 4

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4. QUALITY ASSURANCE PROVISIONS

4.1 RESPONSIBILITY FOR INSPECTION

The supplier is responsible for the performance of all the inspection tests specified herein.

The supplier may utilize his own or any other inspection facility and services acceptable to the

buyer. Inspection records of the examinations and tests shall be kept complete and available

to the buyer as required.

4.2 QUALIFICATION INSPECTION

Qualification inspection shall consist of all tests listed in Table 1 for component wire and

Table 2 for finished cable. Requalification testing shall be performed any time changes in

materials or processes occur that are deemed to have the potential for significantly altering the

form, fit, function, or appearance of the product.

4.2.1 Sampling for Qualification Inspection

Except as provided in 4.2.1.1, a component wire or finished cable sample of the required

length shall be tested for each range of component wire or finished cable sizes for which

qualification is desired. The sample may be any size of component wire or finished cable

within the size range specified below.

Component Wire Size Range Required Length of Sample

AWG mm2 feet m

30 through 24 0.057 through 0.24 400 122

22 through 18 0.38 through 0.96 400 122

16 through 10 1.23 through 4.74 400 122

8 through 0000 8.60 through 106.9 400 122

Cable Size Range (overall diameter) Required Length of Sample

inch mm feet m

< 0.180 < 4.6 100 30

0.180 > 4.6 100 30

4.2.1.1 Optional Qualification Samples

In cases where two or more specification sheets cover component wire or finished cable

identical in materials and construction except for conductor and/or shield (i.e., the specified

conductor or shield may be tin-coated copper, silver-coated high-strength copper alloy or as

specified in the applicable specification sheet), the component wire or finished cable sample in

accordance with 4.2.1 may qualify any one of the specification sheets. Approval of the

qualification sample shall also qualify the same component wire or finished cable size range or

ranges in each of the other specification sheets. (Note: For purposes of determining identity

of construction in specification sheets under this provision, small differences in specified

component wire or finished cable diameter or weight which are due to differences in the

specified conductor or shield shall not be considered as constituting differences in construction

of the component wire or finished cable.)

SPECIFICATION 55F, ISSUE 4 Page 9 of 16

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4.2.2 Qualification Test Reports

When requested by the procuring activity, qualification test reports shall be plainly identified

with the following information:

Qualification test report for

CABLE, ELECTRIC, FILTER LINE

Manufacturer's Name

Part number of qualification sample

Specification 55F

4.3 QUALITY CONFORMANCE INSPECTION

Quality conformance inspection shall consist only of those examinations and tests listed in

Table 1 and Table 2 identified by a group number, as applicable to component wire or to

finished cable. Quality conformance inspection shall be performed on every lot of wire and

cable procured under this specification.

4.3.1 Sampling for Quality Conformance Inspection

ISO 8402 shall apply for definitions of inspection terms used herein. For purposes of this

specification, the following shall apply:

4.3.1.1 Lot

The inspection lot shall include all component wire or finished cable of one part number

subjected to inspection at one time.

4.3.1.2 Unit of Product

The unit of product for determining lot size for sampling shall be one continuous length of

component wire or finished cable as offered for inspection.

4.3.1.3 Sample Unit (Groups 1 and 2 tests)

The sample unit for Groups 1 and 2 tests, except for the Group 1 insulation resistance test,

shall consist of a single length of component wire or finished cable chosen at random from the

inspection lot and of sufficient length to permit all applicable examinations and tests. Unless

otherwise specified, the length of the sample unit for Group 1 tests of Table 1 and Table 2

shall be 20 feet (6.1 m) and the length of the sample unit for Group 2 tests shall be 25 feet

(7.5 m). Not more than one sample unit for each group of tests shall be taken from a single

unit of product.

4.3.1.3.1 Sample Unit for Insulation Resistance Test (Group 1)

The sample unit for the Group 1 insulation resistance test shall be a specimen 26 feet (7.9 m)

in length selected at random from component wire which has passed the insulation flaws test.

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4.3.1.4 Inspection Levels and Sampling Plan (Groups 1 and 2 tests)

The inspection level shall be S-2 for Group 1, S-3 for Group 2, using a C = 0 sampling plan in

accordance with ANSI/ASQ Z1.4.

4.3.1.5 Sampling and Acceptance Level for Group 3 Tests

Unless otherwise specified in the applicable specification sheet, the component wire or

finished cable sample for the Group 3 insulation flaws test or jacket flaws test shall be 100

percent of the component wire or finished cable, and every length of the wire or cable shall be

fully tested. Portions showing breakdown resulting from the test and ends or portions not

subjected to the test shall be marked or removed. Unless otherwise specified in the applicable

specification sheet, the finished cable sample for the Group 3 conductor and shield continuity

and dielectric withstand tests shall be 100 percent of the finished cable. Portions showing

breakdown in these dielectric tests shall be removed and the remaining lengths tested until no

failure occurs.

4.3.2 Nonconforming Inspection Lots

Disposition of material found unacceptable under quality conformance inspection shall be in

accordance with ANSI/ASQ Z1.4.

4.4 PROCESS CONTROL INSPECTION

This inspection comprises tests and examinations (Table 3) of such a nature that they cannot

be performed on the component wire or finished cable and therefore must be performed at an

appropriate stage of manufacture. Process control inspection shall be performed on every lot

of wire or cable procured under this specification.

TABLE 3. PROCESS CONTROL INSPECTION

Examination or Test Requirement Test Method

Construction and Materials Specification Sheet and 3.3 4.5.3

Conductor Splices MIL-C-85485 4.5.3

Insulation Flaws Specification Sheet and 3.4.1 MIL-C-85485

4.4.1 Sampling for Process Control Inspection

4.4.1.1 Conductor Material

Process control sample selection and inspection of uninsulated conductor shall be performed at

receiving inspection. The conductor lot size, for purposes of sampling, shall consist of the

number of reels of a given type and size of conductor received at one time from one supplier

against a single purchase order. For lot sizes of 3 reels or less, one 15-foot (4.5-m) length of

conductor shall be selected from each reel. For lot sizes of not less than 4 and not more than

25 reels, a minimum of three 15-foot (4.5-m) lengths of conductor shall be selected at random,

in such a manner as to be representative of the material. For lot sizes in excess of 25 reels, the

inspection level shall be Level 1 and the AQL shall be 4.0 percent in accordance with

ANSI/ASQ Z1.4.

SPECIFICATION 55F, ISSUE 4 Page 11 of 16

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4.4.1.2 Insulation Flaws (impulse dielectric test or spark test)

One hundred percent of the wire, after the application of the primary insulation, shall be tested

in accordance with the applicable specification sheet and MIL-C-85485.

4.4.2 Rejection and Retest in Process Control Inspection

When a sample selected from an inspection lot fails to meet the specified test (Table 3), except

the insulation flaws test (see 4.4.1.2), no items still on hand or later produced from that lot

shall be accepted until the extent and cause of the failure has been determined.

4.4.2.1 Effect of Process Control Failure on Quality Conformance Testing

Quality conformance testing may be continued during the investigation of the failure of a

process control sample, but final acceptance of the material shall not be made until it is

determined that the lot meets all the process control and quality conformance requirements of

the specification.

4.5 TEST METHODS

4.5.1 Concentricity

The concentricity of the component primary insulation and jacket shall be determined in

accordance with the procedures of 4.5.1.1 and 4.5.1.2, as applicable. All wall thickness

measurements shall be made on cross sections of the wire under suitable magnification. A

wall thickness shall be the shortest distance between the outer rim of the primary insulation or

finished component wire, as applicable, and the outer rim of the outermost strand of the

conductor.

4.5.1.1 Concentric Lay Wires

The concentricity of the component primary insulation and jacket shall be determined in

accordance with MIL-C-85485.

4.5.1.2 Rope Lay Conductor

The concentricity of the primary insulation or of the finished component wire shall be

determined by first locating and recording the minimum wall thickness measured on a cross

section of the primary insulation or of the finished component wire. From this point on the

outer rim of the primary insulation or finished component wire at which the minimum wall

thickness was measured, three more reference points 90 degrees apart on the outside rim of the

primary insulation or finished component wire shall be established. At each of the three

reference points the nearest member of the rope lay conductor shall be selected and the

minimum wall thickness between that member and the outer rim of the primary insulation or

finished component wire shall be measured. The average of the four readings shall be

considered to be the average wall thickness. For rope lay wires, 100 times the ratio of the

minimum wall thickness to the average wall thickness shall define the percent concentricity.

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4.5.2 Crosslinking Proof Test and Life Cycle

A specimen of finished cable shall be tested in accordance with MIL-C-85485 using the time

and temperature specified in the applicable specification sheet, except that the voltage

withstand test shall be conducted on shielded and jacketed specimens only.

4.5.3 Examination of Product

All samples shall be examined carefully to determine conformance to this specification and to

the applicable specification sheet with regard to requirements not covered by specific test

methods.

4.5.4 Fluoride Extraction

For component wire or filler, prior to cabling, or for finished cable, approximately 0.5 gram of

insulation, filler, or jacket material, as applicable, shall be removed, cut into 3-inch (76-mm)

lengths and weighed to the nearest milligram. A polystyrene test tube (without its cap) shall

also be weighed to the nearest 0.1 gram. After filling with approximately 14 ml of distilled

water, the polystyrene test tube shall be reweighed. The insulation, filler, or jacket specimen

shall then be placed into the test tube, making sure that the specimen is fully submerged, and

the test tube cap is tightly attached. The test tube shall then be partially immersed in a

70 ± 2°C water bath so that the water levels of the bath and the test tube are equal. The test

tube shall be so conditioned for 168 hours with the set-up being periodically checked to make

sure that the specimen is still submerged. After conditioning, the test tube shall be removed

from the bath and allowed to cool. The cap shall then be removed from the test tube, and the

tube, water and specimen shall be weighed to determine the water weight loss. If the water

loss is more than 0.5 gram, the test shall be rerun. Otherwise, 5 ml of the test tube water shall

be analyzed for fluoride ion content using an Ion Chromatograph. The fluoride ion content

shall be reported in ppm of water and shall not exceed the amount specified in the applicable

SCD. A blank test in accordance with 4.5.4.1 should also be conducted in case the result is

needed for calculation purposes.

4.5.4.1 Blank Test

A blank test follows the same procedure as 4.5.4 except that a specimen is not included. What

is tested is the distilled water and the specimen tube. Ideally, there are no fluoride ions in

either the test tube or the distilled water such that the result for the blank test would be zero.

However, there may be a low non-zero result (i.e. 0.005 ppm). If this occurs, the ppm of

fluoride for the blank test must be subtracted from the ppm of fluoride obtained from the

specimen. A blank test also performs the same function as a calibration as it can indicate a

problem with the test procedure. For example, should the blank test produce a result of 15

ppm of fluoride, this would be an indication that the ion chromatograph is not functioning

correctly, tap water was used in place of distilled water, etc.

SPECIFICATION 55F, ISSUE 4 Page 13 of 16

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4.5.4.2 Calculation

If necessary, the blank test result shall be subtracted from the specimen result to obtain the net

fluoride ion content (ppm). The fluoride ion content of the insulation, filler, or jacket weight

shall then be calculated as follows:

F ion = Net F ion (ppm) x Original water weight

Specimen weight

4.5.5 Immersion

Specimens of finished cable shall be tested in accordance with MIL-C-85485, except that the

voltage withstand test shall be conducted on shielded and jacketed specimens only.

4.5.6 Insulation Resistance

The uninsulated ends of a wire specimen at least 26 feet (7.9 m) in length shall be connected

electrically to a DC terminal. The specimen shall be immersed to within 6 inches (152 mm) of

its ends in a water bath at 25 ± 5°C containing 0.5 to 1.0 percent of an anionic wetting agent.

After 4 hours minimum of immersion, the specimen shall be subjected to a potential of 250 to

500 volts applied between the conductor and the water bath, which serves as the second

electrode. The insulation resistance of the specimen shall be determined after one minute of

electrification at this potential and shall be calculated to megohms for 1000 feet as follows:

Megohms for 1000 feet = Specimen resistance (megohms) x Immersed length (feet)

1000

4.5.7 Jacket Flexure Endurance

A 12-inch (305-mm) specimen of finished cable shall be bent over a mandrel of the diameter

specified in the applicable specification sheet for 180°, straightened, and reverse bent 180°

over the same mandrel. This cycle shall be repeated for a total of ten cycles, after which the

jacket shall be examined for cracking. Jacket wrinkles created during the test shall not be

cause for rejection.

4.5.8 Low Temperature-Cold Bend

A specimen of finished cable shall be tested in accordance with MIL-C-85485 using the time

and temperature specified in the applicable specification sheet, except that the voltage

withstand test shall be conducted on shielded and jacketed specimens only.

4.5.9 Thermal Stability

A 10-foot (3.0-m) sample of component wire shall be shielded in accordance with the

requirements of the single conductor cable using that particular wire. The 10-foot (3.0-m)

sample of shielded cable shall be formed into a loose coil approximately 1 foot (305 mm) in

diameter and aged in a circulating air oven for the time and temperature specified in the

applicable specification sheet. The velocity of the air past the sample (measured at room

temperature) shall be between 100 and 200 feet per minute. After aging, the sample shall be

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allowed to cool to room temperature and shall then be subjected to the voltage withstand

(dielectric) test in MIL-C-85485. A 6-inch (152-mm) specimen shall then be cut from the

center of the 10-foot (3.0-m) sample. This 6-inch (152-mm) specimen shall be used to

determine the stop band attenuation of the aged cable in accordance with MIL-C-85485. A

24-inch (610-mm) specimen shall be cut from the remaining sample and the shield removed.

The wire shall then be subjected to the bend test, using the mandrel and weight as specified in

the applicable specification sheet for the crosslinking proof test, followed by the voltage

withstand (post-environmental) test specified in MIL-C-85485.

4.5.10 Weight Loss

A 5-foot (1.5-m) length of shielded cable shall be flush cut and weighed to the nearest 0.001

grams. Prior to weighing, the jacket surface of cables with jackets may be wiped clean with a

suitable low boiling solvent such as isopropyl alcohol to remove any accumulation of debris.

If a wipe is performed, the test specimen should be allowed to re-equilibrate to ambient

conditions for 30 minutes. After cleaning, the sample should be handled using cotton gloves

to avoid any contamination with finger oils. The cable jacket, if any, shall be removed by

longitudinally slitting with a razor blade or a similar tool. After removal, the jacket and

shielded inner bundle shall be wrapped into a loose coil and suspended in a forced air flow

oven at 250 ± 2ºC for 20 minutes. After this conditioning, the collective test specimen shall be

allowed to cool to ambient conditions for 30 minutes and then reweighed to the nearest 0.001

grams. The percent weight loss shall be calculated per the following formula:

(Original Weight - Final Weight)

% Weight Loss = Original Weight x 100

4.5.11 Wrap Test

4.5.11.1 Wire Sizes AWG 10 and Smaller

Component wire shall be tested in accordance with MIL-C-85485.

4.5.11.2 Wires Sizes AWG 8 and Larger

A specimen of component wire, with a length of 12 inches (305 mm) plus the additional length

required for wrapping on the mandrel, shall be wrapped tightly for two close turns around a

mandrel, the diameter of which is 3 times the outside diameter of the wire. The wrapping may

be accomplished manually and shall be in the middle portion of the specimen so that 6 inches

(152 mm) of each end shall remain straight. The specimen shall then be placed in an air oven

and conditioned for the time and at the temperature specified in the applicable specification

sheet. After conditioning, the specimen shall be removed from the oven and examined

visually without the aid of magnification for cracks.

5. STANDARD PACKAGING

Unless otherwise specified (see 6.1), the following shall define the standard spooling and

labeling requirements for wire and cable furnished under this specification. Standard shipping

tolerance on ordered quantity, for both wire and cable, shall be ± 10 percent.

SPECIFICATION 55F, ISSUE 4 Page 15 of 16

NOTE: ANY PRINTED COPY OF THIS DOCUMENT

IS AN UNCONTROLLED COPY.

5.1 SPOOLING REQUIREMENTS

All layers of wire and cable shall be wound on spools or reels (see 5.1.3) with sufficient

tension to prevent shifting of layers and creation of crossovers within layers.

5.1.1 Component Wire

Component wire lengths shall be wound on spools or reels with the ends spliced together to

provide one mechanically and electrically continuous length. Unless otherwise specified, the

minimum continuous length between splices shall be in accordance with Table 4.

TABLE 4. COMPONENT WIRE LENGTHS

Wire Size Range

(AWG) Minimum Length

30 through 10

8 and larger

100 feet (30 m)

50 feet (15 m)

(NOTE: Metric lengths specified above apply only to those orders placed in metric.)

5.1.2 Finished Cable

Finished cable lengths shall be wound on spools or reels with all ends exposed. There shall be

no more than 5 lengths per spool or reel and no length shall be less than 50 feet (15 m).

5.1.3 Spools and Reels

Spools and reels shall be of a nonreturnable type. Each spool and reel shall have an

appropriate diameter for the respective wire or cable size. In no case shall the barrel of the

spool or reel have a diameter less than 3.5 inches (89 mm). Spools and reels shall be suitably

finished to prevent corrosion under typical storage and handling conditions. Loaded plastic

spools shall not exceed 50 pounds (23 kg). Loaded wooden reels shall have no weight

restriction.

5.1.4 Containers

Unless otherwise specified (see 6.1), component wire and finished cable shall be delivered in

standard commercial containers so constructed as to ensure acceptance by common or other

carrier for safe transportation at the lowest rate to the point of delivery.

5.2 LABELING REQUIREMENTS

All spools and reels shall be identified with the following information:

Manufacturer's Part Number

Lot Number

Quantity in Feet (or Meters)

Name of Manufacturer

Page 16 of 16 SPECIFICATION 55F, ISSUE 4

NOTE: ANY PRINTED COPY OF THIS DOCUMENT

IS AN UNCONTROLLED COPY.

6. NOTES

6.1 ORDERING DATA

Procurement documents should specify the following:

a. Title, number, and revision of this specification

b. Applicable specification sheet part number

c. Quantity

d. Special preparation for delivery requirements, if applicable (see Section 5)

6.2 METRIC UNITS

Metric units (where shown in parentheses) are for information only.

6.3 MIL-C-85485

Wherever MIL-C-85485 refers to "applicable specification sheet", use the applicable Tyco

Electronics specification sheet (see 3.1).